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PRIORITY CLAIM
This application claims priority of Japanese Patent Application No. 2003-179042, filed on Jun. 24, 2003, and entitled, “Server, Computer Apparatus, Data Processing Method and Program.”
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a technique for sharing a computer resource provided on a network among plural users, and more particularly to data protection when a storage device is shared.
2. Description of Related Art
Nowadays, a variety of services have been made available, including a hosting service for lending computer resources (server, storage device, circuit, application and so on) provided on a network, using the network such as the Internet that is widely spread and a utility computing service in which computer resources can be purchased by a necessary amount, as needed. These services reduce a load on the economy and human resources for maintaining the computer resources from the viewpoint of the user, and are meaningful for the company, because the company is relieved of the load or waste by outsourcing them.
As one of the hosting/utility computing services, there is a service for providing a data storage area of the storage device to the user. In this service, it is important to assure the reliability (fault or failure counter plan) and safety (measure to prevent leakage of information to other companies) of information recorded in the storage device. As a failure counter plan, there is a technique for recording the record information with redundancy, including the RAID (Redundant Arrays of Independent Disks).
On the other hand, the existent schemes for preventing leakage of data include the encryption of recorded data and the access control (authentication). Moreover, to be safer, there is a method for physically separating the recording medium for writing information for each user. For example, information of each user is recorded on different magnetic disk assigned to each user, when the storage device is a magnetic disk device.
FIG. 10 is a diagram showing a hosting server in which physically different magnetic disks are assigned to plural companies.
As shown in FIG. 10 , the hosting server has a disk pool composed of plural magnetic disk devices. Data from different companies are stored in different magnetic disks, such that information Aa of client A is stored in magnetic disks for client A, information Ba of client B in magnetic disks for client B, and so on. In FIG. 10 , for example, information Aa of client A is divided into four blocks of data Aa 1 , Aa 2 , Aa 3 and Aa 4 , with the parity data added, and are stored in five magnetic disks.
In the conventional hosting service, various methods for assuring the safety of recorded data are taken. However, in the case where the recording medium is shared among plural users to permit only the maintenance under access control, all the information for the users sharing the recording medium may be accessed, if the access control is broken.
Also, when the recording media for recording data for each user are physically separated, it is not possible for plural users to share individual recording medium. That is, the recording medium assigned to a certain user is only usable to record the information of the user, even if a large empty area remains. Therefore, the recording medium has a lower utilization efficiency.
Thus, it is an object of the invention to assure the safety of recorded data while sharing the recording medium among plural users, and improve the utilization efficiency of the recording medium.
SUMMARY OF THE INVENTION
In order to achieve the above object, the present invention is implemented as a server with the following constitution. That is, the server provides a storage area of a storage device that is a computer resource via a network to the client, comprising a storage device group composed of plural storage devices, and a data processing unit, in response to a write request from the client, for dividing the write data included in the write request so that concatenating the divided data may restore the original information, and for writing the data so that the plural storage devices storing the write data of each client may partly overlap with each other.
Also, this invention is implemented as a computer apparatus with the following constitution. That is, the computer apparatus comprises a storage device group composed of plural storage devices, and a data processing unit for reading or writing data from or into the storage devices. And this data processing unit, when writing data into the storage devices, divides each data file into plural pieces of divided data so that concatenating the divided data may restore the original information, and writes the data so that storage devices storing the divided data of a certain data file and storage devices storing the divided data of another data file may partly overlap.
Moreover, this invention is implemented as a computer apparatus comprising a disk array composed of plural magnetic disk devices, and a data processing unit for reading or writing data from or into the disk array. In this computer apparatus, the disk array stores plural divided data processed by dividing each data file so that concatenating the divided data may restore the original information, in such a way that magnetic disk devices storing a certain data file and magnetic disk devices storing another data file may partly overlap.
Also, in order to achieve the above object, another embodiment of the present invention is implemented as a data processing method for enabling a computer to write data received from a certain client via a network into a storage device group composed of plural storage devices as configured in the following way. This data processing method comprises a first step of, in response to a write request from the client, dividing the write data included in the write request into plural divided data so that concatenating the divided data may restore the original information, and a second step of storing the divided data into the storage device group so that the plural storage devices storing the write data of each client may partly overlap with each other.
Further, in the server, the computer apparatus and the data processing method according to the invention, when the write data (data file) is divided, there is a redundancy to enable restoration of the original data file even if part of the divided data is lost. In this case, the data is written so that the number of storage devices overlapping storage devices (magnetic disk devices) storing another write data (data file) may be insufficient to restore the original data file.
Preferably, when the write data (data file) is divided, the division number or the size of divided data (data length, block length) is changed for each client making the write request, each data file or each divided data. Furthermore, the divided data is encrypted or scrambled for writing. In this way, the user who is accessible to a certain data file is more securely prevented from acquiring another data file that is not permitted to access, whereby the data file stored in the storage device has higher safety.
Moreover, this invention is implemented as a program for controlling a computer to perform various functions, or the processes corresponding to steps in the data processing method. This program may be stored and distributed in a magnetic disk, an optical disk, a semiconductor memory or other storage media, or distributed via a network.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a typical block diagram showing an example of the hardware configuration of a computer apparatus for implementing a hosting server for use in an embodiment of the invention;
FIG. 2 is a diagram showing the functional configuration of a hosting server implemented by the computer apparatus according to the embodiment as shown in FIG. 1 ;
FIG. 3 is a diagram showing a method for dividing data into plural blocks and writing divided blocks of data into plural disks that are distributed, using a RAID5;
FIG. 4 is a view for explaining whether or not to restore the original data when data is written using the RAID5;
FIG. 5 is a diagram showing a method for writing data into a disk array according to the embodiment;
FIG. 6 is a flowchart for explaining the operation of a data write process by the hosting server according to the embodiment;
FIG. 7 is a diagram showing the data flow in writing data;
FIG. 8 is a flowchart for explaining the operation of a data read process by the hosting server according to the embodiment;
FIG. 9 is a diagram showing the data flow in reading data; and
FIG. 10 is a diagram showing the hosting server in which physically different magnetic disks are assigned to plural companies.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings.
FIG. 1 is a block diagram showing an example of a hardware configuration of a computer apparatus for implementing a hosting server for use in an embodiment of the invention.
The computer apparatus as shown in FIG. 1 comprises a CPU (Central Processing Unit) 101 that is operation means, a main memory 103 connected via an M/B (Mother Board) chip set 102 and a CPU bus to the CPU 101 , a video card 104 connected via the M/B chip set 102 and an AGP (Accelerated Graphics Port) to the CPU 101 , a magnetic disk device (Hard Disk Drive—HDD) 105 connected via a PCI (Peripheral Component Interconnect) bus to the M/B chip set 102 , a network interface 106 , and a floppy disk drive 108 and a keyboard/mouse 109 connected via the PCI bus, a bridge circuit 107 and a low speed bus such as an ISA (Industry Standard Architecture) bus to the M/B chip set 102 .
FIG. 1 only exemplifies the hardware configuration of the computer apparatus for implementing this embodiment, but various other configurations may be taken, as far as this embodiment is applicable. For example, the video card 104 is not provided, but a video memory may be only mounted to process the image data in the CPU 101 . As an external storage device, a CD-R (Compact Disc Recordable) or DVD (Digital Versatile Disc) drive may be provided via an interface such as ATA (AT Attachment) or SCSI (Small Computer System Interface).
In this embodiment, the magnetic disk device 105 is employed as the storage device storing the information of the user. Accordingly, plural magnetic disk devices 105 are prepared to compose a disk array.
FIG. 2 is a diagram showing the functional configuration of the hosting server implemented by the computer apparatus according to the embodiment as shown in FIG. 1 .
Referring to FIG. 2 , the hosting server of this embodiment comprises a disk array 40 composed of plural disks (corresponding to the magnetic disk devices 105 in FIG. 1 ), an I/O (Input/Output) controller 10 for transmitting a request or receiving a response to or from the client (service user), a data/disk management unit 20 for managing various kinds of data or the disk information, and a data processing unit 30 for reading or writing data from or into the disk.
Of the components as shown in FIG. 2 , the I/O controller 10 and the data processing unit 30 are software blocks implemented by the CPU 101 that is controlled by the program as shown in FIG. 1 . Also, the data/disk management unit 20 consists of the CPU 101 controlled by the program and storage means such as the main memory 103 , the magnetic disk device 105 and a cache memory provided in the CPU 101 . The program for controlling the CPU 101 to perform the functions is stored and distributed in a magnetic disk, an optical disk, a semiconductor memory or other recording media, or may be distributed via the network.
The I/O controller 10 accepts a read or write request from the client via the network interface 106 of FIG. 1 , for example, and issues an instruction to the data/disk management unit 20 and the data processing unit 30 . And the I/O controller 10 receives a completion notice of the write process or the read data from the data processing unit 30 , and returns a response to the prior request via the network interface 106 to the client. A specific operation of the data writing or reading process will be described later.
The data/disk management unit 20 comprises a cache processor 21 , a disk array logical model manager 22 , and a data division number/coding policy generator 23 , as shown in FIG. 2 .
The cache processor 21 , in response to an instruction from the I/O controller 10 , collects the information necessary for operating the data processing unit 30 and passes it to the data processing unit. Also, the information acquired through a previous process is cached in the cache memory of the CPU 101 or the main memory 103 . The cache processor 21 makes the processing faster when data is written or read for the same client.
The disk array logical model manager 22 creates and manages a logical model (disk array logical model) for managing at which position the data of each client is recorded in all the disks composing the disk array 40 . The created disk array logical model is stored in a predetermined area of the main memory 103 or the magnetic disk 105 .
The data division number/coding policy generator 23 defines, for each client, the data division number indicating the number of dividing data in writing data and the coding policy indicating the coding method (including a coding function or parameters) for encoding the data. Herein, the data division number means the number of dividing data to be distributed and written into plural disks of the disk array 40 . For example, write data is divided into four blocks, with the parity data added, and are distributed and written into five disks. The generated data division number and coding policy are stored in a predetermined area of the main memory 103 or the magnetic disk device 105 .
The data processing unit 30 comprises a write processing unit 31 for writing data and a read processing unit 32 for reading data, as shown in FIG. 2 .
The write processing unit 31 acquires the disk position, data division number and coding policy from the data/disk management unit 20 , and divides the write data received from the I/O controller 10 , based on these pieces of information, whereby the divided data is encoded and written into a desired disk of the disk array 40 .
The read processing unit 32 acquires the disk position, data division number and coding policy from the data/disk management unit 20 , and reads the desired data from the disk array 40 , based on these pieces of information, whereby the read data is concatenated, decoded and passed to the I/O controller 10 .
The disk array 40 is composed of plural disks, as previously described. And the client data is distributed and recorded into plural disks. In this case, the distributed and recorded data is totally or partly collected to restore the original data.
FIGS. 3 and 4 are diagrams showing a method for dividing data into plural blocks and writing divided blocks of data into plural disks that are distributed, using the RAID 5.
In the RAID 5, data is divided into block units, and recorded in plural disks that are distributed, with the parity data recorded in another disk, as shown in FIG. 3 . In this case, if one disk fails, the original data is restored from the divided data of block units on the remaining disk, as shown in FIG. 4A . On the other hand, when two or more disks are not accessible, the original data is not restored correctly, as shown in FIG. 4B .
Herein, the method for writing data into the disk array 40 according to the embodiment will be described below in detail.
To generalize the division and coding in writing data into the disk array 40 , it is supposed that the information of k bits is encoded with code length n and error correction capability t, and data is written into n disks that are distributed. That is, when the divided data is unreadable from t disks among n disks, the data written in the disk array 40 has a redundancy that the original data can be restored from the remaining divided data of n−t bits. In this case, the disk position of write destination is controlled so that the number of disks shared with another client may be equal to or less than n−(t+1) where the data of certain client is written into n disks in this embodiment.
In this way, if another client takes out the data of another client from the disk shared to acquire the data of n−(t+1) bits, the original data is not resynthesized correctly because the error correction capability is t bits. Of course, it does not matter that the information amount recordable in one disk is one bit or more. The coding systems with error correction capability may include, for example, a cyclic code, a BCH code and an RS code.
In the case where data is recorded using the RAID 5, as shown in FIGS. 3 and 4 , if there are two or more inaccessible disks, the original data is not restored correctly, as described above. Thus, two or more disks without overlapping write data are provided in writing data of each client.
FIG. 5 is a diagram showing a method for writing data into the disk array 40 according to the embodiment.
In FIG. 5 , among m disks ( 41 a to 41 m ) composing the disk array 40 , the disks 41 a to 41 e are assigned to recording the information of client A (Aa and Ab). Also, the disks 41 c to 41 g shifted by two to the right are assigned to recording the information (Ba) of client B. Likewise, the disks 41 e to 41 i are assigned to recording the information (Ca) of client C, and the disks 41 m - 2 to 41 m and the disks 41 a , 41 b are assigned to recording the information (Na) of client N.
For example, in writing the write data sent from the client A, the data is divided into four blocks (Aa 1 to Aa 4 , Ab 1 to Ab 4 ) by the write processing unit 31 in the data processing unit 30 , with the parity data (Aap, Abp) added, and written into five disks 41 a to 41 e . It is possible to arbitrarily decide in which disk the divided data and parity data are stored among assigned disks. In an example of FIG. 5 , the parity data Aap added to the information Aa of client A is written in the disk 41 e , while the parity data Abp added to the information Ab is written in the disk 41 d.
If the data of each client is written in the above way, the original data of another client is prevented from being restored correctly, even though a certain client can access the divided data written by another client by breaching the access control.
By the way, in the case where the information is written into plural disks that are distributed, for example, if information of one bit is described in each of n disks using the code (n, k, t), the original data is restored by retrieving all the data with a computation amount of O(2 t+1 ), as far as the (n, k, t) coding system is known. As a measure for avoiding such an incorrect read, the method for distributing and writing data is changed for each client, or the disk utilization efficiency is lowered to have a smaller number of disks that are shared among plural clients. To change the data writing method involve changing the number of dividing the data for each client, encrypting and scrambling the divided data, changing the block length (data length) of divided data for each client, and other various methods.
The operation of data processing in the hosting server according to the embodiment will be described below.
FIG. 6 is a flowchart for explaining the operation of the data write process by the hosting server according to the embodiment, and FIG. 7 is a diagram showing the data flow in writing data.
When a request for writing data from a certain client is delivered to the hosting server, the client information for specifying the client and a file name of the write data are extracted from the write request by the I/O controller 10 , and sent to the data/disk manager 20 . Also, the write data contained in the write request is sent to the data processing unit 30 (step 601 ).
If the data/disk management unit 20 accepts the client information and the file name, the cache processor 21 acquires the disk position, data division number and coding policy for the client that are specified based on those pieces of information (step 602 ). More specifically, first of all, it is checked whether or not those pieces of information are cached in the cache processor 21 itself. If not cached, an inquiry about those pieces of information is made to the disk array logical model manager 22 and the data division number/coding policy generator 23 (see FIG. 7 ).
When the disk array logical model has information of disk position for the client, the disk array logical manager 22 passes its information to the cache processor 21 . On the other hand, when the disk array logical model does not have the desired information, the disk array logical model manager 22 defines a new disk position, and adds it to the disk array logical model, as well as passing it to the cache processor 21 .
Also, when the data division number/coding policy generator 23 holds the data division number and the coding policy for writing data of the client, the data division number/coding policy generator 23 passes its information to the cache processor 21 . On the other hand, when the desired data division number and coding policy are not held, the data division number/coding policy generator 23 defines and holds a new data division number and coding policy, and passes them to the cache processor 21 .
The cache processor 21 acquires the cache data, or desired information of disk position, data division number and coding policy corresponding to the write request from the disk array logical model manager 22 and the data division number/coding policy generator 23 , and then passes these pieces of information to the data processing unit 30 (see FIG. 7 ). When these pieces of information are acquired from the disk array logical model manager 22 and the data division number/coding policy generator 23 , the cache processor 21 newly caches the acquired information. When the cache capacity of the cache processor 21 is full, no hit cache data is deleted in the order from the oldest data, whereby the empty capacity is kept and the acquired information is cached.
If the information of disk position, data division number and coding policy are obtained in the above way, the write processing unit 31 for the data processing unit 30 divides and encodes the write data, using these pieces of information (step 603 ), and write data into the disk array 40 (step 604 ). And after the writing of data is ended, a write completion notice is issued from the write processing unit 31 , and returned via the I/O controller 10 to the client making the write request (step 605 ).
FIG. 8 is a flowchart for explaining the operation of a data read process by the hosting server according to the embodiment, and FIG. 9 is a diagram showing the data flow in reading data.
When a request for reading data from a certain client is delivered to the hosting server, the client information for specifying the client and a file name of the read data are extracted from the read request by the I/O controller 10 , and sent to the data/disk management unit 20 (step 801 ).
If the data/disk management unit 20 accepts the client information and the file name, the cache processor 21 acquires the disk position of the client, the data division number and the coding policy that are specified based on these pieces of information (step 802 ). The specific operation of acquiring these pieces of information is the same as described in the data write process (see FIG. 9 ).
If the information of disk position, data division number and coding policy are obtained in the above way, the read processing unit 32 for the data processing unit 30 reads data from the disk array 40 , using these pieces of information (step 803 ), and the read data is concatenated and decoded (step 804 ). And the decoded read data is sent from the read processing unit 32 to the I/O controller 10 , and returned to the client having made the read request (step 805 ).
The hosting server of this embodiment provides the computer resources to the client via the network, but may be applied to various conventional services in its service form. More specifically, it may be applied to the on-demand disk providing service, for example.
For most companies, if the IT resources such as hardware resources of the computer are possessed and managed within its own company, there is a great load on the economy and human resources. Therefore, for the management of such resources, it is common to ask other companies for outsourcing or hosting. Thus, for such companies, the hosting server of this embodiment is employed for the on-demand disk providing service to provide the storage area of disk as the storage location of data, as needed.
In this case, in providing the disk to plural companies, a huge disk pool (disk array 40 ) is prepared for each company to designate a disk group accessible in response to a request from each company. One data file of the company is distributed and written into the designated disk group, and the original data file is restored by reintegrating the disk group. A part of the disk group assigned to one company is shared with other companies, but the number of shared disks is limited. Thereby, even if a certain company gaining access to the disk assigned to its company can access a part of the data file distributed for another company, the information of the data file is not completely resynthesized. On the other hand, for the hosting server, individual disks in the disk pool are shared among plural companies, whereby the storage area of the disk is provided to more companies to have the higher utilization ratio than when individual disks are assigned to each company.
Also, another application example of the hosting server according to this embodiment is a data temporary saving service. When the data reduction or system change/management or integration or disintegration is made within the company, it is required to temporarily save or back up the data. In this case, for the reason of assuring higher safety against data loss or lack of resources (storage capacity of disk) in the company computer system, it is considered that the company data is temporarily saved in the huge disk pool in the outside data center. When plural companies employ this service, the hosting server of this embodiment is applied to prevent leakage of the information of each company within the data center to other companies.
In the hosting server of this embodiment, the same disk is physically shared among plural companies. However, even though a certain company can read the divided data of another company written on the accessible disk, the original data is not restored from the divided data, and the information is not leaked. Therefore, it is allowed to share the disk among plural companies while keeping the safety of information temporarily saved, whereby the utilization efficiency of resources in the data center is enhanced.
In this embodiment, the hosting server has the disk array composed of plural magnetic disk devices as the storage device. However, this embodiment may be also applicable to the storage device using various storage media other than the magnetic disk device in the server or computer apparatus having the storage device group composed of plural storage units. Also, in this embodiment, the data to be stored may be not only the write data in response to a write request from the client but also plural data files required to regulate the user accessible to each data file. That is, each data file is stored in plural storage devices distributed so that the storage devices storing individual data files may partly overlap with each other, whereby the access control is more reliable, and the safety of stored data file is assured.
As described above, with this invention, while the recording medium is shared among plural users, the safety of recorded data is assured, and the utilization efficiency of the recording medium is enhanced. | A first array of disk drives overlaps with a second array of disk drives in a Redundant Array of Inexpensive Drives (RAID) system, in which the first and second arrays share at least one disk drive. A first stripe of data from a first client is stored in the first array, and a second stripe of data from a second client is stored in the second array. The shared disk drives are less than the number of drives needed to reconstruct a full stripe. Thus, in the event of a drive failure in the first array, the first client can reconstruct the first data stripe, but is never able to reconstruct the second stripe. Likewise, in the event of a drive failure in the second array, the second client can reconstruct the second data stripe, but is never able to reconstruct the first stripe. | Summarize the patent document, focusing on the invention's functionality and advantages. | [
"PRIORITY CLAIM This application claims priority of Japanese Patent Application No. 2003-179042, filed on Jun. 24, 2003, and entitled, “Server, Computer Apparatus, Data Processing Method and Program.”",
"BACKGROUND OF THE INVENTION 1.",
"Technical Field The present invention relates to a technique for sharing a computer resource provided on a network among plural users, and more particularly to data protection when a storage device is shared.",
"Description of Related Art Nowadays, a variety of services have been made available, including a hosting service for lending computer resources (server, storage device, circuit, application and so on) provided on a network, using the network such as the Internet that is widely spread and a utility computing service in which computer resources can be purchased by a necessary amount, as needed.",
"These services reduce a load on the economy and human resources for maintaining the computer resources from the viewpoint of the user, and are meaningful for the company, because the company is relieved of the load or waste by outsourcing them.",
"As one of the hosting/utility computing services, there is a service for providing a data storage area of the storage device to the user.",
"In this service, it is important to assure the reliability (fault or failure counter plan) and safety (measure to prevent leakage of information to other companies) of information recorded in the storage device.",
"As a failure counter plan, there is a technique for recording the record information with redundancy, including the RAID (Redundant Arrays of Independent Disks).",
"On the other hand, the existent schemes for preventing leakage of data include the encryption of recorded data and the access control (authentication).",
"Moreover, to be safer, there is a method for physically separating the recording medium for writing information for each user.",
"For example, information of each user is recorded on different magnetic disk assigned to each user, when the storage device is a magnetic disk device.",
"FIG. 10 is a diagram showing a hosting server in which physically different magnetic disks are assigned to plural companies.",
"As shown in FIG. 10 , the hosting server has a disk pool composed of plural magnetic disk devices.",
"Data from different companies are stored in different magnetic disks, such that information Aa of client A is stored in magnetic disks for client A, information Ba of client B in magnetic disks for client B, and so on.",
"In FIG. 10 , for example, information Aa of client A is divided into four blocks of data Aa 1 , Aa 2 , Aa 3 and Aa 4 , with the parity data added, and are stored in five magnetic disks.",
"In the conventional hosting service, various methods for assuring the safety of recorded data are taken.",
"However, in the case where the recording medium is shared among plural users to permit only the maintenance under access control, all the information for the users sharing the recording medium may be accessed, if the access control is broken.",
"Also, when the recording media for recording data for each user are physically separated, it is not possible for plural users to share individual recording medium.",
"That is, the recording medium assigned to a certain user is only usable to record the information of the user, even if a large empty area remains.",
"Therefore, the recording medium has a lower utilization efficiency.",
"Thus, it is an object of the invention to assure the safety of recorded data while sharing the recording medium among plural users, and improve the utilization efficiency of the recording medium.",
"SUMMARY OF THE INVENTION In order to achieve the above object, the present invention is implemented as a server with the following constitution.",
"That is, the server provides a storage area of a storage device that is a computer resource via a network to the client, comprising a storage device group composed of plural storage devices, and a data processing unit, in response to a write request from the client, for dividing the write data included in the write request so that concatenating the divided data may restore the original information, and for writing the data so that the plural storage devices storing the write data of each client may partly overlap with each other.",
"Also, this invention is implemented as a computer apparatus with the following constitution.",
"That is, the computer apparatus comprises a storage device group composed of plural storage devices, and a data processing unit for reading or writing data from or into the storage devices.",
"And this data processing unit, when writing data into the storage devices, divides each data file into plural pieces of divided data so that concatenating the divided data may restore the original information, and writes the data so that storage devices storing the divided data of a certain data file and storage devices storing the divided data of another data file may partly overlap.",
"Moreover, this invention is implemented as a computer apparatus comprising a disk array composed of plural magnetic disk devices, and a data processing unit for reading or writing data from or into the disk array.",
"In this computer apparatus, the disk array stores plural divided data processed by dividing each data file so that concatenating the divided data may restore the original information, in such a way that magnetic disk devices storing a certain data file and magnetic disk devices storing another data file may partly overlap.",
"Also, in order to achieve the above object, another embodiment of the present invention is implemented as a data processing method for enabling a computer to write data received from a certain client via a network into a storage device group composed of plural storage devices as configured in the following way.",
"This data processing method comprises a first step of, in response to a write request from the client, dividing the write data included in the write request into plural divided data so that concatenating the divided data may restore the original information, and a second step of storing the divided data into the storage device group so that the plural storage devices storing the write data of each client may partly overlap with each other.",
"Further, in the server, the computer apparatus and the data processing method according to the invention, when the write data (data file) is divided, there is a redundancy to enable restoration of the original data file even if part of the divided data is lost.",
"In this case, the data is written so that the number of storage devices overlapping storage devices (magnetic disk devices) storing another write data (data file) may be insufficient to restore the original data file.",
"Preferably, when the write data (data file) is divided, the division number or the size of divided data (data length, block length) is changed for each client making the write request, each data file or each divided data.",
"Furthermore, the divided data is encrypted or scrambled for writing.",
"In this way, the user who is accessible to a certain data file is more securely prevented from acquiring another data file that is not permitted to access, whereby the data file stored in the storage device has higher safety.",
"Moreover, this invention is implemented as a program for controlling a computer to perform various functions, or the processes corresponding to steps in the data processing method.",
"This program may be stored and distributed in a magnetic disk, an optical disk, a semiconductor memory or other storage media, or distributed via a network.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a typical block diagram showing an example of the hardware configuration of a computer apparatus for implementing a hosting server for use in an embodiment of the invention;",
"FIG. 2 is a diagram showing the functional configuration of a hosting server implemented by the computer apparatus according to the embodiment as shown in FIG. 1 ;",
"FIG. 3 is a diagram showing a method for dividing data into plural blocks and writing divided blocks of data into plural disks that are distributed, using a RAID5;",
"FIG. 4 is a view for explaining whether or not to restore the original data when data is written using the RAID5;",
"FIG. 5 is a diagram showing a method for writing data into a disk array according to the embodiment;",
"FIG. 6 is a flowchart for explaining the operation of a data write process by the hosting server according to the embodiment;",
"FIG. 7 is a diagram showing the data flow in writing data;",
"FIG. 8 is a flowchart for explaining the operation of a data read process by the hosting server according to the embodiment;",
"FIG. 9 is a diagram showing the data flow in reading data;",
"and FIG. 10 is a diagram showing the hosting server in which physically different magnetic disks are assigned to plural companies.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings.",
"FIG. 1 is a block diagram showing an example of a hardware configuration of a computer apparatus for implementing a hosting server for use in an embodiment of the invention.",
"The computer apparatus as shown in FIG. 1 comprises a CPU (Central Processing Unit) 101 that is operation means, a main memory 103 connected via an M/B (Mother Board) chip set 102 and a CPU bus to the CPU 101 , a video card 104 connected via the M/B chip set 102 and an AGP (Accelerated Graphics Port) to the CPU 101 , a magnetic disk device (Hard Disk Drive—HDD) 105 connected via a PCI (Peripheral Component Interconnect) bus to the M/B chip set 102 , a network interface 106 , and a floppy disk drive 108 and a keyboard/mouse 109 connected via the PCI bus, a bridge circuit 107 and a low speed bus such as an ISA (Industry Standard Architecture) bus to the M/B chip set 102 .",
"FIG. 1 only exemplifies the hardware configuration of the computer apparatus for implementing this embodiment, but various other configurations may be taken, as far as this embodiment is applicable.",
"For example, the video card 104 is not provided, but a video memory may be only mounted to process the image data in the CPU 101 .",
"As an external storage device, a CD-R (Compact Disc Recordable) or DVD (Digital Versatile Disc) drive may be provided via an interface such as ATA (AT Attachment) or SCSI (Small Computer System Interface).",
"In this embodiment, the magnetic disk device 105 is employed as the storage device storing the information of the user.",
"Accordingly, plural magnetic disk devices 105 are prepared to compose a disk array.",
"FIG. 2 is a diagram showing the functional configuration of the hosting server implemented by the computer apparatus according to the embodiment as shown in FIG. 1 .",
"Referring to FIG. 2 , the hosting server of this embodiment comprises a disk array 40 composed of plural disks (corresponding to the magnetic disk devices 105 in FIG. 1 ), an I/O (Input/Output) controller 10 for transmitting a request or receiving a response to or from the client (service user), a data/disk management unit 20 for managing various kinds of data or the disk information, and a data processing unit 30 for reading or writing data from or into the disk.",
"Of the components as shown in FIG. 2 , the I/O controller 10 and the data processing unit 30 are software blocks implemented by the CPU 101 that is controlled by the program as shown in FIG. 1 .",
"Also, the data/disk management unit 20 consists of the CPU 101 controlled by the program and storage means such as the main memory 103 , the magnetic disk device 105 and a cache memory provided in the CPU 101 .",
"The program for controlling the CPU 101 to perform the functions is stored and distributed in a magnetic disk, an optical disk, a semiconductor memory or other recording media, or may be distributed via the network.",
"The I/O controller 10 accepts a read or write request from the client via the network interface 106 of FIG. 1 , for example, and issues an instruction to the data/disk management unit 20 and the data processing unit 30 .",
"And the I/O controller 10 receives a completion notice of the write process or the read data from the data processing unit 30 , and returns a response to the prior request via the network interface 106 to the client.",
"A specific operation of the data writing or reading process will be described later.",
"The data/disk management unit 20 comprises a cache processor 21 , a disk array logical model manager 22 , and a data division number/coding policy generator 23 , as shown in FIG. 2 .",
"The cache processor 21 , in response to an instruction from the I/O controller 10 , collects the information necessary for operating the data processing unit 30 and passes it to the data processing unit.",
"Also, the information acquired through a previous process is cached in the cache memory of the CPU 101 or the main memory 103 .",
"The cache processor 21 makes the processing faster when data is written or read for the same client.",
"The disk array logical model manager 22 creates and manages a logical model (disk array logical model) for managing at which position the data of each client is recorded in all the disks composing the disk array 40 .",
"The created disk array logical model is stored in a predetermined area of the main memory 103 or the magnetic disk 105 .",
"The data division number/coding policy generator 23 defines, for each client, the data division number indicating the number of dividing data in writing data and the coding policy indicating the coding method (including a coding function or parameters) for encoding the data.",
"Herein, the data division number means the number of dividing data to be distributed and written into plural disks of the disk array 40 .",
"For example, write data is divided into four blocks, with the parity data added, and are distributed and written into five disks.",
"The generated data division number and coding policy are stored in a predetermined area of the main memory 103 or the magnetic disk device 105 .",
"The data processing unit 30 comprises a write processing unit 31 for writing data and a read processing unit 32 for reading data, as shown in FIG. 2 .",
"The write processing unit 31 acquires the disk position, data division number and coding policy from the data/disk management unit 20 , and divides the write data received from the I/O controller 10 , based on these pieces of information, whereby the divided data is encoded and written into a desired disk of the disk array 40 .",
"The read processing unit 32 acquires the disk position, data division number and coding policy from the data/disk management unit 20 , and reads the desired data from the disk array 40 , based on these pieces of information, whereby the read data is concatenated, decoded and passed to the I/O controller 10 .",
"The disk array 40 is composed of plural disks, as previously described.",
"And the client data is distributed and recorded into plural disks.",
"In this case, the distributed and recorded data is totally or partly collected to restore the original data.",
"FIGS. 3 and 4 are diagrams showing a method for dividing data into plural blocks and writing divided blocks of data into plural disks that are distributed, using the RAID 5.",
"In the RAID 5, data is divided into block units, and recorded in plural disks that are distributed, with the parity data recorded in another disk, as shown in FIG. 3 .",
"In this case, if one disk fails, the original data is restored from the divided data of block units on the remaining disk, as shown in FIG. 4A .",
"On the other hand, when two or more disks are not accessible, the original data is not restored correctly, as shown in FIG. 4B .",
"Herein, the method for writing data into the disk array 40 according to the embodiment will be described below in detail.",
"To generalize the division and coding in writing data into the disk array 40 , it is supposed that the information of k bits is encoded with code length n and error correction capability t, and data is written into n disks that are distributed.",
"That is, when the divided data is unreadable from t disks among n disks, the data written in the disk array 40 has a redundancy that the original data can be restored from the remaining divided data of n−t bits.",
"In this case, the disk position of write destination is controlled so that the number of disks shared with another client may be equal to or less than n−(t+1) where the data of certain client is written into n disks in this embodiment.",
"In this way, if another client takes out the data of another client from the disk shared to acquire the data of n−(t+1) bits, the original data is not resynthesized correctly because the error correction capability is t bits.",
"Of course, it does not matter that the information amount recordable in one disk is one bit or more.",
"The coding systems with error correction capability may include, for example, a cyclic code, a BCH code and an RS code.",
"In the case where data is recorded using the RAID 5, as shown in FIGS. 3 and 4 , if there are two or more inaccessible disks, the original data is not restored correctly, as described above.",
"Thus, two or more disks without overlapping write data are provided in writing data of each client.",
"FIG. 5 is a diagram showing a method for writing data into the disk array 40 according to the embodiment.",
"In FIG. 5 , among m disks ( 41 a to 41 m ) composing the disk array 40 , the disks 41 a to 41 e are assigned to recording the information of client A (Aa and Ab).",
"Also, the disks 41 c to 41 g shifted by two to the right are assigned to recording the information (Ba) of client B. Likewise, the disks 41 e to 41 i are assigned to recording the information (Ca) of client C, and the disks 41 m - 2 to 41 m and the disks 41 a , 41 b are assigned to recording the information (Na) of client N. For example, in writing the write data sent from the client A, the data is divided into four blocks (Aa 1 to Aa 4 , Ab 1 to Ab 4 ) by the write processing unit 31 in the data processing unit 30 , with the parity data (Aap, Abp) added, and written into five disks 41 a to 41 e .",
"It is possible to arbitrarily decide in which disk the divided data and parity data are stored among assigned disks.",
"In an example of FIG. 5 , the parity data Aap added to the information Aa of client A is written in the disk 41 e , while the parity data Abp added to the information Ab is written in the disk 41 d. If the data of each client is written in the above way, the original data of another client is prevented from being restored correctly, even though a certain client can access the divided data written by another client by breaching the access control.",
"By the way, in the case where the information is written into plural disks that are distributed, for example, if information of one bit is described in each of n disks using the code (n, k, t), the original data is restored by retrieving all the data with a computation amount of O(2 t+1 ), as far as the (n, k, t) coding system is known.",
"As a measure for avoiding such an incorrect read, the method for distributing and writing data is changed for each client, or the disk utilization efficiency is lowered to have a smaller number of disks that are shared among plural clients.",
"To change the data writing method involve changing the number of dividing the data for each client, encrypting and scrambling the divided data, changing the block length (data length) of divided data for each client, and other various methods.",
"The operation of data processing in the hosting server according to the embodiment will be described below.",
"FIG. 6 is a flowchart for explaining the operation of the data write process by the hosting server according to the embodiment, and FIG. 7 is a diagram showing the data flow in writing data.",
"When a request for writing data from a certain client is delivered to the hosting server, the client information for specifying the client and a file name of the write data are extracted from the write request by the I/O controller 10 , and sent to the data/disk manager 20 .",
"Also, the write data contained in the write request is sent to the data processing unit 30 (step 601 ).",
"If the data/disk management unit 20 accepts the client information and the file name, the cache processor 21 acquires the disk position, data division number and coding policy for the client that are specified based on those pieces of information (step 602 ).",
"More specifically, first of all, it is checked whether or not those pieces of information are cached in the cache processor 21 itself.",
"If not cached, an inquiry about those pieces of information is made to the disk array logical model manager 22 and the data division number/coding policy generator 23 (see FIG. 7 ).",
"When the disk array logical model has information of disk position for the client, the disk array logical manager 22 passes its information to the cache processor 21 .",
"On the other hand, when the disk array logical model does not have the desired information, the disk array logical model manager 22 defines a new disk position, and adds it to the disk array logical model, as well as passing it to the cache processor 21 .",
"Also, when the data division number/coding policy generator 23 holds the data division number and the coding policy for writing data of the client, the data division number/coding policy generator 23 passes its information to the cache processor 21 .",
"On the other hand, when the desired data division number and coding policy are not held, the data division number/coding policy generator 23 defines and holds a new data division number and coding policy, and passes them to the cache processor 21 .",
"The cache processor 21 acquires the cache data, or desired information of disk position, data division number and coding policy corresponding to the write request from the disk array logical model manager 22 and the data division number/coding policy generator 23 , and then passes these pieces of information to the data processing unit 30 (see FIG. 7 ).",
"When these pieces of information are acquired from the disk array logical model manager 22 and the data division number/coding policy generator 23 , the cache processor 21 newly caches the acquired information.",
"When the cache capacity of the cache processor 21 is full, no hit cache data is deleted in the order from the oldest data, whereby the empty capacity is kept and the acquired information is cached.",
"If the information of disk position, data division number and coding policy are obtained in the above way, the write processing unit 31 for the data processing unit 30 divides and encodes the write data, using these pieces of information (step 603 ), and write data into the disk array 40 (step 604 ).",
"And after the writing of data is ended, a write completion notice is issued from the write processing unit 31 , and returned via the I/O controller 10 to the client making the write request (step 605 ).",
"FIG. 8 is a flowchart for explaining the operation of a data read process by the hosting server according to the embodiment, and FIG. 9 is a diagram showing the data flow in reading data.",
"When a request for reading data from a certain client is delivered to the hosting server, the client information for specifying the client and a file name of the read data are extracted from the read request by the I/O controller 10 , and sent to the data/disk management unit 20 (step 801 ).",
"If the data/disk management unit 20 accepts the client information and the file name, the cache processor 21 acquires the disk position of the client, the data division number and the coding policy that are specified based on these pieces of information (step 802 ).",
"The specific operation of acquiring these pieces of information is the same as described in the data write process (see FIG. 9 ).",
"If the information of disk position, data division number and coding policy are obtained in the above way, the read processing unit 32 for the data processing unit 30 reads data from the disk array 40 , using these pieces of information (step 803 ), and the read data is concatenated and decoded (step 804 ).",
"And the decoded read data is sent from the read processing unit 32 to the I/O controller 10 , and returned to the client having made the read request (step 805 ).",
"The hosting server of this embodiment provides the computer resources to the client via the network, but may be applied to various conventional services in its service form.",
"More specifically, it may be applied to the on-demand disk providing service, for example.",
"For most companies, if the IT resources such as hardware resources of the computer are possessed and managed within its own company, there is a great load on the economy and human resources.",
"Therefore, for the management of such resources, it is common to ask other companies for outsourcing or hosting.",
"Thus, for such companies, the hosting server of this embodiment is employed for the on-demand disk providing service to provide the storage area of disk as the storage location of data, as needed.",
"In this case, in providing the disk to plural companies, a huge disk pool (disk array 40 ) is prepared for each company to designate a disk group accessible in response to a request from each company.",
"One data file of the company is distributed and written into the designated disk group, and the original data file is restored by reintegrating the disk group.",
"A part of the disk group assigned to one company is shared with other companies, but the number of shared disks is limited.",
"Thereby, even if a certain company gaining access to the disk assigned to its company can access a part of the data file distributed for another company, the information of the data file is not completely resynthesized.",
"On the other hand, for the hosting server, individual disks in the disk pool are shared among plural companies, whereby the storage area of the disk is provided to more companies to have the higher utilization ratio than when individual disks are assigned to each company.",
"Also, another application example of the hosting server according to this embodiment is a data temporary saving service.",
"When the data reduction or system change/management or integration or disintegration is made within the company, it is required to temporarily save or back up the data.",
"In this case, for the reason of assuring higher safety against data loss or lack of resources (storage capacity of disk) in the company computer system, it is considered that the company data is temporarily saved in the huge disk pool in the outside data center.",
"When plural companies employ this service, the hosting server of this embodiment is applied to prevent leakage of the information of each company within the data center to other companies.",
"In the hosting server of this embodiment, the same disk is physically shared among plural companies.",
"However, even though a certain company can read the divided data of another company written on the accessible disk, the original data is not restored from the divided data, and the information is not leaked.",
"Therefore, it is allowed to share the disk among plural companies while keeping the safety of information temporarily saved, whereby the utilization efficiency of resources in the data center is enhanced.",
"In this embodiment, the hosting server has the disk array composed of plural magnetic disk devices as the storage device.",
"However, this embodiment may be also applicable to the storage device using various storage media other than the magnetic disk device in the server or computer apparatus having the storage device group composed of plural storage units.",
"Also, in this embodiment, the data to be stored may be not only the write data in response to a write request from the client but also plural data files required to regulate the user accessible to each data file.",
"That is, each data file is stored in plural storage devices distributed so that the storage devices storing individual data files may partly overlap with each other, whereby the access control is more reliable, and the safety of stored data file is assured.",
"As described above, with this invention, while the recording medium is shared among plural users, the safety of recorded data is assured, and the utilization efficiency of the recording medium is enhanced."
] |
BACKGROUND OF THE INVENTION
The present invention relates to an electrostatic copying apparatus for electrostatically transferring an image formed on an image forming body to a copying medium and, more particularly, to an electrostatic copying apparatus with a transfer roller.
Recently, there has been proposed a transfer device with a transfer roller as a means for transferring a toner image formed on a surface of an image forming body such as a photosensitive layer of a photosensitive drum onto a copying medium such as a copying paper.
The transfer device is provided with a transfer roller which is rotatably disposed touchable to the outer peripheral surface of the photosensitive layer. A bias voltage is applied to the outer peripheral surface of the transfer roller. A copying paper being supplied is nipped between the outer periphery surfaces of the photosensitive layer and the transfer roller. At the paper nipping portion, a toner image formed on the photosensitive layer surface is electrostatically attracted from the photosensitive layer surface onto the paper under the applications of the bias voltage. In this way, the toner image is transferred onto the paper. The image transfer by means of the transfer roller is very effective for the electrostatic copying apparatus of the type in which a toner image has been formed temporally on the photosensitive layer before the execution of copying.
In the image transfer using the transfer roller, however, when a part of a toner image for a paper of large size is transferred to a paper of small size, the toner of the toner image portion formed on the area of the photosensitive layer which is other than the area defined by the small size paper directly adheres to the corresponding area on the outer peripheral surface of the transfer roller. In the next transfer stage using a large size paper, the toner left adhering to the outer peripheral surface of the transfer roller adheres to the reverse side of the large size paper to soil the reverse side of the paper.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an electrostatic copying apparatus which can prevent a transfer roller from getting dirty with toner formed from that part of a toner image which cannot be transferred onto a copying medium and which can therefore prevent the copying medium from being stained with the toner.
According to an aspect of the present invention, there is provided an electrostatic copying apparatus having an image forming body forming a toner image on the surface thereof and a transfer device for transferring electrostatically the toner image formed on the surface of the image forming body to a copying medium, the transfer device having a rotatable transfer roller which faces the surface of the image forming body for selectively copying at least two different sizes of the copying medium, wherein the transfer device comprises a drive mechanism for driving the transfer roller for such a period as to feed the copying medium for a distance equal to the length thereof in the feeding direction, while keeping the copying medium in contact with the image forming body.
The present invention will be better understood after careful reading of the following description taken in connection with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a main portion of a first embodiment of an electrostatic copying apparatus according to the present invention;
FIG. 2 is a perspective view of a transfer device used in the copying apparatus shown in FIG. 1;
FIG. 3 is a side view of the transfer device shown in FIG. 2;
FIG. 4A is a perspective view of a charger used in copying apparatus shown in FIG. 1;
FIG. 4B is a bottom view of the charger shown in FIG. 4A;
FIG. 5 is a side view useful in explaining the operation of the copying apparatus shown in FIG. 1;
FIG. 6 is a side view for illustrating a different operation state from that shown in FIG. 5;
FIG. 7 is a side view of a main portion of a second embodiment of an electrostatic copying apparatus according to the present invention;
FIG. 8 is a perspective view of a transfer device used in the copying apparatus shown in FIG. 7;
FIG. 9 is a side view of a main portion of a third embodiment of an elecrostatic copying apparatus according to the present invention; and
FIGS. 10 and 11 are side views of operation states of the copying apparatus which are different from that shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of an electrostatic copying apparatus according to the present invention will be described in detail referring to the accompanying drawings.
In FIG. 1, reference numeral 1 designates a paper transfer path of the electrostatic copying apparatus. Along the path 1 in the order of numbers from a start end of the copying apparatus, there are disposed a paper feed cassette 2 for containing a pile of copying papers P as the copying medium, a first paper guide 3, a paper length detecting switch 4, a second paper guide 5, a copying processing mechanism 6, a fixing device (not shown) and a tray for discharged papers (not shown). A plurality of detecting switches 7 are disposed at the start end of the paper transfer path and above the paper feed cassette 2. These detecting switches 7, arranged side by side in a direction orthogonal to the paper transfer path 1, constitute a paper width detecting means 8. A paper feed roller 9 is disposed touchable to the top of the pile of copying papers P.
The construction of the copying processing mechanism 6 will be described hereinafter.
A photosensitive drum 10 as the image forming body comprises a cylindrical body of aluminum as a base member of which the outer peripheral surface is coated with photosensitive material such as zinc oxide or the like. The photosensitive coated film forms a strong photosensitive layer 10a around the outer peripheral surface of the cylindrical body. The lower end of the outer periphery surface of the drum 10 is disposed in opposition to the transfer path 1. The photosensitive drum 10 is rotated, by means of an external drive means (not shown), in a direction the arrow (clockwise). Disposed around the periphery of the photosensitive drum 10 are, in the order of numerals or in the arrow direction, a charger 11, an image exposure device 12, a developing device 13, a transfer device 14, and a cleaner 15. Those periphery devices constitute the well known copying process mechanism. The charger 11 of those periphery devices has a construction as well illustrated in FIGS. 4A and 4B. As shown, two wires 16a and 16b for corona discharge with different lengths l A and l B are separately arranged in parallel fashion in a longitudinal direction of the charger body 16 within the charger body 16. The lengths l A and l B represent the widths of copying papers of A4 and B4 sizes, respectively. In accordance with the paper widh information of the detecting switch 7 in the paper width detecting means 8, the wire 16a or 16b is selected for its electrical energization. The charged width on the photosensitive layer 10a is switched in accordance with the paper width of A4 or B4, through the selection of the wire.
The transfer device 14 used in the copying processing mechanism 6 is shown in FIGS. 2 and 3.
The transfer device 14 is provided with a rotatable transfer roller 14a. The transfer roller 14a rotatably contacts the lower periphery portion of the photosensitive drum 10, with the paper transfer path 1 interposing therebetween.
When the transfer roller 14a is made to contact with the photosensitive layer 10a, the following requirements must be satisfied in order to improve the transfer efficiency:
(1) the bias voltage must be applied to the portion Y of the photosensitive layer 10a where the transfer roller 14a contacts the layer 10a through a copying paper;
(2) the bias voltage must be applied to as broad a portion of the layer 10a as possible; and
(3) the drum 10a and roller 14a must be rotated at the same circumferential speed thereby to prevent toner from falling from the copying paper P and thus the picture from deteriorating.
Bearing the above requirements in mind, let us consider the transfer roller 14a.
The transfer roller 14a has a conductive, resilient tubular member 16A provided around a metal shaft 15. One end of the shaft 15A of the transfer roller 14a is coupled with a minus terminal of a DC power source 17 as a bias means. The DC power source 17 applies about -50 V to -1 KV, for example, appropriate for the transfer process over the periphery surface of the resilient member 16A. The plus terminal of the DC power source 17 is grounded. One end of the shaft 15A the transfer roller 14a is rotatably coupled with the one end of lever 18a; and the other end of the shaft 15A is similarly coupled to lever 18b. The levers 18a and 18b are rotatably interconnected at the centers with each other by means of a common support shaft 18. The other ends of the levers 18a and 18b are coupled with tension springs 19, respectively. The springs 19 urge the respective levers 18a and 18b about the shaft 18 as a fulcrum counterclockwise as viewed in the drawings. The levers 18a and 18b, the support shaft 18 and the spring 19 cooperatively constitute a driving mechanism 20 for moving the transfer roller 14a toward away from the photosensitive drum. Specifically, when the transfer roller 14a is in the transfer mode, it presses the resilient member 16A against the photosensitive drum 10 to make a depression on the rotatable contact portion Y of the resilient member 16A, thereby increasing the area of the bias voltage impression. The swing mechanism 20 is coupled with a cam clutch mechanism 21a. Mechanisms 20, 21a cooperate to construct a transfer roller swing means 21.
The cam clutch mechanism 21a will be described hereinafter. In the FIG. 2, reference numeral 22 designates a clutch operation arm rotatably supported at the center. The proximal end of the arm 22 is coupled with an actuator 23a of a solenoid 23. The distal end of the arm 22 is provided with a nail like operating part 22a. The solenoid 23 is coupled with the paper length detecting switch 4 and a timer circuit 44. In operation, the paper length detecting switch 4 detects the leading end of the transfer paper P. After t second, which is taken for the leading end of the paper P to travel from the detecting portion of the switch 4 to reach the rotatable contact portion Y of the photosensitive drum 10 with the transfer roller 14a, a detection signal which is delayed by the timer circuit 44 is inputted to the solenoid 23.
Upon receipt of the signal, the solenoid 23 is energized and immediately deenergized. The actuator 23a projects from the solenoid 23 and immediately retreates into the solenoid 23. As the actuator 23a moves back and forth in this manner, the arm 22 swings. Then, the copying paper travels and the trailing end of the transfer paper P is detected by the paper length detecting switch 4. After t second from the trailing end detection, the detection signal is inputted to the solenoid 23. By the input signal, the solenoid 23 is energized and immediately after the energization, it is deenergized. With the energization and deenergization, the actuator 23a advances and retreats the swing the arm 22. A compression spring 24 for arm restoration is connected to the arm 22, which urges the arm 22 in one direction. A clutch system to time the operation of the transfer roller 14a, through the arm 22 will be described hereinafter.
Reference numeral 25 designates a known semirotation clutch. A pair of depressions 25a, formed on the peripheral surface of the semirotation clutch 25, are distant from each other by 180° along the periphery of the clutch 25. In the semirotation clutch 25, the operation part 22a of the arm 22 is inserted into one of the depressions 25a at a predetermined position to stop the rotation of the main body of the clutch. As a result, the rotation of a drive shaft 26 is not transferred to a driven shaft 27. On the other hand, when the operating part 22a is removed from the depression 25a, the rotation of the clutch main body is allowed. Then, at the same position the operating part 22a is inserted into the other depression 25a of the clutch 25 to allow the rotation drive force of the drive shaft 26 to be transmitted to the driven shaft 27. As a result, the driven shaft 27 is rotated by 180°. The operation part 22a of the arm 22 is so arranged that it always contacts the peripheral surface of the clutch body surface and when the depression 25a reaches the given position where the operating part 22a is disposed, the operation part 22a drops into the depression 25a. The drive shaft 26 is coaxially and fixedly mounted to a sprocket 29a which is coupled with a drive source (not shown) by means of a chain 28.
A pair of circular cam plates 29 are eccentrically mounted to the driven shaft 27 of the semirotation clutch 25, being part from each other in parallel. These cam plates 29 are so arranged that, when the semirotation clutch 25 is at the time of no transmission of the drive force either the furthest part of the cam surface from the eccentric shaft or the closest part of each cam plate is disposed at the top portion as viewed in the vertical direction. The cam plates 29 are disposed below the lower surfaces of the levers 18a and 18b, while the cam surfaces of both the cam plates 29 engage with the lower surfaces of the levers 18a and 18b. In operation, when the furthest portion of the cam surface is positioned at the upper side, the levers 18a and 18b are rotated clockwise, while resisting the urging force of the spring 19, to retreat the transfer roller 14a from the surface of the photosensitive drum 10. When the closest portion of the cam surface is disposed on the upper side, the levers 18a and 18b engaging the closest parts of the cams are rotated counterclockwise according to the urging force of the spring 19 to make the transfer roller 14a contact with the surface of the photosensitive drum 10. Under a condition that the transfer roller 14a is rotatably in contact with the surface of the photosensitive drum 10, the cam surface may be in a separation from the lower surfaces of the levers 18a and 18b. According to the eccentricity of the cam surface, the levers 18a and 18b are rotatably moved to press the transfer roller 14a against the photosensitive drum 10a and to separate it from the drum. As a drive system for the transfer roller 14a, a sprocket 31 is fixedly mounted to the end of the shaft 15A, and the sprocket 31 and a drive source (not shown) are coupled with each other by means of a chain 32. During the course of operation of the copying apparatus, the transfer roller 14a normally is rotated by the drive system.
The peripheral speed of the rotation of the transfer roller 14a is equal to that of the resilient member with a distorted radius r' reduced by an amount x of distortion due to the pressure, as shown in FIG. 3. In other words, the peripheral speed of the transfer roller 14a is faster than the peripheral speed of the photosensitive drum 10 by the amount x of distortion, or the difference between the distorted radius r' of the resilient member 16A at the time of the pressure contact of the transfer roller 14a and the radius r of the resilient member 16A at the time of non-contact of the roller 14a. With the peripheral speed adjustment, the peripheral speed of the photosensitive drum at the time of the pressure contact is coincident with that of the transfer roller 14a.
With references to the aforementioned figures, explanation will be given about a case where the copy is made by using the electrostatic copying apparatus.
The paper supply cassette 2 containing a pile of papers P of a small size, for example, an A4 size with a length L A (which extends in the transfer direction of the paper) and a width l A (which extends in the direction orthogonal to the paper transfer direction), is loaded into the main body (not shown) of the copying apparatus. Then, a document is placed on a document table (not shown); an operating section (not shown) is operated to set the copy size to a desired size, for example, A4 size; and a copy start switch (not shown) is operated. Upon the turning on the start switch, the copying process mechanism 6, the paper feed system, and the paper discharging system are in the operation mode.
The document on the document table is exposed in the scanning manner by the exposure device 12. An image on the document is led to the photosensitive layer 10a by the optical fiber lens 33. The charger 11 receives the paper width detecting information of the A4 paper outputted from the detecting switch 7 to electrically energize the shorter wire 16a and to charge the photosensitive layer 10a with the width l A of the A4 size. With the rotation of the photosensitive drum 10, an image is projected, through the optical fiber lens 33, on the photosensitive layer 10a thus charged, thereby to form an electrostatic latent image 34 corresponding to the image of the document on the photosensitive layer 10a. The electrostatic latent image 34 is changed into an visual image, which is led to the transfer device 14.
Note here that the portion of the copying paper P of the B4 size which is larger than the copying paper P of the A4 size in the width of the photosensitive layer 10a, that is to say, the width portion of the photosensitive layer 10a corresponding to the width l W (=l B -l A ), is not charged and has no toner thereon. Hence, toner is never attached to the portion of the transfer roller 14a in opposition to the portion (extending over the width of l W ) of the photosensitive layer 10a.
In the paper feed system, the paper feed roller 9 operates to take out the copying paper P of the A4 size sheet by sheet from the paper feed cassette 2. The copying paper P taken out is transferred to the paper length detecting switch 4 along the paper transfer path 1. When the switch 4 detects the leading end of the paper P, the detecting signal is applied to the timer circuit 44. After t second taken for the leading end of the paper P to travel from the detecting portion by the switch 4 to reach the rotatable contact portion Y on the photosensitive drum 10, the timer circuit 44 produces a signal for transfer to the solenoid 23. Upon receipt of the signal, the solenoid 23 drives the transfer roller 14a to make it rotatably contact with the photosensitive layer 10a.
The solenoid 23 is magnetically excited in response to the signal inputted. By the magnetic excitation, the arm 22 is rotated clockwise in FIG. 2 to separate the operation part 22a from the depression 25a. As a result, the operation part 22a disengages with the operation depression 25a. The disengagement allows the driven shaft 27 of the semirotation clutch 25 to be coupled with the drive shaft 26. The drive force of the drive shaft 26 is transmitted to the driven shaft 27 and the cam plates 29, so that the cam plates 29 start to rotate. Immediately after the clutch body starts to rotate, the solenoid 23 is deenergized to allow the operation part 22a to contact with the peripheral surface of the clutch body. Then, when the cam surface closest to the eccentric shaft reaches the top, the levers 18a and 18b are released to allow the transfer roller 14a to rotatably contact the photosensitive drum 10. Subsequently, the depression 25a distant from the former depression by 180° engages the operation part 22a again, the cam plates 29 are held at the given position. Thus, the transfer roller 14 rotatably contacts with the photosensitive drum 10 at much the same time that the leading end of the copying paper P reaches the rotatable contact portion Y, as shown in FIG. 5.
A toner image 34 of the A4 size of the length L A and the width l A , for example, on the photosensitive layer 10a is electrostatically transferred onto the copying paper P at the contact portion Y by means of the transfer roller 14a.
When the trailing edge of the copying paper P is detected by the detecting switch 4, the detecting signal is inputted to the timer circuit 44, as in the case of the leading edge detection. After the time t second taken for the trailing end of the paper P to travel from the detecting portion of the paper length detecting switch 4 to reach the transfer portion Y on the photosensitive drum 10, the signal is produced from the timer circuit 44 and is applied to the solenoid 23. In response to the signal, the solenoid 23 separates the transfer roller 14 from the photosensitive layer 10a.
That is, the solenoid 23 is energized when it receives the input signal. Upon the energization, the arm 22 is rotated clockwise in FIG. 2 to disengage the operation part 22a from the depression 25a. Upon the disengagement, the driven shaft 27 of the semirotation clutch 25 is coupled with the drive shaft 26. The drive force of the drive shaft 26 is transmitted to the driven shaft 27 and the cam plate 29, so that those shafts 26, 27 are rotated by 180°. When the farthest cam faces of the cam plates 29 reaches the top portion, the levers 18a and 18b are rotated against the urging force of the spring 19 clockwise in the drawing, thereby separating the transfer roller 14 from the photosensitive layer 10a. When the depression 25a distant from the former depression by 180° engages again the operation part 22a, the cam plates 29 are held at the given position. As indicated by two dots-dash line in FIG. 2, a separation state of the transfer roller 14a is realized. That is, the transfer roller 14a is in the separation state substantially simultaneously with the arrival of the trailing end of the paper P at the transfer portion Y. In this way, only when the copying paper P passes the rotatable contact portion Y, the image is transferred to the paper P only at the length of the length L A .
The paper after copied is transferred to the fixing device of the succeeding stage.
After the transfer stage, the photosensitive layer 10a is cleaned by the cleaner 15 and returned to a position near the charger 11.
As described above, the transfer roller 14a is separated from the photosensitive drum in the other mode than the transfer mode, whereby the image transfer is made on only the portion corresponding to the length of the paper P. In addition, the image transfer on only the portion corresponding to the paper width may be realized by charging only the portion of the photosensitive layer 10a corresponding to the paper width. This prevents the toner from sticking onto the portion exceeding the area on the photosensitive layer defined by the paper size.
Therefore, it is possible to prevent the reverse side of the paper P from being dirtied in the next transfer stage. This implies that the cleaning mechanism of the transfer roller 14 may be simplified.
It should be understood that the present invention is not limited to the above-mentioned embodiment but may be changed or modified variously within the scope and spirit of the present invention.
While the present invention detects the leading and trailing ends of the paper P by the paper length detecting switch, and controls the contact and separation of the transfer roller for the photosensitive drum, the detection of the paper ends may be performed by other suitable means. For example, the copy signal is used for detecting the leading end of the copying paper, and is properly processed by the timer circuit and the contact and separation of the transfer roller may be controlled by the control signal.
In the above embodiment, the transfer roller is rotated by using the special drive mechanism, but the roller may be rotated by the photosensitive drum, following the rotation of the drum.
A second embodiment of a transfer device according to the present invention will be described referring to FIGS. 7 and 8 hereinafter. Like and same numerals are used for designating like and same portions in the above embodiment.
In the first embodiment, the toner image formed exceeding the area defined by the paper size is precluded by using the charger with two wires with different lengths. In the second embodiment, an exposure device 41, as a charge remover, therein is disposed at a predetermined location between the exposure device 12 and the developing device 13. The exposure device 41 has an exposure lamp 40 in a main body 42. The exposure device 42 is disposed over the width l W . The exposure device 41 further controls the electrical conduction of the exposure lamp 40 in accordance with the information of the detected A4 or B4 paper width from the detecting switches 7 of the detecting means 8. When the width of the A4 paper is detected, the lamp 40 is lit; while the B4 width is detected, the lamp 40 is turned off. An amount of the exposure light of the lamp 40 is so selected that when the photosensitive layer 10a receives light rays, the surface potential is reduced up to the bias voltage. In this way, the exposure device 41 operating according to the information of the detected paper size A4 produced from the detecting switches 7 exposes the outer periphery surface area l W of the photosensitive layer 10a which does not face the width length l A of the paper P of the A4 size. Through the exposure, the surface potential in the outer periphery area is below the bias voltage and effects no transfer of image.
As described above, the use of the exposure device 41 provides the effects similar to those of the first embodiment. In other words, the transfer of the image area defined by the length and width of the paper P can be performed by controlling the contact and separation of the transfer roller 14a for the photosensitive drum 10 and controlling the exposure of the exposure device 41. Therefore, the toner image formed on the area other than the area defined by the paper size is never stuck to the transfer roller 14. The exposure device 41 is not limited to the fixed amount type as mentioned above, but may be rotatably mounted; for example, it may be mounted movably to change the exposure location along the width direction of the photosensitive layer 10a according to the size of the paper copied.
A third embodiment of a transfer device according to the present invention will be described referring to FIGS. 9 to 11. Like and same numerals are used to designate like and same portions in the first embodiment.
The output of the switches 7 is connected to a search control circuit 43 storing the information of a plurality of paper sizes such as A4, B4 and the like, and the timer circuit 44. Those constitute a size detection means 45. The size detection means 45 responds to the detected information from the switch 7 to switch the electrical conduction of the wires 16a and 16b and thus to switch the charged width on the photosensitive layer 10a to the area of A4 or B4. The first paper guide 3 in the third embodiment is used for directly guiding the copying paper P supplied from the paper feed cassette 2 till the rotatable contact area Y between the transfer device 14 and the photosensitive drum 10. The third embodiment does not use the paper length detecting switch 4 which is used in the first embodiment. Connected to the solenoid 23 are the detecting switches 7 through the search control circuit 43 and the timer circuit 44. When the A4 paper is detected by the detecting switches 7, the search control circuit 43 searches a signal representing the leading and trailing ends of the paper of A4. The searched signal is applied to the timer circuit 44 where it is delayed by a given time and is then applied to the solenoid 23 thereby to drive the solenoid 23. Specifically, after t taken for the leading end of the paper to travel from the detecting portion of the transfer roller 14 to the rotatable portion Y between the photosensitive drum 10 and the transfer roller 14, the leading end position signal from the timer circuit 44 is directed toward the solenoid 23, as shown in FIG. 10. The leading end position signal corresponds to the leading end detected signal of the paper P in the first embodiment. Accordingly, the solenoid 23 operates in a similar manner.
Further, after t taken for the trailing end of the paper P to travel from the detecting portion of the switch 7 to reach the contact portion Y between the photosensitive drum 10 and the transfer roller 14, the timer circuit 44 produces the trailing end position signal toward the solenoid 23. The trailing end position signal corresponds to the signal representing the detected trailing end of the transfer paper P in the first embodiment.
The size detecting means 45 receives the information of the detected paper size of A4 outputted from the detecting switches 7 to electrically energize the shorter wire 16a and to subsequently charge only the width of the A4 size paper on the photosensitive layer 10a.
In the paper feed system, the paper feed roller 9 takes out the A4 size papers sheet by sheet from the cassette 2 to transfer them along the paper transfer path 1. After time t taken for the leading end of the paper P to travel from the detecting portion of the switches 7 to reach the rotatable contact portion on the photosensitive drum 10, the timer circuit 44 produces the leading end position signal toward the solenoid 23 whereby the solenoid presses the transfer roller 14 against the photosensitive layer 10a.
It is evident that the size detection means 45 in the third embodiment may be used for the lamp control of the exposure device 41 in the second embodiment. | An electrostatic copying apparatus comprises a photosensitive body forming a toner image on the surface thereof, and a transfer device for transferring electrostatically the toner image formed on the surface of the drum to a copying paper. The transfer device includes a rotatable transfer roller which faces the surface of the photosensitive drum for selectively transferring at least two different sizes of the copying paper. The transfer device comprises a moving mechanism for driving the transfer roller for such a period as to feed the copying paper for a distance equal to the length thereof in the feeding direction, while keeping the copying paper in contact with the photosensitive drum. Additionally, apparatus is provided for forming a toner image on the surface of the drum corresponding in width to that of the copying paper being utilized. | Identify and summarize the most critical features from the given passage. | [
"BACKGROUND OF THE INVENTION The present invention relates to an electrostatic copying apparatus for electrostatically transferring an image formed on an image forming body to a copying medium and, more particularly, to an electrostatic copying apparatus with a transfer roller.",
"Recently, there has been proposed a transfer device with a transfer roller as a means for transferring a toner image formed on a surface of an image forming body such as a photosensitive layer of a photosensitive drum onto a copying medium such as a copying paper.",
"The transfer device is provided with a transfer roller which is rotatably disposed touchable to the outer peripheral surface of the photosensitive layer.",
"A bias voltage is applied to the outer peripheral surface of the transfer roller.",
"A copying paper being supplied is nipped between the outer periphery surfaces of the photosensitive layer and the transfer roller.",
"At the paper nipping portion, a toner image formed on the photosensitive layer surface is electrostatically attracted from the photosensitive layer surface onto the paper under the applications of the bias voltage.",
"In this way, the toner image is transferred onto the paper.",
"The image transfer by means of the transfer roller is very effective for the electrostatic copying apparatus of the type in which a toner image has been formed temporally on the photosensitive layer before the execution of copying.",
"In the image transfer using the transfer roller, however, when a part of a toner image for a paper of large size is transferred to a paper of small size, the toner of the toner image portion formed on the area of the photosensitive layer which is other than the area defined by the small size paper directly adheres to the corresponding area on the outer peripheral surface of the transfer roller.",
"In the next transfer stage using a large size paper, the toner left adhering to the outer peripheral surface of the transfer roller adheres to the reverse side of the large size paper to soil the reverse side of the paper.",
"SUMMARY OF THE INVENTION It is an object of this invention to provide an electrostatic copying apparatus which can prevent a transfer roller from getting dirty with toner formed from that part of a toner image which cannot be transferred onto a copying medium and which can therefore prevent the copying medium from being stained with the toner.",
"According to an aspect of the present invention, there is provided an electrostatic copying apparatus having an image forming body forming a toner image on the surface thereof and a transfer device for transferring electrostatically the toner image formed on the surface of the image forming body to a copying medium, the transfer device having a rotatable transfer roller which faces the surface of the image forming body for selectively copying at least two different sizes of the copying medium, wherein the transfer device comprises a drive mechanism for driving the transfer roller for such a period as to feed the copying medium for a distance equal to the length thereof in the feeding direction, while keeping the copying medium in contact with the image forming body.",
"The present invention will be better understood after careful reading of the following description taken in connection with the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view of a main portion of a first embodiment of an electrostatic copying apparatus according to the present invention;",
"FIG. 2 is a perspective view of a transfer device used in the copying apparatus shown in FIG. 1;",
"FIG. 3 is a side view of the transfer device shown in FIG. 2;",
"FIG. 4A is a perspective view of a charger used in copying apparatus shown in FIG. 1;",
"FIG. 4B is a bottom view of the charger shown in FIG. 4A;",
"FIG. 5 is a side view useful in explaining the operation of the copying apparatus shown in FIG. 1;",
"FIG. 6 is a side view for illustrating a different operation state from that shown in FIG. 5;",
"FIG. 7 is a side view of a main portion of a second embodiment of an electrostatic copying apparatus according to the present invention;",
"FIG. 8 is a perspective view of a transfer device used in the copying apparatus shown in FIG. 7;",
"FIG. 9 is a side view of a main portion of a third embodiment of an elecrostatic copying apparatus according to the present invention;",
"and FIGS. 10 and 11 are side views of operation states of the copying apparatus which are different from that shown in FIG. 9. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of an electrostatic copying apparatus according to the present invention will be described in detail referring to the accompanying drawings.",
"In FIG. 1, reference numeral 1 designates a paper transfer path of the electrostatic copying apparatus.",
"Along the path 1 in the order of numbers from a start end of the copying apparatus, there are disposed a paper feed cassette 2 for containing a pile of copying papers P as the copying medium, a first paper guide 3, a paper length detecting switch 4, a second paper guide 5, a copying processing mechanism 6, a fixing device (not shown) and a tray for discharged papers (not shown).",
"A plurality of detecting switches 7 are disposed at the start end of the paper transfer path and above the paper feed cassette 2.",
"These detecting switches 7, arranged side by side in a direction orthogonal to the paper transfer path 1, constitute a paper width detecting means 8.",
"A paper feed roller 9 is disposed touchable to the top of the pile of copying papers P. The construction of the copying processing mechanism 6 will be described hereinafter.",
"A photosensitive drum 10 as the image forming body comprises a cylindrical body of aluminum as a base member of which the outer peripheral surface is coated with photosensitive material such as zinc oxide or the like.",
"The photosensitive coated film forms a strong photosensitive layer 10a around the outer peripheral surface of the cylindrical body.",
"The lower end of the outer periphery surface of the drum 10 is disposed in opposition to the transfer path 1.",
"The photosensitive drum 10 is rotated, by means of an external drive means (not shown), in a direction the arrow (clockwise).",
"Disposed around the periphery of the photosensitive drum 10 are, in the order of numerals or in the arrow direction, a charger 11, an image exposure device 12, a developing device 13, a transfer device 14, and a cleaner 15.",
"Those periphery devices constitute the well known copying process mechanism.",
"The charger 11 of those periphery devices has a construction as well illustrated in FIGS. 4A and 4B.",
"As shown, two wires 16a and 16b for corona discharge with different lengths l A and l B are separately arranged in parallel fashion in a longitudinal direction of the charger body 16 within the charger body 16.",
"The lengths l A and l B represent the widths of copying papers of A4 and B4 sizes, respectively.",
"In accordance with the paper widh information of the detecting switch 7 in the paper width detecting means 8, the wire 16a or 16b is selected for its electrical energization.",
"The charged width on the photosensitive layer 10a is switched in accordance with the paper width of A4 or B4, through the selection of the wire.",
"The transfer device 14 used in the copying processing mechanism 6 is shown in FIGS. 2 and 3.",
"The transfer device 14 is provided with a rotatable transfer roller 14a.",
"The transfer roller 14a rotatably contacts the lower periphery portion of the photosensitive drum 10, with the paper transfer path 1 interposing therebetween.",
"When the transfer roller 14a is made to contact with the photosensitive layer 10a, the following requirements must be satisfied in order to improve the transfer efficiency: (1) the bias voltage must be applied to the portion Y of the photosensitive layer 10a where the transfer roller 14a contacts the layer 10a through a copying paper;",
"(2) the bias voltage must be applied to as broad a portion of the layer 10a as possible;",
"and (3) the drum 10a and roller 14a must be rotated at the same circumferential speed thereby to prevent toner from falling from the copying paper P and thus the picture from deteriorating.",
"Bearing the above requirements in mind, let us consider the transfer roller 14a.",
"The transfer roller 14a has a conductive, resilient tubular member 16A provided around a metal shaft 15.",
"One end of the shaft 15A of the transfer roller 14a is coupled with a minus terminal of a DC power source 17 as a bias means.",
"The DC power source 17 applies about -50 V to -1 KV, for example, appropriate for the transfer process over the periphery surface of the resilient member 16A.",
"The plus terminal of the DC power source 17 is grounded.",
"One end of the shaft 15A the transfer roller 14a is rotatably coupled with the one end of lever 18a;",
"and the other end of the shaft 15A is similarly coupled to lever 18b.",
"The levers 18a and 18b are rotatably interconnected at the centers with each other by means of a common support shaft 18.",
"The other ends of the levers 18a and 18b are coupled with tension springs 19, respectively.",
"The springs 19 urge the respective levers 18a and 18b about the shaft 18 as a fulcrum counterclockwise as viewed in the drawings.",
"The levers 18a and 18b, the support shaft 18 and the spring 19 cooperatively constitute a driving mechanism 20 for moving the transfer roller 14a toward away from the photosensitive drum.",
"Specifically, when the transfer roller 14a is in the transfer mode, it presses the resilient member 16A against the photosensitive drum 10 to make a depression on the rotatable contact portion Y of the resilient member 16A, thereby increasing the area of the bias voltage impression.",
"The swing mechanism 20 is coupled with a cam clutch mechanism 21a.",
"Mechanisms 20, 21a cooperate to construct a transfer roller swing means 21.",
"The cam clutch mechanism 21a will be described hereinafter.",
"In the FIG. 2, reference numeral 22 designates a clutch operation arm rotatably supported at the center.",
"The proximal end of the arm 22 is coupled with an actuator 23a of a solenoid 23.",
"The distal end of the arm 22 is provided with a nail like operating part 22a.",
"The solenoid 23 is coupled with the paper length detecting switch 4 and a timer circuit 44.",
"In operation, the paper length detecting switch 4 detects the leading end of the transfer paper P. After t second, which is taken for the leading end of the paper P to travel from the detecting portion of the switch 4 to reach the rotatable contact portion Y of the photosensitive drum 10 with the transfer roller 14a, a detection signal which is delayed by the timer circuit 44 is inputted to the solenoid 23.",
"Upon receipt of the signal, the solenoid 23 is energized and immediately deenergized.",
"The actuator 23a projects from the solenoid 23 and immediately retreates into the solenoid 23.",
"As the actuator 23a moves back and forth in this manner, the arm 22 swings.",
"Then, the copying paper travels and the trailing end of the transfer paper P is detected by the paper length detecting switch 4.",
"After t second from the trailing end detection, the detection signal is inputted to the solenoid 23.",
"By the input signal, the solenoid 23 is energized and immediately after the energization, it is deenergized.",
"With the energization and deenergization, the actuator 23a advances and retreats the swing the arm 22.",
"A compression spring 24 for arm restoration is connected to the arm 22, which urges the arm 22 in one direction.",
"A clutch system to time the operation of the transfer roller 14a, through the arm 22 will be described hereinafter.",
"Reference numeral 25 designates a known semirotation clutch.",
"A pair of depressions 25a, formed on the peripheral surface of the semirotation clutch 25, are distant from each other by 180° along the periphery of the clutch 25.",
"In the semirotation clutch 25, the operation part 22a of the arm 22 is inserted into one of the depressions 25a at a predetermined position to stop the rotation of the main body of the clutch.",
"As a result, the rotation of a drive shaft 26 is not transferred to a driven shaft 27.",
"On the other hand, when the operating part 22a is removed from the depression 25a, the rotation of the clutch main body is allowed.",
"Then, at the same position the operating part 22a is inserted into the other depression 25a of the clutch 25 to allow the rotation drive force of the drive shaft 26 to be transmitted to the driven shaft 27.",
"As a result, the driven shaft 27 is rotated by 180°.",
"The operation part 22a of the arm 22 is so arranged that it always contacts the peripheral surface of the clutch body surface and when the depression 25a reaches the given position where the operating part 22a is disposed, the operation part 22a drops into the depression 25a.",
"The drive shaft 26 is coaxially and fixedly mounted to a sprocket 29a which is coupled with a drive source (not shown) by means of a chain 28.",
"A pair of circular cam plates 29 are eccentrically mounted to the driven shaft 27 of the semirotation clutch 25, being part from each other in parallel.",
"These cam plates 29 are so arranged that, when the semirotation clutch 25 is at the time of no transmission of the drive force either the furthest part of the cam surface from the eccentric shaft or the closest part of each cam plate is disposed at the top portion as viewed in the vertical direction.",
"The cam plates 29 are disposed below the lower surfaces of the levers 18a and 18b, while the cam surfaces of both the cam plates 29 engage with the lower surfaces of the levers 18a and 18b.",
"In operation, when the furthest portion of the cam surface is positioned at the upper side, the levers 18a and 18b are rotated clockwise, while resisting the urging force of the spring 19, to retreat the transfer roller 14a from the surface of the photosensitive drum 10.",
"When the closest portion of the cam surface is disposed on the upper side, the levers 18a and 18b engaging the closest parts of the cams are rotated counterclockwise according to the urging force of the spring 19 to make the transfer roller 14a contact with the surface of the photosensitive drum 10.",
"Under a condition that the transfer roller 14a is rotatably in contact with the surface of the photosensitive drum 10, the cam surface may be in a separation from the lower surfaces of the levers 18a and 18b.",
"According to the eccentricity of the cam surface, the levers 18a and 18b are rotatably moved to press the transfer roller 14a against the photosensitive drum 10a and to separate it from the drum.",
"As a drive system for the transfer roller 14a, a sprocket 31 is fixedly mounted to the end of the shaft 15A, and the sprocket 31 and a drive source (not shown) are coupled with each other by means of a chain 32.",
"During the course of operation of the copying apparatus, the transfer roller 14a normally is rotated by the drive system.",
"The peripheral speed of the rotation of the transfer roller 14a is equal to that of the resilient member with a distorted radius r'",
"reduced by an amount x of distortion due to the pressure, as shown in FIG. 3. In other words, the peripheral speed of the transfer roller 14a is faster than the peripheral speed of the photosensitive drum 10 by the amount x of distortion, or the difference between the distorted radius r'",
"of the resilient member 16A at the time of the pressure contact of the transfer roller 14a and the radius r of the resilient member 16A at the time of non-contact of the roller 14a.",
"With the peripheral speed adjustment, the peripheral speed of the photosensitive drum at the time of the pressure contact is coincident with that of the transfer roller 14a.",
"With references to the aforementioned figures, explanation will be given about a case where the copy is made by using the electrostatic copying apparatus.",
"The paper supply cassette 2 containing a pile of papers P of a small size, for example, an A4 size with a length L A (which extends in the transfer direction of the paper) and a width l A (which extends in the direction orthogonal to the paper transfer direction), is loaded into the main body (not shown) of the copying apparatus.",
"Then, a document is placed on a document table (not shown);",
"an operating section (not shown) is operated to set the copy size to a desired size, for example, A4 size;",
"and a copy start switch (not shown) is operated.",
"Upon the turning on the start switch, the copying process mechanism 6, the paper feed system, and the paper discharging system are in the operation mode.",
"The document on the document table is exposed in the scanning manner by the exposure device 12.",
"An image on the document is led to the photosensitive layer 10a by the optical fiber lens 33.",
"The charger 11 receives the paper width detecting information of the A4 paper outputted from the detecting switch 7 to electrically energize the shorter wire 16a and to charge the photosensitive layer 10a with the width l A of the A4 size.",
"With the rotation of the photosensitive drum 10, an image is projected, through the optical fiber lens 33, on the photosensitive layer 10a thus charged, thereby to form an electrostatic latent image 34 corresponding to the image of the document on the photosensitive layer 10a.",
"The electrostatic latent image 34 is changed into an visual image, which is led to the transfer device 14.",
"Note here that the portion of the copying paper P of the B4 size which is larger than the copying paper P of the A4 size in the width of the photosensitive layer 10a, that is to say, the width portion of the photosensitive layer 10a corresponding to the width l W (=l B -l A ), is not charged and has no toner thereon.",
"Hence, toner is never attached to the portion of the transfer roller 14a in opposition to the portion (extending over the width of l W ) of the photosensitive layer 10a.",
"In the paper feed system, the paper feed roller 9 operates to take out the copying paper P of the A4 size sheet by sheet from the paper feed cassette 2.",
"The copying paper P taken out is transferred to the paper length detecting switch 4 along the paper transfer path 1.",
"When the switch 4 detects the leading end of the paper P, the detecting signal is applied to the timer circuit 44.",
"After t second taken for the leading end of the paper P to travel from the detecting portion by the switch 4 to reach the rotatable contact portion Y on the photosensitive drum 10, the timer circuit 44 produces a signal for transfer to the solenoid 23.",
"Upon receipt of the signal, the solenoid 23 drives the transfer roller 14a to make it rotatably contact with the photosensitive layer 10a.",
"The solenoid 23 is magnetically excited in response to the signal inputted.",
"By the magnetic excitation, the arm 22 is rotated clockwise in FIG. 2 to separate the operation part 22a from the depression 25a.",
"As a result, the operation part 22a disengages with the operation depression 25a.",
"The disengagement allows the driven shaft 27 of the semirotation clutch 25 to be coupled with the drive shaft 26.",
"The drive force of the drive shaft 26 is transmitted to the driven shaft 27 and the cam plates 29, so that the cam plates 29 start to rotate.",
"Immediately after the clutch body starts to rotate, the solenoid 23 is deenergized to allow the operation part 22a to contact with the peripheral surface of the clutch body.",
"Then, when the cam surface closest to the eccentric shaft reaches the top, the levers 18a and 18b are released to allow the transfer roller 14a to rotatably contact the photosensitive drum 10.",
"Subsequently, the depression 25a distant from the former depression by 180° engages the operation part 22a again, the cam plates 29 are held at the given position.",
"Thus, the transfer roller 14 rotatably contacts with the photosensitive drum 10 at much the same time that the leading end of the copying paper P reaches the rotatable contact portion Y, as shown in FIG. 5. A toner image 34 of the A4 size of the length L A and the width l A , for example, on the photosensitive layer 10a is electrostatically transferred onto the copying paper P at the contact portion Y by means of the transfer roller 14a.",
"When the trailing edge of the copying paper P is detected by the detecting switch 4, the detecting signal is inputted to the timer circuit 44, as in the case of the leading edge detection.",
"After the time t second taken for the trailing end of the paper P to travel from the detecting portion of the paper length detecting switch 4 to reach the transfer portion Y on the photosensitive drum 10, the signal is produced from the timer circuit 44 and is applied to the solenoid 23.",
"In response to the signal, the solenoid 23 separates the transfer roller 14 from the photosensitive layer 10a.",
"That is, the solenoid 23 is energized when it receives the input signal.",
"Upon the energization, the arm 22 is rotated clockwise in FIG. 2 to disengage the operation part 22a from the depression 25a.",
"Upon the disengagement, the driven shaft 27 of the semirotation clutch 25 is coupled with the drive shaft 26.",
"The drive force of the drive shaft 26 is transmitted to the driven shaft 27 and the cam plate 29, so that those shafts 26, 27 are rotated by 180°.",
"When the farthest cam faces of the cam plates 29 reaches the top portion, the levers 18a and 18b are rotated against the urging force of the spring 19 clockwise in the drawing, thereby separating the transfer roller 14 from the photosensitive layer 10a.",
"When the depression 25a distant from the former depression by 180° engages again the operation part 22a, the cam plates 29 are held at the given position.",
"As indicated by two dots-dash line in FIG. 2, a separation state of the transfer roller 14a is realized.",
"That is, the transfer roller 14a is in the separation state substantially simultaneously with the arrival of the trailing end of the paper P at the transfer portion Y. In this way, only when the copying paper P passes the rotatable contact portion Y, the image is transferred to the paper P only at the length of the length L A .",
"The paper after copied is transferred to the fixing device of the succeeding stage.",
"After the transfer stage, the photosensitive layer 10a is cleaned by the cleaner 15 and returned to a position near the charger 11.",
"As described above, the transfer roller 14a is separated from the photosensitive drum in the other mode than the transfer mode, whereby the image transfer is made on only the portion corresponding to the length of the paper P. In addition, the image transfer on only the portion corresponding to the paper width may be realized by charging only the portion of the photosensitive layer 10a corresponding to the paper width.",
"This prevents the toner from sticking onto the portion exceeding the area on the photosensitive layer defined by the paper size.",
"Therefore, it is possible to prevent the reverse side of the paper P from being dirtied in the next transfer stage.",
"This implies that the cleaning mechanism of the transfer roller 14 may be simplified.",
"It should be understood that the present invention is not limited to the above-mentioned embodiment but may be changed or modified variously within the scope and spirit of the present invention.",
"While the present invention detects the leading and trailing ends of the paper P by the paper length detecting switch, and controls the contact and separation of the transfer roller for the photosensitive drum, the detection of the paper ends may be performed by other suitable means.",
"For example, the copy signal is used for detecting the leading end of the copying paper, and is properly processed by the timer circuit and the contact and separation of the transfer roller may be controlled by the control signal.",
"In the above embodiment, the transfer roller is rotated by using the special drive mechanism, but the roller may be rotated by the photosensitive drum, following the rotation of the drum.",
"A second embodiment of a transfer device according to the present invention will be described referring to FIGS. 7 and 8 hereinafter.",
"Like and same numerals are used for designating like and same portions in the above embodiment.",
"In the first embodiment, the toner image formed exceeding the area defined by the paper size is precluded by using the charger with two wires with different lengths.",
"In the second embodiment, an exposure device 41, as a charge remover, therein is disposed at a predetermined location between the exposure device 12 and the developing device 13.",
"The exposure device 41 has an exposure lamp 40 in a main body 42.",
"The exposure device 42 is disposed over the width l W .",
"The exposure device 41 further controls the electrical conduction of the exposure lamp 40 in accordance with the information of the detected A4 or B4 paper width from the detecting switches 7 of the detecting means 8.",
"When the width of the A4 paper is detected, the lamp 40 is lit;",
"while the B4 width is detected, the lamp 40 is turned off.",
"An amount of the exposure light of the lamp 40 is so selected that when the photosensitive layer 10a receives light rays, the surface potential is reduced up to the bias voltage.",
"In this way, the exposure device 41 operating according to the information of the detected paper size A4 produced from the detecting switches 7 exposes the outer periphery surface area l W of the photosensitive layer 10a which does not face the width length l A of the paper P of the A4 size.",
"Through the exposure, the surface potential in the outer periphery area is below the bias voltage and effects no transfer of image.",
"As described above, the use of the exposure device 41 provides the effects similar to those of the first embodiment.",
"In other words, the transfer of the image area defined by the length and width of the paper P can be performed by controlling the contact and separation of the transfer roller 14a for the photosensitive drum 10 and controlling the exposure of the exposure device 41.",
"Therefore, the toner image formed on the area other than the area defined by the paper size is never stuck to the transfer roller 14.",
"The exposure device 41 is not limited to the fixed amount type as mentioned above, but may be rotatably mounted;",
"for example, it may be mounted movably to change the exposure location along the width direction of the photosensitive layer 10a according to the size of the paper copied.",
"A third embodiment of a transfer device according to the present invention will be described referring to FIGS. 9 to 11.",
"Like and same numerals are used to designate like and same portions in the first embodiment.",
"The output of the switches 7 is connected to a search control circuit 43 storing the information of a plurality of paper sizes such as A4, B4 and the like, and the timer circuit 44.",
"Those constitute a size detection means 45.",
"The size detection means 45 responds to the detected information from the switch 7 to switch the electrical conduction of the wires 16a and 16b and thus to switch the charged width on the photosensitive layer 10a to the area of A4 or B4.",
"The first paper guide 3 in the third embodiment is used for directly guiding the copying paper P supplied from the paper feed cassette 2 till the rotatable contact area Y between the transfer device 14 and the photosensitive drum 10.",
"The third embodiment does not use the paper length detecting switch 4 which is used in the first embodiment.",
"Connected to the solenoid 23 are the detecting switches 7 through the search control circuit 43 and the timer circuit 44.",
"When the A4 paper is detected by the detecting switches 7, the search control circuit 43 searches a signal representing the leading and trailing ends of the paper of A4.",
"The searched signal is applied to the timer circuit 44 where it is delayed by a given time and is then applied to the solenoid 23 thereby to drive the solenoid 23.",
"Specifically, after t taken for the leading end of the paper to travel from the detecting portion of the transfer roller 14 to the rotatable portion Y between the photosensitive drum 10 and the transfer roller 14, the leading end position signal from the timer circuit 44 is directed toward the solenoid 23, as shown in FIG. 10.",
"The leading end position signal corresponds to the leading end detected signal of the paper P in the first embodiment.",
"Accordingly, the solenoid 23 operates in a similar manner.",
"Further, after t taken for the trailing end of the paper P to travel from the detecting portion of the switch 7 to reach the contact portion Y between the photosensitive drum 10 and the transfer roller 14, the timer circuit 44 produces the trailing end position signal toward the solenoid 23.",
"The trailing end position signal corresponds to the signal representing the detected trailing end of the transfer paper P in the first embodiment.",
"The size detecting means 45 receives the information of the detected paper size of A4 outputted from the detecting switches 7 to electrically energize the shorter wire 16a and to subsequently charge only the width of the A4 size paper on the photosensitive layer 10a.",
"In the paper feed system, the paper feed roller 9 takes out the A4 size papers sheet by sheet from the cassette 2 to transfer them along the paper transfer path 1.",
"After time t taken for the leading end of the paper P to travel from the detecting portion of the switches 7 to reach the rotatable contact portion on the photosensitive drum 10, the timer circuit 44 produces the leading end position signal toward the solenoid 23 whereby the solenoid presses the transfer roller 14 against the photosensitive layer 10a.",
"It is evident that the size detection means 45 in the third embodiment may be used for the lamp control of the exposure device 41 in the second embodiment."
] |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefits of U.S. Provisional Application Ser. No. 60/926,103, filed on Apr. 25, 2007, the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to solar cells and their fabrication, and in particular to nanorod-nanocrystal-polymer hybrid solar cells
BACKGROUND
[0003] To create useful electrical current from electromagnetic radiation, photovoltaic (PV) cells must absorb incident radiation such that an electron is promoted from the valence band to the conduction band (leaving a hole in the valence band), and must be able to separate the electron and hole and deliver these charge carriers to their respective electrodes before they recombine.
[0004] Many different strategies based on diverse materials have been employed, with varying degrees of success, to realize these basic behaviors with commercially satisfactory efficiency. Representative devices include crystalline inorganic solar cells (e.g., silicon, germanium, GaAs), nanocrystalline dye-sensitized solar cells, semiconductor-polymer solar cells, nanoparticle solar cells, and more recently, composite solar cells that incorporate and combine the aforementioned components from other strategies.
1. Inorganic Photovoltaics
[0005] Silicon is by far the most commonly used material for fabricating inorganic photovoltaics. These cells rely on the ability of silicon to absorb light and, consequently, to generate an excited electron-hole pair that is then separated at a p-n junction. The electric field set up by the p-n junction facilitates this separation because of the way electrons and holes move through materials: electrons move to lower energy levels while holes move to higher energy levels.
[0006] Creation of p-n junctions generally involves high-temperature processing in inert atmospheres to form very pure, crystalline silicon wafers, which are inflexible and expensive. Because silicon is an indirect semiconductor, a relatively thick layer is typically needed to achieve a good level of absorption, which increases material costs further. Efficiencies for the most pure (and expensive) silicon photovoltaics are on the order of 20%; efficiencies for the cheaper amorphous silicon cells are approximately 5-10%.
[0007] Today's commercial PV systems can convert from 5% to 15% of sunlight energy into electricity. These systems are highly reliable and generally last 20 years or longer. The possibility of fabricating solar cells by less expensive, lower-temperature techniques is very attractive. Accordingly, nanocrystalline dye-sensitized solar cells (DSSCs), semiconductor-polymer solar cells and nanoparticle solar cells have enjoyed widespread interest.
2. Polymer Photovoltaics
[0008] Semiconducting polymers can be used to make organic photovoltaics. The properties of these polymers can be tuned by functionalization of the constituent monomers. As such, a wide range of polymers with suitable bandgaps, absorption characteristics and physical properties is available. In order to achieve separation of the electron-hole pair, organic photovoltaics rely on donor-acceptor heterojunctions. In polymers, the excited-state electron and hole are bound together, and travel together, as a quasi-particle called an exciton. They remain together until they encounter a heterojunction, which separates them. Unfortunately, excitons are very short-lived and can only travel about 10 nm before recombining. Hence, any photon absorbed more than this diffusion length away from a heterojunction will be wasted. Charge mobilities for polymers are typically low (0.5-0.1 cm 2 V −1 s −1 ) compared to silicon, which is much higher (1500 cm 2 V −1 S −1 ). Current state-of-the-art polymer photovoltaic cells have efficiencies of 1-2%. Although such efficiencies are low, these materials hold promise for low-cost, flexible solar cells.
3. Nanoparticle Photovoltaics
[0009] Inorganic nanoparticles (or nanocrystals) have been used to prepare colloidal, thin-film PV cells that show some of the advantages of polymer photovoltaics while maintaining many of the advantages of inorganic photovoltaics. For example, such cells can contain a bi-layer structure comprising a layer of donor and a layer of acceptor nanoparticles, wherein the two layers exhibit little intermixing, and both contribute to the measured photocurrent. The strong photoconductive effect exhibited by these devices suggests that these materials have a large number of trapped carriers and are better described by a donor-acceptor molecular model than by a p-n band model. Increased bandgap energy compared to that of the bulk semiconductors minimizes the number of carriers available, and spatial separation of the donor and acceptor particles in different phases traps the excitons so that they must split at the donor-acceptor heterojunction. There is no band-bending, so splitting of the exciton is more difficult.
[0010] It should be stressed that simply blending the donor and acceptor nanoparticles together will not create a film that produces a photovoltage. The lack of selectivity at the electrode towards one particle or another means that the electrodes can make contact with both the donor and acceptor species. These species may take the form of nanorods rather than nanospheres because nanorods with high aspect ratios help to disperse the carriers. Quick transfer of the exciton along the length of the nanorods improves the chance of splitting the exciton at the donor-acceptor heterojunction.
[0011] Solution processing of, for example, CdSe rods can achieve a size distribution of 5% in diameter and 10% in length with an aspect ratio of 20 and a length of 100 nm. The substantial control available through solution processing allows for optimization of the cell by variation of nanorod length and bandgap energy.
[0012] 4. Polymer-Nanocrystal Composite Photovoltaics
[0013] The combination of nanomaterials and polymer films has been shown to give good power conversion efficiencies while affording low-temperature solution processes for fabrication. In one approach, nanomaterials are used to conduct charges while the polymer is used as the absorbing material, or alternatively, the nanomaterial serves as a chromophore, i.e., the light absorber, and the semiconductor polymer is employed as a hole conductor. In the former case, a wide-bandgap semiconductor (e.g., TiO 2 ) receives the excited electron from the conduction band of the chromophoric polymer semiconductor; and in the latter case, light-absorbing semiconductor nanocrystals absorb photons and transfer the resulting negative charge to the transparent primary electrode, while the semiconducting polymer transfers the holes to the counter electrode. In both types of cell, a heterojunction between the nanocrystal and the polymer separates the exciton created in the nanocrystal or polymer. The electron is transferred to the conduction band of the nanocrystal and the hole stays in the valence band of the polymer, or the electron stays in the conduction band of the nanocrystal, and the hole is transferred to the valence band of the polymer.
[0014] 4.1 Wide-Bandgap Nanocrystal/Light-Absorbing Polymer
[0015] The active layer in a polymer-nanocrystal cell has two components: a light absorber and a nanoparticulate electron carrier. Typically, the light absorber is a p-type polymeric conductor, e.g., poly(phenylene vinylene) or poly(3-hexylthiophene), and the nanoparticulate electron carrier is a wide-bandgap semiconductor such as ZnO or TiO 2 . In this configuration, the polymer serves to absorb light, to transfer electrons to the electron acceptor/carrier, and to carry holes to the primary electrode. The electron acceptor accepts electrons and transfers the electrons to the metal back contact.
[0016] The morphology of the phase separation is crucial. For example, a bi-layer structure in which each layer has only one component results in a cell with poor performance. The reason is that the lifetime of the excited state of the light-absorbing polymer is generally shorter than the transfer rate of the exciton to the interface, and, consequently, the majority of the excitons formed in the bulk of the polymer never reach the interface separating electrons and holes, resulting in loss of photocurrent. Morphologies in which a bulk heterojunction is formed tend to show greater efficiencies. If the absorber and electron acceptor are in intimate contact throughout the entire active layer, the shorter exciton path length will result in increased electron transfer and higher efficiencies. The best efficiencies obtained from cells of this configuration are around 2%.
[0017] This technology shows promise, but there are obstacles to overcome. One problem is incomplete absorption of the incident radiation. The polymer -which absorbs light very strongly and is referred to as a polymeric dye -has a large extinction coefficient (>100,000 M −1 cm −1 ), but due to low exciton migration rates, the films must generally be thinner than 100 nm, which contributes significantly to incomplete absorption. This effect can be combated by means of an interdigitated array structure of donor and acceptor species.
[0018] 4.2 Wide-Bandgap Nanocrystal/Light-Absorbing Nanocrystals/Hole Transfer Polymer
[0019] A problem associated with the light-absorbing polymer strategy is underutilization of available solar energy due to the narrow absorption bandwidth of typical polymers. Approximately 40% of the light (from about 600 nm out into the near IR) can be wasted. An alternative configuration is to utilize nanocrystals as light absorbers and electron carriers, and employ the polymer as a light absorber and a hole carrier. CdSe nanorod and tetrapod/polymer systems have demonstrated power-conversion efficiencies of up to 1.7%. These systems have the advantage that the absorption of the nanocrystal can be tuned via the size of the nanocrystal, and systems that absorb essentially all of the incoming radiation can therefore be fabricated.
[0020] Unfortunately, it is difficult to disperse inorganic nanocrystals into a solution of monomers. The two phases tend to agglomerate and minimize the electrical contact essential to form the heterojunction which enables charge separation. Dispersion of nanocrystals in polymer phases is an area of great interest.
[0021] Typically, the strategy employed for dispersing the nanocrystals is to functionalize the nanocrystal with a capping agent that has an organic tail, which enhances solubility in the solvent in which the polymerization is carried out. Capping agents for this purpose typically have a head-group with a strong affinity for the nanocrystal; amine, carboxylate, phosphine, thiol, phosphine oxide and phosphonic acid, for example, all bind strongly. The organic tail of the capping agent should be compatible with solvents in which the polymer is soluble. Long hydrocarbon chains typically provide high solubility but are non-conducting; accordingly, it is necessary to balance optimum solubility against conductivity.
[0022] The most popular polymers used for composite studies are PDFC, P3Ht and MEH-PPV (where PDFC refers to -{poly[9,9-dihexylfluorenyl-2,7-diyl)-alt-co-(9-ethyl-3,6-carbazole)]}-, P3Ht refers to poly(3-hexylthiophene), and MEH-PPV refers to poly(2-methoxy-5-(2′-ethyl-hexyloxy)-1,4-phenylene vinylene)). Each of these polymers has sites for functionalization, allowing the manipulation of the valence/conduction band energies to achieve optimal conditions for charge transfer to and from the nanocrystals. It has been suggested that the capping agent may also serve as the organic acceptor phase; for example, P3HT functionalized with phosphonic acid groups has been shown to isolate CdSe nanocrystals.
5. Dye-Sensitized Solar Cells
[0023] DSSCs incorporate a substrate which has been coated with a transparent conducting oxide (which serves as the primary electrode). The counter electrode may also be coated with a transparent conducting oxide, but may also be a non-corrosive metal, such as titanium coated with a very thin layer of platinum. A porous layer of a wide-bandgap semiconductor (such as TiO 2 ) is deposited on the conductive surface of the primary electrode. This porous layer is then coated with a dye having a strong absorption in the visible region of the spectrum. To be optimally effective, the dye concentration should be limited to a monolayer of dye molecules. Because of this, a huge surface area is necessary to accommodate enough dye to absorb all of the incoming light. Therefore, nanocrystals (e.g., TiO 2 ) are used to make the highly porous films. Electrolyte containing a redox couple (typically I − /I 3 − ) is absorbed into the titania layer. To complete the cell, the substrate bearing the primary electrode and the sensitized titania layer is brought into face-to-face contact with the counter electrode.
[0024] Typical dyes are inorganic-ruthenium-based, although organic dyes are receiving increased interest. The dye absorbs visible light, and the excited state injects an electron into the TiO 2 conduction band. Before back electron transfer can occur, the oxidized dye is reduced by a redox active species in solution (typically I − /I 3 − ), regenerating the dye. The oxidized redox active species diffuses to the counter electrode, where it is reduced, finishing the cycle and completing the circuit. Work can be done by passing the injected electron through an external load before allowing it to reduce the oxidized redox active species at the counter electrode.
[0025] Inexpensive DSSC devices, which exhibit up to 10% energy conversion efficiency, can be fabricated. There are many issues to be addressed with this technology to improve performance and stability, including replacing the best performing liquid electrolytes with solid-state or higher-boiling electrolytes; improving spectral overlap; using a redox mediator with a lower redox potential; and lowering recombination losses due to poor electron conduction through the nanoparticle TiO 2 layer.
6. Hybrid Cells
[0026] Hybrid cells combine dye-sensitized titania, coated and sintered onto a transparent semiconducting oxide, with a p-type polymer that carries electrons to the oxidized dye. Since just one polymer replaces the multi-component electrolyte, these cells can be fabricated conveniently and reproducibly. Ruthenium dye-sensitized, nanorod-based DSSCs tend to exhibit low efficiency, however, because the lower surface area does not accommodate enough dye to absorb all of the incident light. The most efficient dyes found so far only have extinction coefficients on the order of ˜20,000 M −1 cm −1 , and therefore a large surface area is needed to bind enough dye to get maximal absorbance.
SUMMARY OF THE INVENTION
[0027] Aspects of the present invention provide a photovoltaic (PV) cell comprising a semiconducting nanorod-nanocrystal-polymer hybrid layer, as well as methods for fabricating the same. In PV cells according to this invention, the nanocrystals serve both as the light-absorbing material and as the heterojunctions at which the excited electron-hole pairs (i.e., excitons) split. The nanorods function as electron carriers and are electrically connected to the anode of the cell, and the polymer acts as the hole carrier and is electrically connected to the cathode of the cell.
[0028] One of the advantages of the invention lies in the use of small particles, the nanocrystals, as both light absorber and heterojunction. The resulting spatio-temporal proximity of exciton generation and splitting entails a significant reduction in recombination losses, compared, for example, with those of conventional polymer PV cells, and consequently in higher conversion efficiencies of photons into electricity. Embodiments of the invention offer the additional advantages of mechanical flexibility and low cost manufacturing processes.
[0029] Accordingly, in a first aspect, the invention provides a photovoltaic cell containing two electrodes and, in between these electrodes, a plurality of aligned semiconducting nanorods surrounded by and bound to a plurality of photoresponsive nanocrystals, and a semiconductor polymer surrounding the nanorods and bound to the nanocrystals. The nanocrystals act as heterojunctions channeling electrons into the nanorods and holes into the polymer, or vice versa. The nanorods are electrically connected to the first electrode, and electrically insulated from the second electrode by a thin layer of polymer bound to the second electrode. In various embodiments, the polymer is a hole-transfer polymer, and consequently, the nanocrystals channel holes into the polymer and electrons into the nanorods. In various embodiments, the nanocrystals are bound to the nanorods by a bifunctional capping agent, which can, for example, be mercaptoacetic acid. For example, the nanorods may be grown on the first electrode, and the other electrode can later be deposited on the nanorod-nanocrystal-polymer layer in a manner ensuring insulation of the nanorods from the second electrode.
[0030] Advantageous nanorods have aspect ratios (i.e., ratios of the longest dimension to the shortest dimension of the particle) of at least 3, and their shortest dimension is not greater than 100 nm. Preferred nanorods are single-crystalline. Suitable nanorod materials according to the invention include, but are not limited to, wide bandgap semiconductors such as, for example, ZnO, SnO, and TiO 2 , whereby ZnO is the preferred material.
[0031] Suitable nanocrystals according to the invention include semiconducting, monocrystalline or polycrystalline nanoparticles of diameter not greater than 20 nm, which may (but need not) be generally spherical in shape. Suitable nanocrystal materials include, but are not limited to CuInSe 2 , CuInS 2 , CuIn 1−x Ga x Se 2 (where 0≦x≦1), GaAs, InAs, InP, PbS, PbSe, PbTe, GaSb, InSb, CdTe and CdSe. Nanocrystals with extinction coefficients of at least 100,000 M −1 cm −1 are preferred. In various embodiments, the largest spatial dimension of the nanocrystals is no greater than the average diffusion distance of the excitons created in the nanocrystal upon absorption of light.
[0032] Suitable polymer materials include, but are not limited to, poly(3-hexylthiophene), polyphenylenevinylene (PPV) and its derivatives, and polyfluorene (PFO) and its derivatives. In various embodiments, the polymer is bound to the nanocrystals but not to the nanorods.
[0033] In a second aspect, the invention provides a method of fabricating a semiconductor structure with heterojunctions; the structure can be used in a photovoltaic cell. Embodiments of the method involve providing a plurality of nanorods and a plurality of photoresponsive nanocrystals capped with a first capping agent; exposing the nanorods or the nanocrystals to a second, bifunctional capping agent; then combining the nanocrystals with the nanorods so that the nanocrystals bind to the nanorods via the bifunctional capping agent; combining the bound nanorods and nanocrystals with a functionalized monomer which has a binding group with (i) stronger affinity for the nanocrystals than the first capping agent and (ii) weaker affinity for the nanorods than the bifunctional capping agent, so that the monomer preferentially displaces the first capping agent and binds to the nanocrystals; and polymerizing the monomer. The bifunctional capping agent can first bind to the nanorods, and then bind to the nanocrystals, replacing some of the first capping agent. Alternatively, the bifunctional capping agent can first bind to the nanocrystals (replacing some of the first capping agent), and then bind with its free ends to the nanorods. In various embodiments, the first capping agent contains a thiol, selenol, amine, phosphine, phosphine oxide, and/or aromatic heterocycle functionality. A non-limiting example of a suitable capping agent is octanethiol.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The foregoing discussion will be understood more readily from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
[0035] FIG. 1A schematically depicts an embodiment of a nanorod-nanocrystal-polymer hybrid solar cell according to the invention.
[0036] FIG. 1B is an enlarged schematic view of the three major components of the hybrid semiconductor layer of FIG. 1A , and of their interconnections.
[0037] FIG. 2A is a flow diagram detailing a method of fabricating the structure depicted in FIG. 1A according to one embodiment.
[0038] FIG. 2B is a flow diagram detailing a method of fabricating the structure depicted in FIG. 1A according to an alternative embodiment.
[0039] FIG. 3 illustrates at a microscopic level some of the steps of the method shown in FIG. 2 and the resulting products.
DETAILED DESCRIPTION OF THE INVENTION
1. Nanorod-nanocrystal-polymer Hybrid Structure
[0040] In polymer-based photovoltaics, excitons travel on average of the order of 10 nm before recombining; accordingly, there is a need to separate the excitons, i.e., to have them encounter a heterojunction as soon as possible. This need is met in embodiments of the present invention, in which nanocrystals (quantum dots) serve as a bridge between a hole-transfer polymer and a wide-bandgap semiconductor electron acceptor, thus constituting the heterojunction, and serve simultaneously as the light absorber, i.e., the place where the excitons are created. The diameter of a nanocrystal according to the invention is approximately equal to, or smaller than, the diffusion distance of an exciton. As a result, an exciton generated in the nanocrystal will generally encounter the interface of the nanocrystal with the electron acceptor or the hole-transfer polymer within its average diffusion distance, regardless of the direction in which it migrates. Consequently, the exciton splits very efficiently, and recombination within the nanocrystal occurs infrequently. The electron enters into the wide-bandgap semiconductor, and the hole enters into the polymer.
[0041] The structure of a PV cell 100 according to the invention is illustrated in FIG. 1A . In between two electrodes, an anode 101 and a cathode 103 , a plurality of aligned wide-bandgap semiconductor nanorods 106 , which constitute the electron acceptor, is arranged. As shown in the detail of FIG. 1A , the nanorods 106 are each surrounded by photosensitive nanocrystals 109 . The sensitized nanorods, in turn, are surrounded by the hole-transfer polymer 112 , which fills the remaining space between the electrodes 101 , 103 . The polymer 112 also forms a thin layer underneath the cathode 103 , which electrically isolates the cathode 103 from the sensitized nanorods 106 .
[0042] FIG. 1B shows how these three components are interconnected in preferred embodiments of the invention. The nanocrystals 109 are bound to the nanorods 106 by means of a bifunctional binding molecule 115 . In various embodiments, the bifunctional capping agent 115 has thiol and carboxylate moieties. The thiol groups bind preferentially to the nanocrystals 109 , and the carboxylate groups bind preferentially to the (metal oxide) nanorods 106 . The intervening chain should be short enough so that charge transfer from nanocrystal 109 to nanorod 106 is not impeded. A representative bifunctional capping agent 115 is mercaptoacetic acid. The hole-transfer polymer 112 is directly bound to the nanocrystals 109 , but preferably not to the nanorods 106 .
[0043] A representative, non-limiting example of a system of nanorods, bifunctional molecules, nanocrystals, and polymers comprises ZnO nanorods capped with mercaptoacetic acid, CuInSe 2 quantum dots, and poly(3-hexylthiophene).
[0044] 1.1 Nanocrystals 109
[0045] The semiconductor material used for nanocrystals in a particular application depends on the suitability of valence and conduction band energy levels. The conduction band should be of sufficient energy to be able to inject electrons efficiently into the nanorods, while the valence band should be of sufficiently low energy to inject holes into the polymer valence band. The latter constraint is generally straightforward to satisfy, as suitable polymers having a higher-energy valence band than the nanocrystal can readily be identified. Subject to the above constraints, the bandgap of the nanocrystal should be small enough to allow for a large portion of the solar spectrum to be absorbed. Suitable nanocrystal materials include materials based on copper-indium-diselenide and variants thereof, for example, CuInS 2 , CuInSe 2 , or CuIn 1−x Ga x Se 2 (wherein 0≦x≦1), as well as CdSe, GaAs, InAs, and InP.
[0046] Nanocrystals can be synthesized using techniques described, for example, in U.S. Pat. No. 6,379,635 and co-pending U.S. patent application Ser. Nos. 11/579,050 and 11/588,880, the entire contents of which are hereby incorporated by reference.
[0047] A method for producing CIGS nanocrystals of any desirable stoichiometry employing a selenol compound is disclosed in U.S. Provisional Application Ser. No. 60/991,510, the entire content of which is hereby incorporated by reference. Embodiments of the method involve dispersing at least a first portion of a nanocrystal precursor composition (comprising sources of at least one of Al, Ga, and/or In, and at least one of Cu, Ag, Zn, and/or Cd) in a solvent (e.g., a long-chain hydrocarbon solvent); heating the solvent to a first temperature for an appropriate length of time; adding a selenol compound to the solvent and heating the solvent; adding a second portion of the nanocrystal precursor composition to the reaction mixture; heating the mixture to a second temperature higher than the first temperature over an appropriate length of time; and maintaining the temperature for up to 10 hours. Once the particles have been formed, the surface atoms of the particles will typically be coordinated to a capping agent, which can comprise the selenol compound employed in the method. If a volatile selenol compound is used, this capping agent can be driven off with heating to yield ‘naked’ nanocrystals amenable to capping with other coordinating ligands and further processing. Examples 1 and 2 provide further details regarding the implementation of this method:
[0048] Example 1: Cu(I) acetate (1 mmol) and In(III) acetate (1 mmol) are added to a clean and dry RB-flask. Octadecene ODE (5 mL) is added the reaction mixture heated at 100° C. under vacuum for 30 mins. The flask is back-filled with nitrogen and the temperature raised to 140° C. 1-octane selenol is injected and the temperature falls to 120° C. The resulting orange suspension is heated with stirring and a transparent orange/red solution is obtained when the temperature has reached 140° C. This temperature is maintained for 30 minutes, then IM tri-octyl-phoshine selenide TOPSe (2 mL, 2 mmol) is added dropwise and the solution heated at 160° C. The PL is monitored until it reaches the desired wavelength, after which it is cooled and the resulting oil washed with methanol/acetone (2:1) 4-5 times and finally isolated by precipitation with acetone.
[0049] Example 2 (Large Scale Production): A stock solution of TOPSe was prepared by dissolving Se powder (10.9, 138 mmol) in TOP (60 mL) under nitrogen. To dry, degassed ODE was added Cu(I) acetate (7.89 g, 64.4 mmol) and In(III) acetate (20.0 g, 68.5 mmol). The reaction vessel was evacuated and heated at 140° C. for 10 min, backfilled with N 2 and cooled to room temp. 1-Octane selenol (200 mL) was added to produce a bright orange suspension. The temperature of the flask was raised to 140° C. and acetic acid distilled from the reaction at 120° C. On reaching 140° C. the TOPSe solution was added dropwise over the course of 1 hour. After 3 hours the temperature was raised to 160° C. The progress of the reaction was monitored by taking aliquots from the reaction periodically and measuring the UV/Visible and photoluminescence spectra. After 7 hours the reaction was cooled to room temperature and the resulting black oil washed with methanol. Methanol washing was continued until it was possible to precipitate a fine black material from the oil by addition of acetone. The black precipitate was isolated by centrifugation, washed with acetone and dried under vacuum. Yield: 31.97 g.
[0050] For the purpose of optimizing the composition, size, and charge of the nanocrystals, they can be characterized by conventional techniques, including, but not limited to, XRD, UV/Vis/Near-IR spectrometry, SEM, TEM, EDAX, photoluminescence spectrometry, and elemental analysis.
[0051] Some embodiments of the invention utilize nanocrystals with extinction coefficients of at least 100,000 M −1 cm −1 . At such high absorptivities, fewer nanocrystals are needed to achieve the same overall absorption. Consequently, embodiments of this invention based on these nanocrystals can benefit from increased absorption without incurring losses in efficiency due to enhanced recombination.
[0052] 1.2 Nanorods 106
[0053] Nanorods can be produced by direct chemical synthesis, utilizing a suitable combination of ligands such as trioctylphosphine oxide (TOPO) and various phosphonic acids, e.g., octadecylphosphonic acid, for shape control. Moreover, different types of metal oxides can be grown in ordered nanorod arrays, using techniques such as, for example, electrochemical etching of metal foil, or substrate seeding followed by nanorod growth, in a chemical bath, in a direction perpendicular to the substrate. See, e.g., D. C. Olson et al., J. Phys. Chem. C, 2007, 111, 16640-16645; and J. Yang et al., Crystal Growth & Design, 2007, 12/2562, the disclosures of which are hereby incorporated by reference in their entireties.
[0054] In preferred embodiments of the invention, the nanorods have high aspect ratios exceeding 3, and are up to 200 nm long. A preferred nanorod material is ZnO. Other materials that might be suitable include SnO, TiO 2 , and other metal oxides.
[0055] As mentioned previously, the small size of the nanocrystals greatly reduces recombination within the particle. In order to further reduce recombination losses, preferred embodiments of the invention utilize single-crystal nanorods. While in nanoporous particle-based films, such as those employed in DSSC cells, electrons percolate slowly through the film, enabling recombination with the electrolyte to take place, electron transfer through single-crystal nanorods is very fast, which limits the recombination of electrons from the nanorods with holes in the nanocrystals or the polymer.
[0056] In preferred embodiments and as discussed in greater detail below, the nanorods are coated with a layer of a bifunctional capping agent, which binds the quantum dots closely to the nanorods, thereby preventing the semiconductor polymer from coming into the proximity of the nanorod, which diminishes nanorod-polymer recombination losses even further.
[0057] 1.3 Polymer 112
[0058] Polymer 112 should have a valence band energy that allows holes to efficiently transfer from the nanocrystal valence band to the polymer valence band. Suitable polymers include poly(3-hexylthiophene), polyphenylenevinylene (PPV) and its derivatives, and polyfluorene (PFO) and its derivatives. These polymers are efficient hole-transfer polymers due to the high hole mobility in organic materials.
2. Method for Fabricating a Nanorod-nanoparticle-polymer Hybrid Structure
[0059] Hybrid semiconductor structures according to the invention can be fabricated using low-cost deposition technologies, such as printing, dip coating, or chemical bath deposition. An important consideration regarding fabrication is control over where the various pieces bind together. For example, binding of the polymer to the nanorod would most likely result in substantial losses in efficiency due to recombination. In preferred embodiments, the nanocrystals are bound to both the nanorods and to the semiconducting polymer to promote optimal performance as a heterojunction, and the polymer is not directly bound to the nanorods. This structure can be achieved with suitable capping agents in appropriate processing steps.
[0060] FIGS. 2A and 2B illustrate representative process sequences 200 A and 200 B implementing embodiments of the present invention. Some steps of these sequences, and the structures they result in, are further illustrated in FIG. 3 at a microscopic level. In a first step 202 , nanorods are grown on an anodic substrate, e.g., by printing seeds on the substrate and then growing the nanorods perpendicularly to the substrate via a chemical bath. In this structure, the nanorods are inherently in electrical contact with the substrate. In subsequent steps, the nanocrystals and monomers are introduced to the resulting film of aligned nanorods.
[0061] In step 204 , nanocrystals capped with a (first) capping agent which contains functionalities that bind weakly to the nanocrystals are provided. Suitable functionalities include thiol, selenol, amine, phosphine, phosphine oxide, and aromatic heterocycles. Typically, the nanocrystals are dissolved in a non-polar organic solvent. The capping agent serves to control binding of the nanocrystals to the nanorods and the polymer; the bond is reversible and the capping agent can later be exchanged for other ligands. Examples of capping agents suitable for use with CuInSe 2 nanocrystals are octanethiol or pyridine.
[0062] In steps 206 , 208 , the nanorods are coated by the nanocrystals, whereby the bond between nanorods and nanocrystals is established via the bifunctional capping agent 115 (e.g., mercaptoacetic acid), which has strong binding groups for both the nanorods and the nanocrystals. This can be accomplished in different ways. In some embodiments, as illustrated in FIG. 2A and FIG. 3 , the nanorods are capped with the bifunctional capping agent (step 206 A), for example, by dipping the substrate with the nanorods into a solution of the bifunctional capping agent. For example, the capping agent may be bound to the nanorods via a carboxylate functionality. The capped nanocrystals 302 are then introduced to the film of capped nanorods 300 (step 208 A), for example, by dipping the rinced substrate with nanorods 300 into the nanocrystal solution(s). At this stage, a fraction of the weak capping agent of the nanocrystals is replaced by the stronger binding groups of the bifunctional capping agent, e.g., the thiol functionality of mercaptoacetic acid, which results in nanocrystal-sensitized nanorods 304 .
[0063] In alternative embodiments, as illustrated in FIG. 2B , a solution of the capped nanocrystals in a non-polar organic solvent is added to a solution of the bifunctional capping agent in a polar organic solvent which is not miscible with the non-polar solvent, and the solution is shaken to ensure good mixing (step 206 B). The nanocrystals undergo ligand exchange and transfer from a non-polar organic phase to a polar organic phase. Subsequently, the substrate with the aligned nanorods on the surface is dipped into the nanocrystal solution or otherwise exposed to the nanocrystals (step 208 B), whereby the nanorods bind the nanocrystals via a carboxylic acid functionality of the capping agent. These embodiment likewise result in nanocrystal-sensitized nanorods 304 .
[0064] The monomers are functionalized (step 210 ) with a binding group that has a stronger affinity for the nanocrystals than the (first) nanocrystal capping agent, but a weaker affinity for the nanorods than the bifunctional capping agent. Moreover, the affinity of the binding group at the monomer for the nanocrystal is preferably weaker than the affinity of the bifunctional capping agent for the nanocrystal. The monomer functionality should not interfere with the polymerization reaction. Binding groups with suitable differential binding affinities are straightforwardly identified by those of skill in the art without undue experimentation based on the identities of the capping agents and their substituents (e.g., whether they are unidentate or multidentate, or on the presence of electron withdrawing groups, etc.) and the size of the nanocrystal. The functionalized monomers are then combined with the nanocrystal-sensitized nanorods (step 212 ), where they bind to the nanocrystals (but not the nanorods), preferentially replacing the weak capping agent on the nanocrystal, but leaving the nanorod-nanocrystal bond intact, resulting in structure 306 . A subsequent polymerization step 214 results in the nanorod-nanocrystal-polymer semiconductor structure 308 .
[0065] Finally, a metal cathode (e.g., Al) can be deposited on the structure (step 216 ), for example, by sputtering or metal evaporation, so that the nanorods form an array of aligned rods deposited between two opposing electrodes. The polymer layer below the cathode should be sufficiently thick to electrically isolate the cathode from the nanorods.
[0066] Although the present invention has been described with reference to specific details, it is not intended that such details should be regarded as limitations upon the scope of the invention, except as and to the extent that they are included in the accompanying claims. | Embodiments of the present invention involve photovoltaic (PV) cells comprising a semiconducting nanorod-nanocrystal-polymer hybrid layer, as well as methods for fabricating the same. In PV cells according to this invention, the nanocrystals may serve both as the light-absorbing material and as the heterojunctions at which excited electron-hole pairs split. | Summarize the patent document, focusing on the invention's functionality and advantages. | [
"CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority to and the benefits of U.S. Provisional Application Ser.",
"No. 60/926,103, filed on Apr. 25, 2007, the entire disclosure of which is hereby incorporated by reference.",
"FIELD OF THE INVENTION [0002] The present invention relates to solar cells and their fabrication, and in particular to nanorod-nanocrystal-polymer hybrid solar cells BACKGROUND [0003] To create useful electrical current from electromagnetic radiation, photovoltaic (PV) cells must absorb incident radiation such that an electron is promoted from the valence band to the conduction band (leaving a hole in the valence band), and must be able to separate the electron and hole and deliver these charge carriers to their respective electrodes before they recombine.",
"[0004] Many different strategies based on diverse materials have been employed, with varying degrees of success, to realize these basic behaviors with commercially satisfactory efficiency.",
"Representative devices include crystalline inorganic solar cells (e.g., silicon, germanium, GaAs), nanocrystalline dye-sensitized solar cells, semiconductor-polymer solar cells, nanoparticle solar cells, and more recently, composite solar cells that incorporate and combine the aforementioned components from other strategies.",
"Inorganic Photovoltaics [0005] Silicon is by far the most commonly used material for fabricating inorganic photovoltaics.",
"These cells rely on the ability of silicon to absorb light and, consequently, to generate an excited electron-hole pair that is then separated at a p-n junction.",
"The electric field set up by the p-n junction facilitates this separation because of the way electrons and holes move through materials: electrons move to lower energy levels while holes move to higher energy levels.",
"[0006] Creation of p-n junctions generally involves high-temperature processing in inert atmospheres to form very pure, crystalline silicon wafers, which are inflexible and expensive.",
"Because silicon is an indirect semiconductor, a relatively thick layer is typically needed to achieve a good level of absorption, which increases material costs further.",
"Efficiencies for the most pure (and expensive) silicon photovoltaics are on the order of 20%;",
"efficiencies for the cheaper amorphous silicon cells are approximately 5-10%.",
"[0007] Today's commercial PV systems can convert from 5% to 15% of sunlight energy into electricity.",
"These systems are highly reliable and generally last 20 years or longer.",
"The possibility of fabricating solar cells by less expensive, lower-temperature techniques is very attractive.",
"Accordingly, nanocrystalline dye-sensitized solar cells (DSSCs), semiconductor-polymer solar cells and nanoparticle solar cells have enjoyed widespread interest.",
"Polymer Photovoltaics [0008] Semiconducting polymers can be used to make organic photovoltaics.",
"The properties of these polymers can be tuned by functionalization of the constituent monomers.",
"As such, a wide range of polymers with suitable bandgaps, absorption characteristics and physical properties is available.",
"In order to achieve separation of the electron-hole pair, organic photovoltaics rely on donor-acceptor heterojunctions.",
"In polymers, the excited-state electron and hole are bound together, and travel together, as a quasi-particle called an exciton.",
"They remain together until they encounter a heterojunction, which separates them.",
"Unfortunately, excitons are very short-lived and can only travel about 10 nm before recombining.",
"Hence, any photon absorbed more than this diffusion length away from a heterojunction will be wasted.",
"Charge mobilities for polymers are typically low (0.5-0.1 cm 2 V −1 s −1 ) compared to silicon, which is much higher (1500 cm 2 V −1 S −1 ).",
"Current state-of-the-art polymer photovoltaic cells have efficiencies of 1-2%.",
"Although such efficiencies are low, these materials hold promise for low-cost, flexible solar cells.",
"Nanoparticle Photovoltaics [0009] Inorganic nanoparticles (or nanocrystals) have been used to prepare colloidal, thin-film PV cells that show some of the advantages of polymer photovoltaics while maintaining many of the advantages of inorganic photovoltaics.",
"For example, such cells can contain a bi-layer structure comprising a layer of donor and a layer of acceptor nanoparticles, wherein the two layers exhibit little intermixing, and both contribute to the measured photocurrent.",
"The strong photoconductive effect exhibited by these devices suggests that these materials have a large number of trapped carriers and are better described by a donor-acceptor molecular model than by a p-n band model.",
"Increased bandgap energy compared to that of the bulk semiconductors minimizes the number of carriers available, and spatial separation of the donor and acceptor particles in different phases traps the excitons so that they must split at the donor-acceptor heterojunction.",
"There is no band-bending, so splitting of the exciton is more difficult.",
"[0010] It should be stressed that simply blending the donor and acceptor nanoparticles together will not create a film that produces a photovoltage.",
"The lack of selectivity at the electrode towards one particle or another means that the electrodes can make contact with both the donor and acceptor species.",
"These species may take the form of nanorods rather than nanospheres because nanorods with high aspect ratios help to disperse the carriers.",
"Quick transfer of the exciton along the length of the nanorods improves the chance of splitting the exciton at the donor-acceptor heterojunction.",
"[0011] Solution processing of, for example, CdSe rods can achieve a size distribution of 5% in diameter and 10% in length with an aspect ratio of 20 and a length of 100 nm.",
"The substantial control available through solution processing allows for optimization of the cell by variation of nanorod length and bandgap energy.",
"[0012] 4.",
"Polymer-Nanocrystal Composite Photovoltaics [0013] The combination of nanomaterials and polymer films has been shown to give good power conversion efficiencies while affording low-temperature solution processes for fabrication.",
"In one approach, nanomaterials are used to conduct charges while the polymer is used as the absorbing material, or alternatively, the nanomaterial serves as a chromophore, i.e., the light absorber, and the semiconductor polymer is employed as a hole conductor.",
"In the former case, a wide-bandgap semiconductor (e.g., TiO 2 ) receives the excited electron from the conduction band of the chromophoric polymer semiconductor;",
"and in the latter case, light-absorbing semiconductor nanocrystals absorb photons and transfer the resulting negative charge to the transparent primary electrode, while the semiconducting polymer transfers the holes to the counter electrode.",
"In both types of cell, a heterojunction between the nanocrystal and the polymer separates the exciton created in the nanocrystal or polymer.",
"The electron is transferred to the conduction band of the nanocrystal and the hole stays in the valence band of the polymer, or the electron stays in the conduction band of the nanocrystal, and the hole is transferred to the valence band of the polymer.",
"[0014] 4.1 Wide-Bandgap Nanocrystal/Light-Absorbing Polymer [0015] The active layer in a polymer-nanocrystal cell has two components: a light absorber and a nanoparticulate electron carrier.",
"Typically, the light absorber is a p-type polymeric conductor, e.g., poly(phenylene vinylene) or poly(3-hexylthiophene), and the nanoparticulate electron carrier is a wide-bandgap semiconductor such as ZnO or TiO 2 .",
"In this configuration, the polymer serves to absorb light, to transfer electrons to the electron acceptor/carrier, and to carry holes to the primary electrode.",
"The electron acceptor accepts electrons and transfers the electrons to the metal back contact.",
"[0016] The morphology of the phase separation is crucial.",
"For example, a bi-layer structure in which each layer has only one component results in a cell with poor performance.",
"The reason is that the lifetime of the excited state of the light-absorbing polymer is generally shorter than the transfer rate of the exciton to the interface, and, consequently, the majority of the excitons formed in the bulk of the polymer never reach the interface separating electrons and holes, resulting in loss of photocurrent.",
"Morphologies in which a bulk heterojunction is formed tend to show greater efficiencies.",
"If the absorber and electron acceptor are in intimate contact throughout the entire active layer, the shorter exciton path length will result in increased electron transfer and higher efficiencies.",
"The best efficiencies obtained from cells of this configuration are around 2%.",
"[0017] This technology shows promise, but there are obstacles to overcome.",
"One problem is incomplete absorption of the incident radiation.",
"The polymer -which absorbs light very strongly and is referred to as a polymeric dye -has a large extinction coefficient (>100,000 M −1 cm −1 ), but due to low exciton migration rates, the films must generally be thinner than 100 nm, which contributes significantly to incomplete absorption.",
"This effect can be combated by means of an interdigitated array structure of donor and acceptor species.",
"[0018] 4.2 Wide-Bandgap Nanocrystal/Light-Absorbing Nanocrystals/Hole Transfer Polymer [0019] A problem associated with the light-absorbing polymer strategy is underutilization of available solar energy due to the narrow absorption bandwidth of typical polymers.",
"Approximately 40% of the light (from about 600 nm out into the near IR) can be wasted.",
"An alternative configuration is to utilize nanocrystals as light absorbers and electron carriers, and employ the polymer as a light absorber and a hole carrier.",
"CdSe nanorod and tetrapod/polymer systems have demonstrated power-conversion efficiencies of up to 1.7%.",
"These systems have the advantage that the absorption of the nanocrystal can be tuned via the size of the nanocrystal, and systems that absorb essentially all of the incoming radiation can therefore be fabricated.",
"[0020] Unfortunately, it is difficult to disperse inorganic nanocrystals into a solution of monomers.",
"The two phases tend to agglomerate and minimize the electrical contact essential to form the heterojunction which enables charge separation.",
"Dispersion of nanocrystals in polymer phases is an area of great interest.",
"[0021] Typically, the strategy employed for dispersing the nanocrystals is to functionalize the nanocrystal with a capping agent that has an organic tail, which enhances solubility in the solvent in which the polymerization is carried out.",
"Capping agents for this purpose typically have a head-group with a strong affinity for the nanocrystal;",
"amine, carboxylate, phosphine, thiol, phosphine oxide and phosphonic acid, for example, all bind strongly.",
"The organic tail of the capping agent should be compatible with solvents in which the polymer is soluble.",
"Long hydrocarbon chains typically provide high solubility but are non-conducting;",
"accordingly, it is necessary to balance optimum solubility against conductivity.",
"[0022] The most popular polymers used for composite studies are PDFC, P3Ht and MEH-PPV (where PDFC refers to -{poly[9,9-dihexylfluorenyl-2,7-diyl)-alt-co-(9-ethyl-3,6-carbazole)]}-, P3Ht refers to poly(3-hexylthiophene), and MEH-PPV refers to poly(2-methoxy-5-(2′-ethyl-hexyloxy)-1,4-phenylene vinylene)).",
"Each of these polymers has sites for functionalization, allowing the manipulation of the valence/conduction band energies to achieve optimal conditions for charge transfer to and from the nanocrystals.",
"It has been suggested that the capping agent may also serve as the organic acceptor phase;",
"for example, P3HT functionalized with phosphonic acid groups has been shown to isolate CdSe nanocrystals.",
"Dye-Sensitized Solar Cells [0023] DSSCs incorporate a substrate which has been coated with a transparent conducting oxide (which serves as the primary electrode).",
"The counter electrode may also be coated with a transparent conducting oxide, but may also be a non-corrosive metal, such as titanium coated with a very thin layer of platinum.",
"A porous layer of a wide-bandgap semiconductor (such as TiO 2 ) is deposited on the conductive surface of the primary electrode.",
"This porous layer is then coated with a dye having a strong absorption in the visible region of the spectrum.",
"To be optimally effective, the dye concentration should be limited to a monolayer of dye molecules.",
"Because of this, a huge surface area is necessary to accommodate enough dye to absorb all of the incoming light.",
"Therefore, nanocrystals (e.g., TiO 2 ) are used to make the highly porous films.",
"Electrolyte containing a redox couple (typically I − /I 3 − ) is absorbed into the titania layer.",
"To complete the cell, the substrate bearing the primary electrode and the sensitized titania layer is brought into face-to-face contact with the counter electrode.",
"[0024] Typical dyes are inorganic-ruthenium-based, although organic dyes are receiving increased interest.",
"The dye absorbs visible light, and the excited state injects an electron into the TiO 2 conduction band.",
"Before back electron transfer can occur, the oxidized dye is reduced by a redox active species in solution (typically I − /I 3 − ), regenerating the dye.",
"The oxidized redox active species diffuses to the counter electrode, where it is reduced, finishing the cycle and completing the circuit.",
"Work can be done by passing the injected electron through an external load before allowing it to reduce the oxidized redox active species at the counter electrode.",
"[0025] Inexpensive DSSC devices, which exhibit up to 10% energy conversion efficiency, can be fabricated.",
"There are many issues to be addressed with this technology to improve performance and stability, including replacing the best performing liquid electrolytes with solid-state or higher-boiling electrolytes;",
"improving spectral overlap;",
"using a redox mediator with a lower redox potential;",
"and lowering recombination losses due to poor electron conduction through the nanoparticle TiO 2 layer.",
"Hybrid Cells [0026] Hybrid cells combine dye-sensitized titania, coated and sintered onto a transparent semiconducting oxide, with a p-type polymer that carries electrons to the oxidized dye.",
"Since just one polymer replaces the multi-component electrolyte, these cells can be fabricated conveniently and reproducibly.",
"Ruthenium dye-sensitized, nanorod-based DSSCs tend to exhibit low efficiency, however, because the lower surface area does not accommodate enough dye to absorb all of the incident light.",
"The most efficient dyes found so far only have extinction coefficients on the order of ˜20,000 M −1 cm −1 , and therefore a large surface area is needed to bind enough dye to get maximal absorbance.",
"SUMMARY OF THE INVENTION [0027] Aspects of the present invention provide a photovoltaic (PV) cell comprising a semiconducting nanorod-nanocrystal-polymer hybrid layer, as well as methods for fabricating the same.",
"In PV cells according to this invention, the nanocrystals serve both as the light-absorbing material and as the heterojunctions at which the excited electron-hole pairs (i.e., excitons) split.",
"The nanorods function as electron carriers and are electrically connected to the anode of the cell, and the polymer acts as the hole carrier and is electrically connected to the cathode of the cell.",
"[0028] One of the advantages of the invention lies in the use of small particles, the nanocrystals, as both light absorber and heterojunction.",
"The resulting spatio-temporal proximity of exciton generation and splitting entails a significant reduction in recombination losses, compared, for example, with those of conventional polymer PV cells, and consequently in higher conversion efficiencies of photons into electricity.",
"Embodiments of the invention offer the additional advantages of mechanical flexibility and low cost manufacturing processes.",
"[0029] Accordingly, in a first aspect, the invention provides a photovoltaic cell containing two electrodes and, in between these electrodes, a plurality of aligned semiconducting nanorods surrounded by and bound to a plurality of photoresponsive nanocrystals, and a semiconductor polymer surrounding the nanorods and bound to the nanocrystals.",
"The nanocrystals act as heterojunctions channeling electrons into the nanorods and holes into the polymer, or vice versa.",
"The nanorods are electrically connected to the first electrode, and electrically insulated from the second electrode by a thin layer of polymer bound to the second electrode.",
"In various embodiments, the polymer is a hole-transfer polymer, and consequently, the nanocrystals channel holes into the polymer and electrons into the nanorods.",
"In various embodiments, the nanocrystals are bound to the nanorods by a bifunctional capping agent, which can, for example, be mercaptoacetic acid.",
"For example, the nanorods may be grown on the first electrode, and the other electrode can later be deposited on the nanorod-nanocrystal-polymer layer in a manner ensuring insulation of the nanorods from the second electrode.",
"[0030] Advantageous nanorods have aspect ratios (i.e., ratios of the longest dimension to the shortest dimension of the particle) of at least 3, and their shortest dimension is not greater than 100 nm.",
"Preferred nanorods are single-crystalline.",
"Suitable nanorod materials according to the invention include, but are not limited to, wide bandgap semiconductors such as, for example, ZnO, SnO, and TiO 2 , whereby ZnO is the preferred material.",
"[0031] Suitable nanocrystals according to the invention include semiconducting, monocrystalline or polycrystalline nanoparticles of diameter not greater than 20 nm, which may (but need not) be generally spherical in shape.",
"Suitable nanocrystal materials include, but are not limited to CuInSe 2 , CuInS 2 , CuIn 1−x Ga x Se 2 (where 0≦x≦1), GaAs, InAs, InP, PbS, PbSe, PbTe, GaSb, InSb, CdTe and CdSe.",
"Nanocrystals with extinction coefficients of at least 100,000 M −1 cm −1 are preferred.",
"In various embodiments, the largest spatial dimension of the nanocrystals is no greater than the average diffusion distance of the excitons created in the nanocrystal upon absorption of light.",
"[0032] Suitable polymer materials include, but are not limited to, poly(3-hexylthiophene), polyphenylenevinylene (PPV) and its derivatives, and polyfluorene (PFO) and its derivatives.",
"In various embodiments, the polymer is bound to the nanocrystals but not to the nanorods.",
"[0033] In a second aspect, the invention provides a method of fabricating a semiconductor structure with heterojunctions;",
"the structure can be used in a photovoltaic cell.",
"Embodiments of the method involve providing a plurality of nanorods and a plurality of photoresponsive nanocrystals capped with a first capping agent;",
"exposing the nanorods or the nanocrystals to a second, bifunctional capping agent;",
"then combining the nanocrystals with the nanorods so that the nanocrystals bind to the nanorods via the bifunctional capping agent;",
"combining the bound nanorods and nanocrystals with a functionalized monomer which has a binding group with (i) stronger affinity for the nanocrystals than the first capping agent and (ii) weaker affinity for the nanorods than the bifunctional capping agent, so that the monomer preferentially displaces the first capping agent and binds to the nanocrystals;",
"and polymerizing the monomer.",
"The bifunctional capping agent can first bind to the nanorods, and then bind to the nanocrystals, replacing some of the first capping agent.",
"Alternatively, the bifunctional capping agent can first bind to the nanocrystals (replacing some of the first capping agent), and then bind with its free ends to the nanorods.",
"In various embodiments, the first capping agent contains a thiol, selenol, amine, phosphine, phosphine oxide, and/or aromatic heterocycle functionality.",
"A non-limiting example of a suitable capping agent is octanethiol.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0034] The foregoing discussion will be understood more readily from the following detailed description of the invention when taken in conjunction with the accompanying drawings.",
"[0035] FIG. 1A schematically depicts an embodiment of a nanorod-nanocrystal-polymer hybrid solar cell according to the invention.",
"[0036] FIG. 1B is an enlarged schematic view of the three major components of the hybrid semiconductor layer of FIG. 1A , and of their interconnections.",
"[0037] FIG. 2A is a flow diagram detailing a method of fabricating the structure depicted in FIG. 1A according to one embodiment.",
"[0038] FIG. 2B is a flow diagram detailing a method of fabricating the structure depicted in FIG. 1A according to an alternative embodiment.",
"[0039] FIG. 3 illustrates at a microscopic level some of the steps of the method shown in FIG. 2 and the resulting products.",
"DETAILED DESCRIPTION OF THE INVENTION 1.",
"Nanorod-nanocrystal-polymer Hybrid Structure [0040] In polymer-based photovoltaics, excitons travel on average of the order of 10 nm before recombining;",
"accordingly, there is a need to separate the excitons, i.e., to have them encounter a heterojunction as soon as possible.",
"This need is met in embodiments of the present invention, in which nanocrystals (quantum dots) serve as a bridge between a hole-transfer polymer and a wide-bandgap semiconductor electron acceptor, thus constituting the heterojunction, and serve simultaneously as the light absorber, i.e., the place where the excitons are created.",
"The diameter of a nanocrystal according to the invention is approximately equal to, or smaller than, the diffusion distance of an exciton.",
"As a result, an exciton generated in the nanocrystal will generally encounter the interface of the nanocrystal with the electron acceptor or the hole-transfer polymer within its average diffusion distance, regardless of the direction in which it migrates.",
"Consequently, the exciton splits very efficiently, and recombination within the nanocrystal occurs infrequently.",
"The electron enters into the wide-bandgap semiconductor, and the hole enters into the polymer.",
"[0041] The structure of a PV cell 100 according to the invention is illustrated in FIG. 1A .",
"In between two electrodes, an anode 101 and a cathode 103 , a plurality of aligned wide-bandgap semiconductor nanorods 106 , which constitute the electron acceptor, is arranged.",
"As shown in the detail of FIG. 1A , the nanorods 106 are each surrounded by photosensitive nanocrystals 109 .",
"The sensitized nanorods, in turn, are surrounded by the hole-transfer polymer 112 , which fills the remaining space between the electrodes 101 , 103 .",
"The polymer 112 also forms a thin layer underneath the cathode 103 , which electrically isolates the cathode 103 from the sensitized nanorods 106 .",
"[0042] FIG. 1B shows how these three components are interconnected in preferred embodiments of the invention.",
"The nanocrystals 109 are bound to the nanorods 106 by means of a bifunctional binding molecule 115 .",
"In various embodiments, the bifunctional capping agent 115 has thiol and carboxylate moieties.",
"The thiol groups bind preferentially to the nanocrystals 109 , and the carboxylate groups bind preferentially to the (metal oxide) nanorods 106 .",
"The intervening chain should be short enough so that charge transfer from nanocrystal 109 to nanorod 106 is not impeded.",
"A representative bifunctional capping agent 115 is mercaptoacetic acid.",
"The hole-transfer polymer 112 is directly bound to the nanocrystals 109 , but preferably not to the nanorods 106 .",
"[0043] A representative, non-limiting example of a system of nanorods, bifunctional molecules, nanocrystals, and polymers comprises ZnO nanorods capped with mercaptoacetic acid, CuInSe 2 quantum dots, and poly(3-hexylthiophene).",
"[0044] 1.1 Nanocrystals 109 [0045] The semiconductor material used for nanocrystals in a particular application depends on the suitability of valence and conduction band energy levels.",
"The conduction band should be of sufficient energy to be able to inject electrons efficiently into the nanorods, while the valence band should be of sufficiently low energy to inject holes into the polymer valence band.",
"The latter constraint is generally straightforward to satisfy, as suitable polymers having a higher-energy valence band than the nanocrystal can readily be identified.",
"Subject to the above constraints, the bandgap of the nanocrystal should be small enough to allow for a large portion of the solar spectrum to be absorbed.",
"Suitable nanocrystal materials include materials based on copper-indium-diselenide and variants thereof, for example, CuInS 2 , CuInSe 2 , or CuIn 1−x Ga x Se 2 (wherein 0≦x≦1), as well as CdSe, GaAs, InAs, and InP.",
"[0046] Nanocrystals can be synthesized using techniques described, for example, in U.S. Pat. No. 6,379,635 and co-pending U.S. patent application Ser.",
"Nos. 11/579,050 and 11/588,880, the entire contents of which are hereby incorporated by reference.",
"[0047] A method for producing CIGS nanocrystals of any desirable stoichiometry employing a selenol compound is disclosed in U.S. Provisional Application Ser.",
"No. 60/991,510, the entire content of which is hereby incorporated by reference.",
"Embodiments of the method involve dispersing at least a first portion of a nanocrystal precursor composition (comprising sources of at least one of Al, Ga, and/or In, and at least one of Cu, Ag, Zn, and/or Cd) in a solvent (e.g., a long-chain hydrocarbon solvent);",
"heating the solvent to a first temperature for an appropriate length of time;",
"adding a selenol compound to the solvent and heating the solvent;",
"adding a second portion of the nanocrystal precursor composition to the reaction mixture;",
"heating the mixture to a second temperature higher than the first temperature over an appropriate length of time;",
"and maintaining the temperature for up to 10 hours.",
"Once the particles have been formed, the surface atoms of the particles will typically be coordinated to a capping agent, which can comprise the selenol compound employed in the method.",
"If a volatile selenol compound is used, this capping agent can be driven off with heating to yield ‘naked’ nanocrystals amenable to capping with other coordinating ligands and further processing.",
"Examples 1 and 2 provide further details regarding the implementation of this method: [0048] Example 1: Cu(I) acetate (1 mmol) and In(III) acetate (1 mmol) are added to a clean and dry RB-flask.",
"Octadecene ODE (5 mL) is added the reaction mixture heated at 100° C. under vacuum for 30 mins.",
"The flask is back-filled with nitrogen and the temperature raised to 140° C. 1-octane selenol is injected and the temperature falls to 120° C. The resulting orange suspension is heated with stirring and a transparent orange/red solution is obtained when the temperature has reached 140° C. This temperature is maintained for 30 minutes, then IM tri-octyl-phoshine selenide TOPSe (2 mL, 2 mmol) is added dropwise and the solution heated at 160° C. The PL is monitored until it reaches the desired wavelength, after which it is cooled and the resulting oil washed with methanol/acetone (2:1) 4-5 times and finally isolated by precipitation with acetone.",
"[0049] Example 2 (Large Scale Production): A stock solution of TOPSe was prepared by dissolving Se powder (10.9, 138 mmol) in TOP (60 mL) under nitrogen.",
"To dry, degassed ODE was added Cu(I) acetate (7.89 g, 64.4 mmol) and In(III) acetate (20.0 g, 68.5 mmol).",
"The reaction vessel was evacuated and heated at 140° C. for 10 min, backfilled with N 2 and cooled to room temp.",
"1-Octane selenol (200 mL) was added to produce a bright orange suspension.",
"The temperature of the flask was raised to 140° C. and acetic acid distilled from the reaction at 120° C. On reaching 140° C. the TOPSe solution was added dropwise over the course of 1 hour.",
"After 3 hours the temperature was raised to 160° C. The progress of the reaction was monitored by taking aliquots from the reaction periodically and measuring the UV/Visible and photoluminescence spectra.",
"After 7 hours the reaction was cooled to room temperature and the resulting black oil washed with methanol.",
"Methanol washing was continued until it was possible to precipitate a fine black material from the oil by addition of acetone.",
"The black precipitate was isolated by centrifugation, washed with acetone and dried under vacuum.",
"Yield: 31.97 g. [0050] For the purpose of optimizing the composition, size, and charge of the nanocrystals, they can be characterized by conventional techniques, including, but not limited to, XRD, UV/Vis/Near-IR spectrometry, SEM, TEM, EDAX, photoluminescence spectrometry, and elemental analysis.",
"[0051] Some embodiments of the invention utilize nanocrystals with extinction coefficients of at least 100,000 M −1 cm −1 .",
"At such high absorptivities, fewer nanocrystals are needed to achieve the same overall absorption.",
"Consequently, embodiments of this invention based on these nanocrystals can benefit from increased absorption without incurring losses in efficiency due to enhanced recombination.",
"[0052] 1.2 Nanorods 106 [0053] Nanorods can be produced by direct chemical synthesis, utilizing a suitable combination of ligands such as trioctylphosphine oxide (TOPO) and various phosphonic acids, e.g., octadecylphosphonic acid, for shape control.",
"Moreover, different types of metal oxides can be grown in ordered nanorod arrays, using techniques such as, for example, electrochemical etching of metal foil, or substrate seeding followed by nanorod growth, in a chemical bath, in a direction perpendicular to the substrate.",
"See, e.g., D. C. Olson et al.",
", J. Phys.",
"Chem.",
"C, 2007, 111, 16640-16645;",
"and J. Yang et al.",
", Crystal Growth &",
"Design, 2007, 12/2562, the disclosures of which are hereby incorporated by reference in their entireties.",
"[0054] In preferred embodiments of the invention, the nanorods have high aspect ratios exceeding 3, and are up to 200 nm long.",
"A preferred nanorod material is ZnO.",
"Other materials that might be suitable include SnO, TiO 2 , and other metal oxides.",
"[0055] As mentioned previously, the small size of the nanocrystals greatly reduces recombination within the particle.",
"In order to further reduce recombination losses, preferred embodiments of the invention utilize single-crystal nanorods.",
"While in nanoporous particle-based films, such as those employed in DSSC cells, electrons percolate slowly through the film, enabling recombination with the electrolyte to take place, electron transfer through single-crystal nanorods is very fast, which limits the recombination of electrons from the nanorods with holes in the nanocrystals or the polymer.",
"[0056] In preferred embodiments and as discussed in greater detail below, the nanorods are coated with a layer of a bifunctional capping agent, which binds the quantum dots closely to the nanorods, thereby preventing the semiconductor polymer from coming into the proximity of the nanorod, which diminishes nanorod-polymer recombination losses even further.",
"[0057] 1.3 Polymer 112 [0058] Polymer 112 should have a valence band energy that allows holes to efficiently transfer from the nanocrystal valence band to the polymer valence band.",
"Suitable polymers include poly(3-hexylthiophene), polyphenylenevinylene (PPV) and its derivatives, and polyfluorene (PFO) and its derivatives.",
"These polymers are efficient hole-transfer polymers due to the high hole mobility in organic materials.",
"Method for Fabricating a Nanorod-nanoparticle-polymer Hybrid Structure [0059] Hybrid semiconductor structures according to the invention can be fabricated using low-cost deposition technologies, such as printing, dip coating, or chemical bath deposition.",
"An important consideration regarding fabrication is control over where the various pieces bind together.",
"For example, binding of the polymer to the nanorod would most likely result in substantial losses in efficiency due to recombination.",
"In preferred embodiments, the nanocrystals are bound to both the nanorods and to the semiconducting polymer to promote optimal performance as a heterojunction, and the polymer is not directly bound to the nanorods.",
"This structure can be achieved with suitable capping agents in appropriate processing steps.",
"[0060] FIGS. 2A and 2B illustrate representative process sequences 200 A and 200 B implementing embodiments of the present invention.",
"Some steps of these sequences, and the structures they result in, are further illustrated in FIG. 3 at a microscopic level.",
"In a first step 202 , nanorods are grown on an anodic substrate, e.g., by printing seeds on the substrate and then growing the nanorods perpendicularly to the substrate via a chemical bath.",
"In this structure, the nanorods are inherently in electrical contact with the substrate.",
"In subsequent steps, the nanocrystals and monomers are introduced to the resulting film of aligned nanorods.",
"[0061] In step 204 , nanocrystals capped with a (first) capping agent which contains functionalities that bind weakly to the nanocrystals are provided.",
"Suitable functionalities include thiol, selenol, amine, phosphine, phosphine oxide, and aromatic heterocycles.",
"Typically, the nanocrystals are dissolved in a non-polar organic solvent.",
"The capping agent serves to control binding of the nanocrystals to the nanorods and the polymer;",
"the bond is reversible and the capping agent can later be exchanged for other ligands.",
"Examples of capping agents suitable for use with CuInSe 2 nanocrystals are octanethiol or pyridine.",
"[0062] In steps 206 , 208 , the nanorods are coated by the nanocrystals, whereby the bond between nanorods and nanocrystals is established via the bifunctional capping agent 115 (e.g., mercaptoacetic acid), which has strong binding groups for both the nanorods and the nanocrystals.",
"This can be accomplished in different ways.",
"In some embodiments, as illustrated in FIG. 2A and FIG. 3 , the nanorods are capped with the bifunctional capping agent (step 206 A), for example, by dipping the substrate with the nanorods into a solution of the bifunctional capping agent.",
"For example, the capping agent may be bound to the nanorods via a carboxylate functionality.",
"The capped nanocrystals 302 are then introduced to the film of capped nanorods 300 (step 208 A), for example, by dipping the rinced substrate with nanorods 300 into the nanocrystal solution(s).",
"At this stage, a fraction of the weak capping agent of the nanocrystals is replaced by the stronger binding groups of the bifunctional capping agent, e.g., the thiol functionality of mercaptoacetic acid, which results in nanocrystal-sensitized nanorods 304 .",
"[0063] In alternative embodiments, as illustrated in FIG. 2B , a solution of the capped nanocrystals in a non-polar organic solvent is added to a solution of the bifunctional capping agent in a polar organic solvent which is not miscible with the non-polar solvent, and the solution is shaken to ensure good mixing (step 206 B).",
"The nanocrystals undergo ligand exchange and transfer from a non-polar organic phase to a polar organic phase.",
"Subsequently, the substrate with the aligned nanorods on the surface is dipped into the nanocrystal solution or otherwise exposed to the nanocrystals (step 208 B), whereby the nanorods bind the nanocrystals via a carboxylic acid functionality of the capping agent.",
"These embodiment likewise result in nanocrystal-sensitized nanorods 304 .",
"[0064] The monomers are functionalized (step 210 ) with a binding group that has a stronger affinity for the nanocrystals than the (first) nanocrystal capping agent, but a weaker affinity for the nanorods than the bifunctional capping agent.",
"Moreover, the affinity of the binding group at the monomer for the nanocrystal is preferably weaker than the affinity of the bifunctional capping agent for the nanocrystal.",
"The monomer functionality should not interfere with the polymerization reaction.",
"Binding groups with suitable differential binding affinities are straightforwardly identified by those of skill in the art without undue experimentation based on the identities of the capping agents and their substituents (e.g., whether they are unidentate or multidentate, or on the presence of electron withdrawing groups, etc.) and the size of the nanocrystal.",
"The functionalized monomers are then combined with the nanocrystal-sensitized nanorods (step 212 ), where they bind to the nanocrystals (but not the nanorods), preferentially replacing the weak capping agent on the nanocrystal, but leaving the nanorod-nanocrystal bond intact, resulting in structure 306 .",
"A subsequent polymerization step 214 results in the nanorod-nanocrystal-polymer semiconductor structure 308 .",
"[0065] Finally, a metal cathode (e.g., Al) can be deposited on the structure (step 216 ), for example, by sputtering or metal evaporation, so that the nanorods form an array of aligned rods deposited between two opposing electrodes.",
"The polymer layer below the cathode should be sufficiently thick to electrically isolate the cathode from the nanorods.",
"[0066] Although the present invention has been described with reference to specific details, it is not intended that such details should be regarded as limitations upon the scope of the invention, except as and to the extent that they are included in the accompanying claims."
] |
This application is related to our copending U.S. applications Ser. No. 09/041,141, filed Mar. 12, 1998 and Ser. No. 09/615,074, filed Jul. 12, 2000.
This application is the national stage of PCT/GB95/02065, filed Sep. 1, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to navigation information systems. It is particularly suitable for use in providing users of road vehicles with route guidance, but other applications are possible and are discussed below.
2. Related Art
Navigation of a vehicle through an unfamiliar complex road network is a difficult task. Large amounts of fuel and time are wasted as a result of drivers getting lost or using an inefficient route. Accidents can also be caused by drivers attempting to read maps or complex road signs and losing concentration on the road ahead. Moreover, a driver may choose an inefficient route as a result of using an out-of-date map.
An additional problem can occur even if a driver knows a route to his or her destination. That route may be congested or blocked as a result of accidents or maintenance work, so that an alternative route would be more efficient.
Several proposals have been made for navigation guidance systems. In some such proposals a vehicle-borne system has a navigation computer and a geographical information system which is essentially a digitised map stored on a CD-ROM. The system gives the driver information and guidance by screen and/or speech display. These systems would be very expensive. Each vehicle requires a navigation computer and geographical information system. The cost of the complex vehicle-borne equipment involved is estimated to be in the region of £1000. The system is complex to operate, and could only be safely operated by the driver whilst the vehicle is stationary. The geographical information system would require periodic updating, which requires new disks to be distributed to subscribers from time to time.
In some proposed systems of this type real-time data would be broadcast over a radio network to update fixed information held on the geographical information system. Even so, the geographical information system would only be accurate up to its last update. Moreover, a broadcast channel needs to be allocated for the updating service.
It has also been proposed that the guidance service provider collects statistical traffic flow data from which traffic congestion predictions can be made which are fed into the real-time data to be broadcast. The traffic flow data may be collected using roadside sensors, or they may be collected by monitoring the operation of the mobile user equipment. The latter approach can only collect data relating to users of the system, but has a lower capital cost.
In an alternative approach a system of short-range roadside beacons is used to transmit guidance information to passing vehicles equipped with simple transceivers. The beacons transmit information to suitably equipped passing vehicles to give turn instructions appropriate to their chosen destinations. For each beacon the territory to be covered is divided into as many zones as there are exits from the junction the beacon relates to. The zone in which the user's chosen destination falls is determined, and instructions are given appropriate to that zone. At any given beacon all vehicles whose destinations are in the same zone get the same instruction. The definitions of the zones are dependant on the location of the beacons, and each zone comprises the set of destinations which should be reached from the beacon by taking the direction associated with that zone.
SUMMARY OF THE INVENTION
Each beacon only gives instructions for reaching the next beacon along the route to the vehicle's destination. For two vehicles starting from the same point for different destinations for which the routes are initially coincident, the beacons along the coincident section of route will each give both users the same instructions, because for those beacons both users are travelling to the same zone. Only for the beacon at the point of divergence are the two users' destinations in different zones, and therefore different instructions are given.
The beacons programming may be modified from time to time by control signals from a central control station, in a way analogous to remotely controlled adjustable signposts, but in its interactions with the user equipment the beacon is autonomous, identifying which of its zones the user's desired destination is in, and transmitting the appropriate “turn” information to get it to the next beacon on the way. The beacon has no knowledge of the rest of the route.
Each beacon has a detailed map of a small local area (the boundaries of which are, in fact, the adjacent beacons), and if the destination is in this area the beacon gives full information of the route to the destination. The system can therefore provide a user with directions to a destination defined more precisely than the beacon spacing. However, at the beginning of a journey, a user cannot use the system until he encounters a beacon.
This proposed system allows instant updating of the guidance instructions from a central control, and simpler in-vehicle equipment, but requires vast capital expenditure in roadside beacons.
A problem encountered with both the proposed systems described above is that it is difficult for them to provide alternative routings in response to congestion, either current or future, without the risk of creating worse problems on the alternative routes. Although predictions of regularly occurring congestion peaks are relatively simple to programme into the guidance information, and, at least in the beacon system, real-time updates on road congestion can also be fed to the programming of the beacons, the control system does not have any information of vehicle movements from which to predict future congestion. In any case, if the system is in use by a significant fraction of the vehicles, the system will tend to produce congestion on the diversionary routes.
According to a first aspect of the invention, there is provided a navigation information system for providing information to a mobile user dependent on the location of the mobile user, the system comprising a mobile communications system having a fixed part and one or more mobile units for communicating with the fixed part, each mobile unit including means for transmitting to the fixed part a request for guidance information relating to a destination specified by the user of the mobile unit, and for receiving such guidance information from the fixed part, and the fixed part including: means for determining the location of a mobile unit requesting guidance information, means for generating guidance information according to the present location and specified destination of the mobile unit, and means for transmitting the guidance information so generated to the mobile unit, whereby information dependent on the present location and specified destination of the mobile unit can be transmitted to the mobile unit.
According to a second aspect of the invention, there is provided a navigation information system for providing information to one or more mobile users dependent on their locations, the system comprising: means for determining the location of a mobile unit requesting guidance information relating to a specified destination, means for generating information for guidance of the user of the mobile unit according to the present location and specified destination of the mobile unit, and a communications system for transmitting the guidance information so generated to the mobile unit, whereby guidance information dependent on the present location and specified destination of the mobile unit can be transmitted to the mobile unit.
According to a third aspect, there is provided a mobile unit for a navigation information system, comprising means for identifying the present position of the mobile unit, means for transmitting, over a communications link, a request for guidance to a specified destination, and guidance instruction means controllable by guidance instruction information received over the communications link, whereby guidance instructions between the present location and the specified location can be communicated to a user by means of the guidance instruction means.
According to a fourth aspect, there is provided a method of providing navigation guidance information to mobile units of a mobile radio system, the information being dependent on the locations of the mobile units, the method comprising the steps of: transmitting, from a mobile unit to the fixed part, a request for navigation guidance to a specified destination; determining the location of the mobile unit; generating guidance information on the basis of the location information, the requested destination, and navigation data stored in the fixed part; and transmitting the guidance information from the fixed part to the mobile unit; whereby guidance information relevant to the present location and specified destination of the mobile unit is transmitted to the mobile unit.
This invention has advantages over both the prior art systems discussed above. Considerable improvements can be made over the prior on-board navigation system proposals by putting the intelligence in the fixed part of the system. Firstly, there is no need to distribute maps or updates to subscribers because the data is held centrally. New roads can be added to the system at the instant they are opened. Total capital expenditure is minimised since all users share the same database. Moreover, the computing resources are used more efficiently, because an in-vehicle system spends most of its time inactive but a centralised system can the time-shared.
Moreover, in contrast to the prior art roadside beacon system, the invention can be implemented with little deployment of equipment in the field, thereby offering considerable economies in capital cost and maintenance, and allowing rapid installation and modification of the system to meet changing requirements.
Preferably the system includes means for determining the location of the mobile part in relation to a geographical overlay comprising a plurality of overlay areas, and means for transmitting information associated with an overlay area which includes the location of the mobile part, whereby a mobile part within that overlay area receives information associated with that overlay area. This allows information associated with a particular overlay area to be transmitted to any mobile units in that overlay area. The system may also comprise means for determining when a mobile part enters a predetermined overlay area, and means for transmitting a message, to a user other than the said mobile part, in response to the said mobile part entering the predetermined overlay area. For example, one overlay area may cover part of a road approaching a junction, and the message may be the appropriate instruction to the driver, as he approaches the junction, as to which way he should turn. Each individual overlay area therefore gives navigation instructions specific to that overlay area. The overlay areas may overlap, and may be of any size down to the practical minimum of the resolution of the location determination process. Large overlay areas are suitable for transmitting general information, whilst smaller areas can be used to target information to users in very precise locations, such as individual elements of a complicated road layout. The overlay areas may be delimited in two or three dimensions.
An advantage of this preferred arrangement over the fixed beacon systems is that the geographical overlay can be readily modified. Advantageously, the system includes means for storing a digital representation of the geographical overlay, and means for modifying the stored representation such that the configurations of the overlay areas may be selected to meet changing requirements. The overlay areas can be readily combined or subdivided, or their boundaries otherwise altered to meet changing circumstances without any modification to the hardware, simply by reconfiguring the geographical overlay defined in the central database. Moreover, unlike the prior art beacon system discussed above, there is no major cost in street furniture and supporting infrastructure, because existing cellular mobile communications systems may be used to transmit the instructions from a central database. If the driver enters an overlay area which is not on the route chosen by the system, an error message can be transmitted. Such messages may be transmitted to a user other than the mobile unit, for instance in order to monitor the whereabouts of valuable cargoes or of personnel working away from a base.
The geographical overlay may also be used to operate an access-control system, for example for site security or for levying tolls. In this arrangement, if a user enters an overlay area for which he does not have permission, an alert signal can be sent to a system controller, or to security staff on site who can intercept the interloper. Means may be provided (either in a fixed location or with the mobile user) to store a value associated with the mobile unit, and means arranged to modify the stored value in response to the messages transmitted in accordance with the location of the mobile unit, either to increment the value e.g. for subsequent billing, or to decrement the value e.g. in a prepaid stored-value device.
The fixed part may include means for storing map information or other data for use in providing information, herein referred to as guidance data, means for updating the stored guidance data, means for identifying mobile parts to which the updated data are applicable, and means for transmitting such data over the communications system to the mobile parts so identified. This allows information about changing traffic situations to be transmitted to all users who will be affected, without needing to broadcast the details to other users as would be the case with those prior art systems where updating is possible.
Although the information transmitted to the user is specific to the location, information about the user can be processed centrally. This allows short-term traffic predictions to be made. The guidance data transmitted to the mobile units can therefore be based on the position measurements of a plurality of the mobile parts. If the mobile parts are vehicles, these position measurements will identify the locations of roads, and an indication of their traffic density. As new roads are built or routes are diverted, traffic will move to the new routes. Measuring the position of the traffic will therefore result in the data being updated automatically. To reduce the volume of information transmitted, the fixed part may comprise means for transmitting to the mobile part an expected range of movement information and for receiving from the mobile part movement measurements outside the expected range, and the mobile part comprising means for measuring location and time to derive movement information, means to compare the movement information with the expected range received from a fixed part of the system, and means to automatically report to the fixed system movement measurements outside the expected range. In this way only exceptional traffic conditions are reported.
The fixed part may include means for generating and maintaining guidance data based on vehicle movement data derived from time information and position measurements of a plurality of the mobile parts and/or estimations of future locations of the mobile parts based on the guidance information previously transmitted to the mobile parts. Estimations of future locations of the mobile parts based on the guidance information previously transmitted to the mobile parts can be used to make estimates of future traffic situations.
The data stored in the data storage means may be updated, for example in response to changing traffic conditions, accidents, or highway maintenance. The system may include means for identifying the mobile units to which the updated data are applicable, and transmitting amended instructions over the communications system to said mobile parts. With knowledge of the journeys being planned by a large number of users, a better prediction of demand for particular roads (and hence of congestion on those roads) can be built up. This can be more stable than existing autonomous route-planning systems because the navigation system can take account of the journeys planned for other users.
Advantageously the invention can be implemented using a public cellular radio data service on an individual dial-up basis, providing a simple mechanism for billing and avoiding the need for a separate radio transmission system.
The means for determining the location of the mobile part may comprise means to interrogate a location-identifying means forming part of the mobile part operating for example by means of dead reckoning from a known start point, using an inertial navigation system or distance and direction measuring devices such as a compass and an odometer. Alternatively, the means for locating position may include means for identifying the location of the mobile part in relation to elements of the fixed part of the communications system. The location of the mobile part may be determined by a radio location system associated with the cellular radio system. In another alternative arrangement, a satellite navigation system may be used. In one preferred arrangement the fixed part has means to determine the approximate location of the mobile part, and the location identifying means of the mobile part is arranged to respond to a location request from the interrogation means with a non-unique location signal which, in combination with the approximate location determined by the fixed part, determines a unique location.
In a preferred arrangement, the fixed part and the mobile parts each have a satellite navigation system receiver, and the positions of the mobile parts as measured by the satellite navigation system are compared with those of the fixed part as measured by the satellite navigation system. The position of the fixed part can be known with great accuracy and provides a reference measurement which allows the position of the mobile part to be determined with greater accuracy than is possible by direct measurement using the satellite system alone.
Preferably the fixed part has one or more servers and means for allocating a server to a mobile part only when it requires service. In practice only a very small number of mobile units will require service at any given time, so this allows the computing resources of the fixed part to be used most efficiently, and the system can support many more mobile units in total than it has server capacity for. This is in contrast to the prior art system discussed above, in which each mobile unit requires a dedicated computer carried on board, which is only used for a fraction of the time. Moreover, all the servers can use a common road-use database, which can use the information on routes it has planned for mobile users to build a prediction of future road use status, such as likely congestion points, and build this into its guidance instruction process. For example the system can be arranged such that it does not direct more than a predetermined number of users to use a particular stretch of road at a particular time, and finds alternative routes for any users who would otherwise be directed along that road at that time. In this way the system can predict likely congestion points and take pre-emptive action.
The mobile part may include guidance instruction means controllable by instructions contained in the guidance information transmitted from the fixed part over the communications link, whereby guidance instructions can be communicated to the user by means of the guidance instruction means.
For some applications the vehicle may be controlled directly in response to the guidance information received over the communications link. However, for use on the public highway, it is preferable that the guidance information controls display means, which may be visual or audible or both, to indicate to a driver the direction to take.
The guidance instruction means may be programmable from the fixed part over the communications link, either automatically or by a human operator. The guidance instruction means may include a speech synthesiser, which may be located in the fixed part, transmitting voice messages to the user over the communications system, or may be located in the mobile unit and controlled by data messages from the fixed part. The former arrangement allows the mobile unit to be simplified, whilst the latter arrangement requires a smaller signalling load.
In the described embodiment the mobile part is in a vehicle, but it may be a hand-held device for guiding a pedestrian. In one form, the mobile part may be a conventional mobile cellular radio unit. This allows a basic service to be provide to a user without the need for any dedicated equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example with reference to the drawings, in which:
FIG. 1 shows a mobile part and a fixed part of a navigation information system according to an embodiment of the invention;
FIG. 2 illustrates how the invention may be applied to a simple road layout;
FIG. 3 illustrates the division of a territory into zones according to the instructions generated by the system;
FIG. 4 illustrates an application of the invention to a more complex road layout;
FIGS. 5 a and 5 b illustrate the modification of an overlay in response to a change in traffic circumstances; and
FIG. 6 illustrates a road network, showing overlay areas defined by the method of the invention in relation to a cellular radio network
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
According to the embodiment of FIG. 1 the navigation system has a fixed part (comprising elements 12 to 19 ) and a number of mobile parts, of which one only is shown (comprising elements 1 to 10 ), interconnected by a cellular telephone network 11 .
The mobile part comprises a mobile telephone 1 having an audio output 2 , an audio input 3 and a radio antenna (transmit/receive) 4 . The output 2 is connected to a decoder 5 to translate Dual-Tone Multi-Frequency (DTMF) signals received by the telephone 1 into data which is fed to an interface controller 6 . The interface controller 6 also receives input from a GPS (Global Positioning System) satellite receiver 7 . The interface controller transmits data to a DTMF encoder 8 which generates tones to be fed to the audio input of the mobile telephone. The audio output 2 and input 3 also include a loudspeaker 9 and microphone 10 respectively, to allow the telephone to be used for speech.
The fixed part comprises an interface with the cellular telephone network 11 , connected through a DTMF decoder 12 and encoder 13 and a controller interface 14 to a computer 15 . The computer 15 comprises a number of servers 16 , one of which is allocated to each active mobile unit. The servers 16 have access to a geographical database 17 , and a database of standard messages 18 . The geographical database 17 is updateable through updating input 19 . The database 17 stores the definitions of a number of overlay areas which together form a geographical overlay to the territory to be covered. Examples of overlays are illustrated in FIGS. 2, 4 , 5 a , 5 b , and 6 , to be described in detail later.
The mobile part obtains location information using the GPS receiver 7 and transmits this information, together with a request for directions to a specified destination, to the fixed part, where a server 16 relates the location information to its geographical database 17 and obtains message information associated with the location from the database 18 , and transmits the information back to the mobile part.
The computer 15 may transmit messages in DTMF code, using the encoder 1 2 , or it may generate voice messages which are transmitted through a voice output 20 to the cellular network 11 .
DTMF signals are used to transmit the position of the vehicle to the computer 15 which can then offer information and guidance either to the vehicle or to a third party on demand.
In the following discussion, variations on the basic apparatus depicted in FIG. 1 will also be described, in which certain elements are modified or replaced.
The system is operated as follows:
At the start of a journey the driver requests service by activating a pre-dialled control on the telephone 1 . This service request is transmitted to the control interface 14 over the telephone network 11 . The control interface 14 then allocates a free server 16 to answer the call and interrogate the vehicle GPS receiver 7 to determine its geographical position. The encoder 8 takes the latitude and longitude data and translates the numbers into DTMF tone-pairs, in a manner to be described in more detail below.
The cellular telephone couples this audio signal into its speech input path. This is easy to do with a hands-free vehicle-mounted cellular telephone since the microphone lead is accessible or alternatively, a small transducer can be mounted next to the microphone 10 . A DTMF receiver 5 coupled to the loudspeaker 9 (again acoustically or electrically) decodes supervisory data (again in DTMF format) coming back from the server 16 to acknowledge the reception of location messages. If no acknowledgement is received by the DTMF unit then the data message is repeated.
The fixed end of the system comprises a DTMF decoder 12 and encoder 13 coupled to a serial data interface 14 of the server computer 15 . This computer, on the one hand, can call the mobile part which will answer automatically and then provide its location using the DTMF signalling system or on the other hand can receive an unsolicited call, which would include the DTMF encoded identity of the mobile unit and would also provide the vehicle location using the DTMF interface 6 .
The server 16 then captures the current position of the user, and identifies the overlay area within which that position falls. The server also captures any permanent user-specific information such as the type of vehicle, which may be relevant for the route to be selected e.g. because of height or weight restrictions. The user may encode those requirements which are not permanent, but are specific to the present information request, (in particular his destination) by using the telephone keypad in response to voice prompts. However, in a preferred arrangement the call is presented to a human operator for the capture of this data. This allows the user to obtain assistance in identifying his desired destination to the system, and also allows the driver to speak his requirements, keeping his hands and eyes free for driving.
The operator then remotely programs the in-vehicle interface 6 with system data identifying the vehicle destination, for use in subsequent update processes, and instigates the generation of voice given directions and instructions to the driver by a speech generation subsystem of the computer server 16 .
Position fixes may be made at regular intervals, e.g. every two minutes, or every kilometer. Alternatively the fixed part may request the mobile unit to send its next position fix after a specified interval or distance.
As the driver follows the route further instructions can automatically be sent as the driver enters each new overlay area and the driver can be alerted if the route has been left or if any new traffic problems have been detected that will affect the individual driver. The system is arranged such that when the system locates a mobile unit entering an overlay area having a message defined for it, for example the next turn instruction (or an error message if the mobile unit has gone off the selected route), that message is transmitted. The system may also be arranged to transmit messages to users other than the mobile unit in question, for example to monitor the progress of valuable cargoes.
At any time the driver can call the human operator if service requirements change or additional help is needed.
Because a central database is used all vehicle movements can be monitored. Traffic models can be used to optimise traffic flows and reduce journey times. The system can also ensure that it does not itself cause congestion, by limiting the number of vehicles it directs to use the same road at the same time. The control system can use the location data to calculate and record movement vectors from these vehicles.
Using the data collected by this method, it is possible for the central system to derive a digital map of valid routes. The following data could be derived automatically: valid travel lanes; permitted directions) of flow; allowable turns; average travel times; trends in travel times according to time of day and other factors.
The system would automatically update the map to show permanent changes (new road links, changes to one way systems etc.). Temporary lane closures from road works etc. would also be recorded. Manual updating of data would be necessary (for instance to alert the system to a new bypass opening) before the system acquired the information from vehicle flow data, to ensure vehicles are routed over the new road initially. Any approximations in the pre-entered data would automatically be corrected by the system described here.
The system could be further enhanced to include any other information that may be relevant to travellers, by a combination of manual and automated data entry, e.g. location of bus stops, telephone boxes and other street furniture, and proximity to enterprises such as shops, banks or offices.
The variation of transit time trends according to time of day, for each link, could be used to derive a congestion prediction model, as the basis for route guidance. The system may monitor the progress of the mobile units along the routes selected for them, to identify any areas of traffic congestion etc, by comparing actual transit times between predetermined locations. This may be done by the fixed system monitoring the location updates of individual units, or it may be done by the mobile unit, in co-operation with the fixed unit. In this latter case, the fixed part transmits an expected range of transit times within which the mobile is expected to reach a predetermined location. If the mobile unit reaches the location outside this range, it reports the fact to the fixed part. By “reporting by exception” the data processing overhead can be reduced considerably.
However, these systems can become unstable if too many drivers have access to route guidance based on information about current or predicted congestion. To avoid these instabilities route plans are created and updated centrally and passed to individual vehicles. The impact of these vehicles using the suggested routes is then added to the prediction. As more vehicles use the system the prediction produced could become more accurate.
The routes derived can be passed to the vehicles (via a mobile data link, or possibly a short range communications link or other temporary access to a fixed telecommunications network—prior to departure). The vehicle would then operate autonomously, unless the road conditions varied significantly from those predicted.
If the central system detected a problem (from vehicle data or other sources), which had a severe impact on predictions, sufficient to cause a change to advice already given, then the central system could broadcast news of the problem, such that those vehicles affected could automatically call in via a mobile data communications link to receive a new route from its present location to its destination.
If a vehicle system encountered unexpected transit times along its programmed route it would send a report to the central system.
The data flowing though the system will therefore allow it to “learn” more of the road network's characteristic congestion behaviour, e.g. by use of neural net techniques, and to select routes for traffic which avoid using routes at times when they are likely to be congested. In addition, the system can generate digital road maps or other data automatically, based on the position measurements of vehicles using the roads.
A particular advantage of this system is the ability to predict unusual patterns of congestion from the route guidance information requested by the users. Because route guidance is generated centrally, the system can monitor the number of requests for destination information to a given location. By determining the predicted arrival times for each user (which will depend on their starting points, and the time the journey started), a build-up of traffic converging on a particular location at a particular future time (e.g. for a major sporting event) can be detected. Traffic for other destinations, which might have been routed by way of this location, can then be diverted to other routes.
The system described above uses an analogue telecommunications link, in which DTMF codes may be used. For an analogue cellular radio network DTMF is an ideal signalling medium when only short status messages are required to be transmitted. It can survive in the severe signal fading and noise of the mobile environment which frequently precludes the use of fast phase or frequency shift data modulation. Another advantage is the ability to co-exist with speech. For example a DTMF data burst containing vehicle position data could be sent at the start of a call and at intervals during the call. Other simple coded DTMF messages can also be conveyed to indicate emergencies, provide simple driver indications (e.g. illuminated arrows to turn left or right) or trigger synthetic speech generated by another sub-system in the vehicle.
The DTMF coding described above is suitable for an analogue system. In a digital cellular network digitised data can be transmitted over an associated packet data system such as the Short Message Service (SMS) of GSM (Global System for Mobile Communications), or the General Packet Radio Service (GPRS) proposed for GSM.
In the embodiment described above, the speech generation subsystem forms part of the server 16 . Alternatively, it can be carried on board the vehicle. In this arrangement the subsystem has various stored speech commands which are controlled from the in-vehicle interface 6 in response to commands transmitted from the fixed part. This arrangement reduces the signalling traffic required over the radio link 11 , but increases the complexity of the in-vehicle equipment.
The location-determination system will now be described in greater detail. GPS (Global Positioning System) satellite navigation receivers are now becoming very cheap and are available with a serial data output. These can provide latitude and longitude data to within a tenth of a second of arc (defining position to within 3 meters, which is sufficient to identify which carriageway of a dual carriageway road a user is on),
Satellite positioning systems such as the Global Positioning System (GPS) are prone to small systematic errors, for example as a result of instabilities in the orbits of the satellites. The accuracy of the position measurement may be enhanced by a process known as “Differential GPS” in which a number of fixed reference points are used, whose positions are determined with great precision e.g. using surveying techniques. GPS is used to obtain a measure of the position of one or more of the fixed reference points. This measure is compared with the known, true location to generate a correction value which can be used to correct the position of the mobile unit as measured by GPS.
The position data received from the satellite positioning system may include some redundant data. If the system is only to operate within a limited area of the globe the most significant digits of the position data are redundant, and need not be transmitted from the mobile unit to the fixed part. For example, any point in Germany can be uniquely defined by the units digits of its latitude and of its longitude, as that country lies entirely between 45 and 55 degrees North, and between 5 and 15 degrees East. It is also possible to define any point in the United Kingdom in this way, although in that case a 10 degree offset in longitude has to be applied to avoid duplication of longitudes East and West of the zero meridian.
For larger territories e.g. a pan-European system, or one covering the USA, this simple method of data reduction is impractical. However, it is nevertheless possible to reduce the data requirements by dynamically defining the territory. After an initialisation step using the full location, the system selects as each new location the closest candidate to the previous one. For example, if the mobile unit was last reported at 99 degrees W and the units digit of the longitude is now 0, the user is taken to be at 100 degrees W rather than, for example, 90 degrees or 110 degrees.
If location updates take place sufficiently frequently that the user's position cannot have changed by more than half a degree, the units digit of degrees may also be dispensed with, and the location given only in minutes and seconds of arc. The more frequent the updates, the more digits can be dispensed with.
An alternative method of obtaining the coarse position location is interrogation of the cellular radio system's operating system to identify the cell in which the user is currently located. Cell sizes can be up to about 40 km across (although they are often much smaller, so identifying the cell can identify the user's location to within 40 km, which identifies latitude to better than half a degree. (1 degree of latitude=111 km). The separation of lines of longitude varies with the cosine of the latitude but even at the Arctic Circle (66 degrees North) a 40 km resolution will identify longitude to the nearest whole degree (1 degree of longitude=111 km (cos latitude)=approximately 45 km at 66 degrees North).
By left-truncating the position data by omitting the degrees digits a basic position message would therefore consist of 10 decimal digits (minutes, seconds, and tenths of seconds). Altitude data giving altitude in meters would require a further four digits, since all points on the Earth's surface lie within a range of 10,000 meters, but this data can also be left-truncated, as it is unlikely that any multi-level road system would exceed 100 meters in height (or if it did, that a GPS system would work effectively for any receiver on the lower levels). This gives a total of twelve digits, which can be transmitted by DTMF in less than 2 seconds.
If the data is left-truncated as described above, the “coarse” data is added by the interface controller 14 by reference to the previous position or to the cellular radio operating system.
When the computer 15 receives a location message, it stores the location and then searches its database for an overlay area within which that position lies. The overlay areas are defined in the database by co-ordinates of latitude and longitude and have associated attributes which define messages which can be passed to mobile subscribers within the overlay area defined. In some instances height (altitude) information, also available using satellite positioning systems, may be used, for example to distinguish between levels in a multi-level highway intersection. When a DTMF location message has co-ordinates which fall inside an overlay area having an associated message, the message is then transmitted to the mobile part as a computer synthesised speech message, a DTMF coded message (to activate other subsystems) or as a high speed conventional data message.
If the mobile unit fell within the same overlay area at the previous location update, and the message associated with that overlay area is unchanged, the transmission of the message may be suspended.
The frequency at which location updates are requested by the system may be tailored to the size and nature of the current overlay area. For example, an intricate road layout may comprise a large number of small overlay areas, requiring frequent location updates to ensure that a user does not miss an instruction by passing through its associated area between two updates. However, a long stretch of road without junctions may be covered by a single overlay area, so less frequent updates are appropriate. The speed with which a vehicle is likely to be moving, which will differ between urban, rural, and motorway environments may also be used as a factor in determining when the next location update should be requested.
As suggested above, there may be circumstances when a satellite positioning system may be unusable, for example in tunnels or built-up areas where a line-of-sight view of the satellites may be impossible to obtain. Alternative arrangements for identifying and updating the mobile part's location which do not rely on a satellite receiver may be used, either on their own, or to interpolate between points where a satellite system can be used. In one variant, a navigation system based on dead-reckoning may be used. In such systems the user identifies his initial location and the on-board system measures the system's movement e.g. by magnetic bearing measurements, distance counters, and inertial navigation means such as gyrocompasses and accelerometers. Such systems are self-contained, but require knowledge of the starting point. This may be obtained, for example from a satellite positioning system.
In another variant, a method of location may be used which relies on the propagation characteristics of the cellular radio system used for communication with the central control station. Examples of such systems are disclosed in German Patent specifications DE3825661 (Licentia Patent Verwaltungs) and DE 3516357 (Bosch), U.S. Pat. No. 4,210,913 (Newhouse), European Patent specification EP0320913 (Nokia), and International Patent applications WO92/13284 (Song) and WO 88/01061 (Ventana). By comparison of signal strength or other characteristics of several cellular base stations, a position fix can be determined. In this arrangement the location measurement may be made directly by the fixed system. This allows the mobile part of the system to be embodied by a conventional cellular telephone, with inputs being provided by speech, or by DTMF tones generated by the keypad, and instructions to the user being transmitted by voice commands.
Examples of the kind of navigation information which may be stored in the database 17 will now be discussed, with reference to FIGS. 2 to 6 . Briefly, FIG. 2 shows a junction J having four approach roads 21 , 22 , 23 , 24 ; each having associated with it an overlay area 21 a , 22 a , 23 a , 24 a respectively. In this figure, and all other figures illustrating road layouts, the roads are shown arranged for lefthand running, as used for example in the UK, Japan, Australia etc. FIG. 3 shows part of a road network surrounding the junction J, including towns A, B, C, and a motorway M. Each of the roads 21 , 22 , 23 , 24 has an associated destination zone 21 z etc. FIG. 4 shows a complex grade-separated junction interlinking four roads N, S, E, W. The junction has superimposed on it an overlay having twelve overlay areas, Na, Ni, Nd, Sa, Si, Sd, Ea, Ei, Ed, Wa, Wi, Wd. FIG. 5 a shows a small region having a main road 33 and a side road 30 . The main road 33 has two associated overlay areas 31 , 32 . FIG. 5 b is similar to FIG. 5 a , but an obstruction X is present on the main road 33 , and the overlay area 32 has been subdivided into two overlay areas 32 a , 32 b , separated by the obstruction. FIG. 6 shows an overlay comprising ten overlay areas 40 - 49 superimposed on a cellular radio coverage region comprising five cells 50 - 54 .
In greater detail, the road junction J (FIG. 2) has four approach roads 21 , 22 , 23 , 24 . On each road, at the approach to the junction, an overlay area ( 21 a , 22 a , 23 a , 24 a ) is defined. These overlay areas have directional information associated with them, giving turn instructions or other navigational information. As shown in FIG. 3, the entire territory covered by the navigation system can be divided into four zones 21 z , 22 z , 23 z , 24 z , each comprising the set of all locations for which the corresponding road 21 , 22 , 23 , 24 should be taken from the junction J. In this particular example, road 24 leads directly into town A and is only used for local destinations (zone 24 z ), road 23 leads to town B (zone 23 z ), road 22 leads to town D (zone 22 z ) and road 21 leads to the motorway M, for all other destinations including town C and part of town A. These zones are defined differently for each junction: for example at junction J′ different directions are appropriate for towns A and C, so these towns fall in different zones with respect to the overlay areas at that junction. The zones may even be defined differently for different overlay areas at the same junction. For example, if U-turns are not possible at the junction J, any traffic approaching the junction J by road 22 and requiring town D (perhaps as the result of a previous error, or a change of plan) must be routed by way of roads 21 , M, and 25 . Thus, for overlay area 22 a there are only three zones: 24 z , 23 z and the combined 21 z / 22 z , corresponding to the three permitted exits 21 , 23 , 24 .
The zones may be re-defined according to circumstances. For example, when the motorway M is congested, the best route from junction J to town C may be by way of town B. In such circumstances, zones 21 z and 23 z are redefined so that town C now falls within zone 23 z . It should be noted, however, that the total number of zones remains the number of exit routes from the relevant overlay area.
The overlay areas 21 a , 22 a , 23 a , and 24 a should be large enough to ensure that any vehicle approaching the junction gets at least one location update whilst within the relevant overlay area, and is thus sent the relevant turn instruction. As shown in FIG. 2, these overlay areas are discrete, and may be considered equivalent to the coverage areas of the beacons of the prior art system discussed above. They may, however, be made contiguous, as shown in FIGS. 4, 5 a , 5 b and 6 .
FIG. 4 shows a more complex, grade-separated junction, in which there are twelve overlay areas Each road N, E, S, W intersecting at the junction has a corresponding approach overlay area Na, Ea, Sa, Wa, (Wa shown shaded), and a depart overlay area Nd, Ed, Sd, Wd (Ed shown shaded). There are also four intermediate overlay areas Ni, Ei, Si, Wi (Si shown shaded). In the vicinity of the flyover F height (altitude) information obtainable from the GPS system can be used to determine which level, and therefore which overlay area, the user is currently in.
The approach and intermediate overlay areas each end at a decision point P 1 to P 8 . In the database 17 each overlay area has direction information associated with it, providing instructions as to which fork to take at the associated decision point. For example, the direction information associated with zone Si instructs users for destinations served by road N to go straight on at point P 1 , and users for destinations served by roads E, S, and W to turn left. It will be seen that traffic using the intersection will pass through one approach overlay area, one departure overlay area, and may also pass through one or more intermediate overlay areas. There may also be information associated with the departure overlay areas Nd, Sd, Ed, Wd, for example warning of hazards ahead. The departure overlay areas may be continuous with approach overlay areas for the next junction in each direction.
As a user approaches the junction on road S, a location update identifies the user equipment as being within overlay area Sa. If the co-ordinates of the user's destination are within the zone served by road W, the user is sent an instruction to turn left at point P 2 . If the user obeys this instruction, he will enter overlay area Wd and on the next location update he will be sent information relevant to that overlay area (if any).
If the co-ordinates of the user's destination are within the zone served by road N, the user in overlay area Sa is instead sent an instruction to continue straight on at point P 2 . If the user obeys this instruction, he will enter overlay area Si.
For a user in overlay area Si, if the co-ordinates of the user's destination are within the zone served by road N the user is sent an instruction to go straight on at point P 1 . On obeying this instruction, he will enter the overlay area Nd and on the next location update he will be sent information relevant to that overlay area (if any).
If the co-ordinates of the destination of a user in overlay area Si are in the zone served by roads E, S, or W, the user will be sent an instruction to turn left at point P 1 . On obeying this instruction, he will enter overlay area Wi.
Similar information is associated with the other overlay areas. By being given appropriate instructions as the user negotiates a succession of junctions (decision points), the user can be directed to any destination. It should be noted that all users who are to be directed to the same exit from the junction are given the same instruction, whatever their ultimate destination.
FIGS. 5 a and 5 b illustrate the reconfiguration of the overlay areas to meet changing circumstances. Initially (FIG. 5 a ) an overlay area 31 is defined for the approach to a junction between a major road 33 and a side road 30 , and a second overlay area 32 is defined for that part of the major road 33 beyond the junction. Information associated with the overlay area 31 includes turn information to instruct traffic for the zone served by the side road 30 to turn off. Information may also be associated with the overlay area 32 .
In FIG. 5 b the major road 33 has been blocked at a point X. In order to accommodate this, the overlay area 32 has been subdivided into two overlay areas 32 a , 32 b . The information (if any) associated with overlay area 32 b is the same as that previously associated with overlay area 32 . Traffic in overlay area 32 a is given new information warning it of the hazard ahead. The information associated with the overlay area 31 is modified, so that all traffic is now instructed to turn off onto the side road 30 . (Effectively this means that the destination zones associated with the overlay area 31 are merged into one)
FIG. 6 shows how the overlay areas may be defined for a road network. In this example there is an overlay area 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 corresponding to each side of each section of road. Information appropriate to each direction of travel on each section is Therefore available to users throughout the relevant section. Superimposed on this overlay there is a cellular radio network, five cells of which ( 50 , 51 , 52 , 53 , 54 ) are shown. The position of the user, as determined for example by a satellite positioning system, determines which overlay area is appropriate to the user. The information is transmitted to the service control centre by means of the cellular radio network. Handovers between cellular base stations occur in conventional manner at cell boundaries. These handovers are, however, unrelated to the boundaries between the overlay areas 40 - 49
Although the described embodiment relates to the provision of route guidance information, other locality-dependant information may be provided as well, or instead, such as information about local facilities, tourist attractions, weather forecasts, public transport information, etc. The term “guidance information”, as used in this specification, embraces any such information. | A navigation information system includes a communications system having a fixed part and at least one mobile part, the fixed part including data storage and a processor identifying the location of a mobile unit, generating guidance information appropriate to that location and transmitting it to the mobile unit. By locating most of the complexity with the service provider, in particular the navigation computer and geographical database, the system can be readily updated and the capital cost of the in-vehicle system, which in its simplest form may be a standard cellular telephone, can be minimized. The user makes a request for guidance information, and the system, having determined the user's present location, then transmits instructions to the user. The user's present location can be determined by a Satellite Positioning System or the like. | Briefly summarize the main idea's components and working principles as described in the context. | [
"This application is related to our copending U.S. applications Ser.",
"No. 09/041,141, filed Mar. 12, 1998 and Ser.",
"No. 09/615,074, filed Jul. 12, 2000.",
"This application is the national stage of PCT/GB95/02065, filed Sep. 1, 1995.",
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to navigation information systems.",
"It is particularly suitable for use in providing users of road vehicles with route guidance, but other applications are possible and are discussed below.",
"Related Art Navigation of a vehicle through an unfamiliar complex road network is a difficult task.",
"Large amounts of fuel and time are wasted as a result of drivers getting lost or using an inefficient route.",
"Accidents can also be caused by drivers attempting to read maps or complex road signs and losing concentration on the road ahead.",
"Moreover, a driver may choose an inefficient route as a result of using an out-of-date map.",
"An additional problem can occur even if a driver knows a route to his or her destination.",
"That route may be congested or blocked as a result of accidents or maintenance work, so that an alternative route would be more efficient.",
"Several proposals have been made for navigation guidance systems.",
"In some such proposals a vehicle-borne system has a navigation computer and a geographical information system which is essentially a digitised map stored on a CD-ROM.",
"The system gives the driver information and guidance by screen and/or speech display.",
"These systems would be very expensive.",
"Each vehicle requires a navigation computer and geographical information system.",
"The cost of the complex vehicle-borne equipment involved is estimated to be in the region of £1000.",
"The system is complex to operate, and could only be safely operated by the driver whilst the vehicle is stationary.",
"The geographical information system would require periodic updating, which requires new disks to be distributed to subscribers from time to time.",
"In some proposed systems of this type real-time data would be broadcast over a radio network to update fixed information held on the geographical information system.",
"Even so, the geographical information system would only be accurate up to its last update.",
"Moreover, a broadcast channel needs to be allocated for the updating service.",
"It has also been proposed that the guidance service provider collects statistical traffic flow data from which traffic congestion predictions can be made which are fed into the real-time data to be broadcast.",
"The traffic flow data may be collected using roadside sensors, or they may be collected by monitoring the operation of the mobile user equipment.",
"The latter approach can only collect data relating to users of the system, but has a lower capital cost.",
"In an alternative approach a system of short-range roadside beacons is used to transmit guidance information to passing vehicles equipped with simple transceivers.",
"The beacons transmit information to suitably equipped passing vehicles to give turn instructions appropriate to their chosen destinations.",
"For each beacon the territory to be covered is divided into as many zones as there are exits from the junction the beacon relates to.",
"The zone in which the user's chosen destination falls is determined, and instructions are given appropriate to that zone.",
"At any given beacon all vehicles whose destinations are in the same zone get the same instruction.",
"The definitions of the zones are dependant on the location of the beacons, and each zone comprises the set of destinations which should be reached from the beacon by taking the direction associated with that zone.",
"SUMMARY OF THE INVENTION Each beacon only gives instructions for reaching the next beacon along the route to the vehicle's destination.",
"For two vehicles starting from the same point for different destinations for which the routes are initially coincident, the beacons along the coincident section of route will each give both users the same instructions, because for those beacons both users are travelling to the same zone.",
"Only for the beacon at the point of divergence are the two users'",
"destinations in different zones, and therefore different instructions are given.",
"The beacons programming may be modified from time to time by control signals from a central control station, in a way analogous to remotely controlled adjustable signposts, but in its interactions with the user equipment the beacon is autonomous, identifying which of its zones the user's desired destination is in, and transmitting the appropriate “turn”",
"information to get it to the next beacon on the way.",
"The beacon has no knowledge of the rest of the route.",
"Each beacon has a detailed map of a small local area (the boundaries of which are, in fact, the adjacent beacons), and if the destination is in this area the beacon gives full information of the route to the destination.",
"The system can therefore provide a user with directions to a destination defined more precisely than the beacon spacing.",
"However, at the beginning of a journey, a user cannot use the system until he encounters a beacon.",
"This proposed system allows instant updating of the guidance instructions from a central control, and simpler in-vehicle equipment, but requires vast capital expenditure in roadside beacons.",
"A problem encountered with both the proposed systems described above is that it is difficult for them to provide alternative routings in response to congestion, either current or future, without the risk of creating worse problems on the alternative routes.",
"Although predictions of regularly occurring congestion peaks are relatively simple to programme into the guidance information, and, at least in the beacon system, real-time updates on road congestion can also be fed to the programming of the beacons, the control system does not have any information of vehicle movements from which to predict future congestion.",
"In any case, if the system is in use by a significant fraction of the vehicles, the system will tend to produce congestion on the diversionary routes.",
"According to a first aspect of the invention, there is provided a navigation information system for providing information to a mobile user dependent on the location of the mobile user, the system comprising a mobile communications system having a fixed part and one or more mobile units for communicating with the fixed part, each mobile unit including means for transmitting to the fixed part a request for guidance information relating to a destination specified by the user of the mobile unit, and for receiving such guidance information from the fixed part, and the fixed part including: means for determining the location of a mobile unit requesting guidance information, means for generating guidance information according to the present location and specified destination of the mobile unit, and means for transmitting the guidance information so generated to the mobile unit, whereby information dependent on the present location and specified destination of the mobile unit can be transmitted to the mobile unit.",
"According to a second aspect of the invention, there is provided a navigation information system for providing information to one or more mobile users dependent on their locations, the system comprising: means for determining the location of a mobile unit requesting guidance information relating to a specified destination, means for generating information for guidance of the user of the mobile unit according to the present location and specified destination of the mobile unit, and a communications system for transmitting the guidance information so generated to the mobile unit, whereby guidance information dependent on the present location and specified destination of the mobile unit can be transmitted to the mobile unit.",
"According to a third aspect, there is provided a mobile unit for a navigation information system, comprising means for identifying the present position of the mobile unit, means for transmitting, over a communications link, a request for guidance to a specified destination, and guidance instruction means controllable by guidance instruction information received over the communications link, whereby guidance instructions between the present location and the specified location can be communicated to a user by means of the guidance instruction means.",
"According to a fourth aspect, there is provided a method of providing navigation guidance information to mobile units of a mobile radio system, the information being dependent on the locations of the mobile units, the method comprising the steps of: transmitting, from a mobile unit to the fixed part, a request for navigation guidance to a specified destination;",
"determining the location of the mobile unit;",
"generating guidance information on the basis of the location information, the requested destination, and navigation data stored in the fixed part;",
"and transmitting the guidance information from the fixed part to the mobile unit;",
"whereby guidance information relevant to the present location and specified destination of the mobile unit is transmitted to the mobile unit.",
"This invention has advantages over both the prior art systems discussed above.",
"Considerable improvements can be made over the prior on-board navigation system proposals by putting the intelligence in the fixed part of the system.",
"Firstly, there is no need to distribute maps or updates to subscribers because the data is held centrally.",
"New roads can be added to the system at the instant they are opened.",
"Total capital expenditure is minimised since all users share the same database.",
"Moreover, the computing resources are used more efficiently, because an in-vehicle system spends most of its time inactive but a centralised system can the time-shared.",
"Moreover, in contrast to the prior art roadside beacon system, the invention can be implemented with little deployment of equipment in the field, thereby offering considerable economies in capital cost and maintenance, and allowing rapid installation and modification of the system to meet changing requirements.",
"Preferably the system includes means for determining the location of the mobile part in relation to a geographical overlay comprising a plurality of overlay areas, and means for transmitting information associated with an overlay area which includes the location of the mobile part, whereby a mobile part within that overlay area receives information associated with that overlay area.",
"This allows information associated with a particular overlay area to be transmitted to any mobile units in that overlay area.",
"The system may also comprise means for determining when a mobile part enters a predetermined overlay area, and means for transmitting a message, to a user other than the said mobile part, in response to the said mobile part entering the predetermined overlay area.",
"For example, one overlay area may cover part of a road approaching a junction, and the message may be the appropriate instruction to the driver, as he approaches the junction, as to which way he should turn.",
"Each individual overlay area therefore gives navigation instructions specific to that overlay area.",
"The overlay areas may overlap, and may be of any size down to the practical minimum of the resolution of the location determination process.",
"Large overlay areas are suitable for transmitting general information, whilst smaller areas can be used to target information to users in very precise locations, such as individual elements of a complicated road layout.",
"The overlay areas may be delimited in two or three dimensions.",
"An advantage of this preferred arrangement over the fixed beacon systems is that the geographical overlay can be readily modified.",
"Advantageously, the system includes means for storing a digital representation of the geographical overlay, and means for modifying the stored representation such that the configurations of the overlay areas may be selected to meet changing requirements.",
"The overlay areas can be readily combined or subdivided, or their boundaries otherwise altered to meet changing circumstances without any modification to the hardware, simply by reconfiguring the geographical overlay defined in the central database.",
"Moreover, unlike the prior art beacon system discussed above, there is no major cost in street furniture and supporting infrastructure, because existing cellular mobile communications systems may be used to transmit the instructions from a central database.",
"If the driver enters an overlay area which is not on the route chosen by the system, an error message can be transmitted.",
"Such messages may be transmitted to a user other than the mobile unit, for instance in order to monitor the whereabouts of valuable cargoes or of personnel working away from a base.",
"The geographical overlay may also be used to operate an access-control system, for example for site security or for levying tolls.",
"In this arrangement, if a user enters an overlay area for which he does not have permission, an alert signal can be sent to a system controller, or to security staff on site who can intercept the interloper.",
"Means may be provided (either in a fixed location or with the mobile user) to store a value associated with the mobile unit, and means arranged to modify the stored value in response to the messages transmitted in accordance with the location of the mobile unit, either to increment the value e.g. for subsequent billing, or to decrement the value e.g. in a prepaid stored-value device.",
"The fixed part may include means for storing map information or other data for use in providing information, herein referred to as guidance data, means for updating the stored guidance data, means for identifying mobile parts to which the updated data are applicable, and means for transmitting such data over the communications system to the mobile parts so identified.",
"This allows information about changing traffic situations to be transmitted to all users who will be affected, without needing to broadcast the details to other users as would be the case with those prior art systems where updating is possible.",
"Although the information transmitted to the user is specific to the location, information about the user can be processed centrally.",
"This allows short-term traffic predictions to be made.",
"The guidance data transmitted to the mobile units can therefore be based on the position measurements of a plurality of the mobile parts.",
"If the mobile parts are vehicles, these position measurements will identify the locations of roads, and an indication of their traffic density.",
"As new roads are built or routes are diverted, traffic will move to the new routes.",
"Measuring the position of the traffic will therefore result in the data being updated automatically.",
"To reduce the volume of information transmitted, the fixed part may comprise means for transmitting to the mobile part an expected range of movement information and for receiving from the mobile part movement measurements outside the expected range, and the mobile part comprising means for measuring location and time to derive movement information, means to compare the movement information with the expected range received from a fixed part of the system, and means to automatically report to the fixed system movement measurements outside the expected range.",
"In this way only exceptional traffic conditions are reported.",
"The fixed part may include means for generating and maintaining guidance data based on vehicle movement data derived from time information and position measurements of a plurality of the mobile parts and/or estimations of future locations of the mobile parts based on the guidance information previously transmitted to the mobile parts.",
"Estimations of future locations of the mobile parts based on the guidance information previously transmitted to the mobile parts can be used to make estimates of future traffic situations.",
"The data stored in the data storage means may be updated, for example in response to changing traffic conditions, accidents, or highway maintenance.",
"The system may include means for identifying the mobile units to which the updated data are applicable, and transmitting amended instructions over the communications system to said mobile parts.",
"With knowledge of the journeys being planned by a large number of users, a better prediction of demand for particular roads (and hence of congestion on those roads) can be built up.",
"This can be more stable than existing autonomous route-planning systems because the navigation system can take account of the journeys planned for other users.",
"Advantageously the invention can be implemented using a public cellular radio data service on an individual dial-up basis, providing a simple mechanism for billing and avoiding the need for a separate radio transmission system.",
"The means for determining the location of the mobile part may comprise means to interrogate a location-identifying means forming part of the mobile part operating for example by means of dead reckoning from a known start point, using an inertial navigation system or distance and direction measuring devices such as a compass and an odometer.",
"Alternatively, the means for locating position may include means for identifying the location of the mobile part in relation to elements of the fixed part of the communications system.",
"The location of the mobile part may be determined by a radio location system associated with the cellular radio system.",
"In another alternative arrangement, a satellite navigation system may be used.",
"In one preferred arrangement the fixed part has means to determine the approximate location of the mobile part, and the location identifying means of the mobile part is arranged to respond to a location request from the interrogation means with a non-unique location signal which, in combination with the approximate location determined by the fixed part, determines a unique location.",
"In a preferred arrangement, the fixed part and the mobile parts each have a satellite navigation system receiver, and the positions of the mobile parts as measured by the satellite navigation system are compared with those of the fixed part as measured by the satellite navigation system.",
"The position of the fixed part can be known with great accuracy and provides a reference measurement which allows the position of the mobile part to be determined with greater accuracy than is possible by direct measurement using the satellite system alone.",
"Preferably the fixed part has one or more servers and means for allocating a server to a mobile part only when it requires service.",
"In practice only a very small number of mobile units will require service at any given time, so this allows the computing resources of the fixed part to be used most efficiently, and the system can support many more mobile units in total than it has server capacity for.",
"This is in contrast to the prior art system discussed above, in which each mobile unit requires a dedicated computer carried on board, which is only used for a fraction of the time.",
"Moreover, all the servers can use a common road-use database, which can use the information on routes it has planned for mobile users to build a prediction of future road use status, such as likely congestion points, and build this into its guidance instruction process.",
"For example the system can be arranged such that it does not direct more than a predetermined number of users to use a particular stretch of road at a particular time, and finds alternative routes for any users who would otherwise be directed along that road at that time.",
"In this way the system can predict likely congestion points and take pre-emptive action.",
"The mobile part may include guidance instruction means controllable by instructions contained in the guidance information transmitted from the fixed part over the communications link, whereby guidance instructions can be communicated to the user by means of the guidance instruction means.",
"For some applications the vehicle may be controlled directly in response to the guidance information received over the communications link.",
"However, for use on the public highway, it is preferable that the guidance information controls display means, which may be visual or audible or both, to indicate to a driver the direction to take.",
"The guidance instruction means may be programmable from the fixed part over the communications link, either automatically or by a human operator.",
"The guidance instruction means may include a speech synthesiser, which may be located in the fixed part, transmitting voice messages to the user over the communications system, or may be located in the mobile unit and controlled by data messages from the fixed part.",
"The former arrangement allows the mobile unit to be simplified, whilst the latter arrangement requires a smaller signalling load.",
"In the described embodiment the mobile part is in a vehicle, but it may be a hand-held device for guiding a pedestrian.",
"In one form, the mobile part may be a conventional mobile cellular radio unit.",
"This allows a basic service to be provide to a user without the need for any dedicated equipment.",
"BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the invention will now be described by way of example with reference to the drawings, in which: FIG. 1 shows a mobile part and a fixed part of a navigation information system according to an embodiment of the invention;",
"FIG. 2 illustrates how the invention may be applied to a simple road layout;",
"FIG. 3 illustrates the division of a territory into zones according to the instructions generated by the system;",
"FIG. 4 illustrates an application of the invention to a more complex road layout;",
"FIGS. 5 a and 5 b illustrate the modification of an overlay in response to a change in traffic circumstances;",
"and FIG. 6 illustrates a road network, showing overlay areas defined by the method of the invention in relation to a cellular radio network DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS According to the embodiment of FIG. 1 the navigation system has a fixed part (comprising elements 12 to 19 ) and a number of mobile parts, of which one only is shown (comprising elements 1 to 10 ), interconnected by a cellular telephone network 11 .",
"The mobile part comprises a mobile telephone 1 having an audio output 2 , an audio input 3 and a radio antenna (transmit/receive) 4 .",
"The output 2 is connected to a decoder 5 to translate Dual-Tone Multi-Frequency (DTMF) signals received by the telephone 1 into data which is fed to an interface controller 6 .",
"The interface controller 6 also receives input from a GPS (Global Positioning System) satellite receiver 7 .",
"The interface controller transmits data to a DTMF encoder 8 which generates tones to be fed to the audio input of the mobile telephone.",
"The audio output 2 and input 3 also include a loudspeaker 9 and microphone 10 respectively, to allow the telephone to be used for speech.",
"The fixed part comprises an interface with the cellular telephone network 11 , connected through a DTMF decoder 12 and encoder 13 and a controller interface 14 to a computer 15 .",
"The computer 15 comprises a number of servers 16 , one of which is allocated to each active mobile unit.",
"The servers 16 have access to a geographical database 17 , and a database of standard messages 18 .",
"The geographical database 17 is updateable through updating input 19 .",
"The database 17 stores the definitions of a number of overlay areas which together form a geographical overlay to the territory to be covered.",
"Examples of overlays are illustrated in FIGS. 2, 4 , 5 a , 5 b , and 6 , to be described in detail later.",
"The mobile part obtains location information using the GPS receiver 7 and transmits this information, together with a request for directions to a specified destination, to the fixed part, where a server 16 relates the location information to its geographical database 17 and obtains message information associated with the location from the database 18 , and transmits the information back to the mobile part.",
"The computer 15 may transmit messages in DTMF code, using the encoder 1 2 , or it may generate voice messages which are transmitted through a voice output 20 to the cellular network 11 .",
"DTMF signals are used to transmit the position of the vehicle to the computer 15 which can then offer information and guidance either to the vehicle or to a third party on demand.",
"In the following discussion, variations on the basic apparatus depicted in FIG. 1 will also be described, in which certain elements are modified or replaced.",
"The system is operated as follows: At the start of a journey the driver requests service by activating a pre-dialled control on the telephone 1 .",
"This service request is transmitted to the control interface 14 over the telephone network 11 .",
"The control interface 14 then allocates a free server 16 to answer the call and interrogate the vehicle GPS receiver 7 to determine its geographical position.",
"The encoder 8 takes the latitude and longitude data and translates the numbers into DTMF tone-pairs, in a manner to be described in more detail below.",
"The cellular telephone couples this audio signal into its speech input path.",
"This is easy to do with a hands-free vehicle-mounted cellular telephone since the microphone lead is accessible or alternatively, a small transducer can be mounted next to the microphone 10 .",
"A DTMF receiver 5 coupled to the loudspeaker 9 (again acoustically or electrically) decodes supervisory data (again in DTMF format) coming back from the server 16 to acknowledge the reception of location messages.",
"If no acknowledgement is received by the DTMF unit then the data message is repeated.",
"The fixed end of the system comprises a DTMF decoder 12 and encoder 13 coupled to a serial data interface 14 of the server computer 15 .",
"This computer, on the one hand, can call the mobile part which will answer automatically and then provide its location using the DTMF signalling system or on the other hand can receive an unsolicited call, which would include the DTMF encoded identity of the mobile unit and would also provide the vehicle location using the DTMF interface 6 .",
"The server 16 then captures the current position of the user, and identifies the overlay area within which that position falls.",
"The server also captures any permanent user-specific information such as the type of vehicle, which may be relevant for the route to be selected e.g. because of height or weight restrictions.",
"The user may encode those requirements which are not permanent, but are specific to the present information request, (in particular his destination) by using the telephone keypad in response to voice prompts.",
"However, in a preferred arrangement the call is presented to a human operator for the capture of this data.",
"This allows the user to obtain assistance in identifying his desired destination to the system, and also allows the driver to speak his requirements, keeping his hands and eyes free for driving.",
"The operator then remotely programs the in-vehicle interface 6 with system data identifying the vehicle destination, for use in subsequent update processes, and instigates the generation of voice given directions and instructions to the driver by a speech generation subsystem of the computer server 16 .",
"Position fixes may be made at regular intervals, e.g. every two minutes, or every kilometer.",
"Alternatively the fixed part may request the mobile unit to send its next position fix after a specified interval or distance.",
"As the driver follows the route further instructions can automatically be sent as the driver enters each new overlay area and the driver can be alerted if the route has been left or if any new traffic problems have been detected that will affect the individual driver.",
"The system is arranged such that when the system locates a mobile unit entering an overlay area having a message defined for it, for example the next turn instruction (or an error message if the mobile unit has gone off the selected route), that message is transmitted.",
"The system may also be arranged to transmit messages to users other than the mobile unit in question, for example to monitor the progress of valuable cargoes.",
"At any time the driver can call the human operator if service requirements change or additional help is needed.",
"Because a central database is used all vehicle movements can be monitored.",
"Traffic models can be used to optimise traffic flows and reduce journey times.",
"The system can also ensure that it does not itself cause congestion, by limiting the number of vehicles it directs to use the same road at the same time.",
"The control system can use the location data to calculate and record movement vectors from these vehicles.",
"Using the data collected by this method, it is possible for the central system to derive a digital map of valid routes.",
"The following data could be derived automatically: valid travel lanes;",
"permitted directions) of flow;",
"allowable turns;",
"average travel times;",
"trends in travel times according to time of day and other factors.",
"The system would automatically update the map to show permanent changes (new road links, changes to one way systems etc.).",
"Temporary lane closures from road works etc.",
"would also be recorded.",
"Manual updating of data would be necessary (for instance to alert the system to a new bypass opening) before the system acquired the information from vehicle flow data, to ensure vehicles are routed over the new road initially.",
"Any approximations in the pre-entered data would automatically be corrected by the system described here.",
"The system could be further enhanced to include any other information that may be relevant to travellers, by a combination of manual and automated data entry, e.g. location of bus stops, telephone boxes and other street furniture, and proximity to enterprises such as shops, banks or offices.",
"The variation of transit time trends according to time of day, for each link, could be used to derive a congestion prediction model, as the basis for route guidance.",
"The system may monitor the progress of the mobile units along the routes selected for them, to identify any areas of traffic congestion etc, by comparing actual transit times between predetermined locations.",
"This may be done by the fixed system monitoring the location updates of individual units, or it may be done by the mobile unit, in co-operation with the fixed unit.",
"In this latter case, the fixed part transmits an expected range of transit times within which the mobile is expected to reach a predetermined location.",
"If the mobile unit reaches the location outside this range, it reports the fact to the fixed part.",
"By “reporting by exception”",
"the data processing overhead can be reduced considerably.",
"However, these systems can become unstable if too many drivers have access to route guidance based on information about current or predicted congestion.",
"To avoid these instabilities route plans are created and updated centrally and passed to individual vehicles.",
"The impact of these vehicles using the suggested routes is then added to the prediction.",
"As more vehicles use the system the prediction produced could become more accurate.",
"The routes derived can be passed to the vehicles (via a mobile data link, or possibly a short range communications link or other temporary access to a fixed telecommunications network—prior to departure).",
"The vehicle would then operate autonomously, unless the road conditions varied significantly from those predicted.",
"If the central system detected a problem (from vehicle data or other sources), which had a severe impact on predictions, sufficient to cause a change to advice already given, then the central system could broadcast news of the problem, such that those vehicles affected could automatically call in via a mobile data communications link to receive a new route from its present location to its destination.",
"If a vehicle system encountered unexpected transit times along its programmed route it would send a report to the central system.",
"The data flowing though the system will therefore allow it to “learn”",
"more of the road network's characteristic congestion behaviour, e.g. by use of neural net techniques, and to select routes for traffic which avoid using routes at times when they are likely to be congested.",
"In addition, the system can generate digital road maps or other data automatically, based on the position measurements of vehicles using the roads.",
"A particular advantage of this system is the ability to predict unusual patterns of congestion from the route guidance information requested by the users.",
"Because route guidance is generated centrally, the system can monitor the number of requests for destination information to a given location.",
"By determining the predicted arrival times for each user (which will depend on their starting points, and the time the journey started), a build-up of traffic converging on a particular location at a particular future time (e.g. for a major sporting event) can be detected.",
"Traffic for other destinations, which might have been routed by way of this location, can then be diverted to other routes.",
"The system described above uses an analogue telecommunications link, in which DTMF codes may be used.",
"For an analogue cellular radio network DTMF is an ideal signalling medium when only short status messages are required to be transmitted.",
"It can survive in the severe signal fading and noise of the mobile environment which frequently precludes the use of fast phase or frequency shift data modulation.",
"Another advantage is the ability to co-exist with speech.",
"For example a DTMF data burst containing vehicle position data could be sent at the start of a call and at intervals during the call.",
"Other simple coded DTMF messages can also be conveyed to indicate emergencies, provide simple driver indications (e.g. illuminated arrows to turn left or right) or trigger synthetic speech generated by another sub-system in the vehicle.",
"The DTMF coding described above is suitable for an analogue system.",
"In a digital cellular network digitised data can be transmitted over an associated packet data system such as the Short Message Service (SMS) of GSM (Global System for Mobile Communications), or the General Packet Radio Service (GPRS) proposed for GSM.",
"In the embodiment described above, the speech generation subsystem forms part of the server 16 .",
"Alternatively, it can be carried on board the vehicle.",
"In this arrangement the subsystem has various stored speech commands which are controlled from the in-vehicle interface 6 in response to commands transmitted from the fixed part.",
"This arrangement reduces the signalling traffic required over the radio link 11 , but increases the complexity of the in-vehicle equipment.",
"The location-determination system will now be described in greater detail.",
"GPS (Global Positioning System) satellite navigation receivers are now becoming very cheap and are available with a serial data output.",
"These can provide latitude and longitude data to within a tenth of a second of arc (defining position to within 3 meters, which is sufficient to identify which carriageway of a dual carriageway road a user is on), Satellite positioning systems such as the Global Positioning System (GPS) are prone to small systematic errors, for example as a result of instabilities in the orbits of the satellites.",
"The accuracy of the position measurement may be enhanced by a process known as “Differential GPS”",
"in which a number of fixed reference points are used, whose positions are determined with great precision e.g. using surveying techniques.",
"GPS is used to obtain a measure of the position of one or more of the fixed reference points.",
"This measure is compared with the known, true location to generate a correction value which can be used to correct the position of the mobile unit as measured by GPS.",
"The position data received from the satellite positioning system may include some redundant data.",
"If the system is only to operate within a limited area of the globe the most significant digits of the position data are redundant, and need not be transmitted from the mobile unit to the fixed part.",
"For example, any point in Germany can be uniquely defined by the units digits of its latitude and of its longitude, as that country lies entirely between 45 and 55 degrees North, and between 5 and 15 degrees East.",
"It is also possible to define any point in the United Kingdom in this way, although in that case a 10 degree offset in longitude has to be applied to avoid duplication of longitudes East and West of the zero meridian.",
"For larger territories e.g. a pan-European system, or one covering the USA, this simple method of data reduction is impractical.",
"However, it is nevertheless possible to reduce the data requirements by dynamically defining the territory.",
"After an initialisation step using the full location, the system selects as each new location the closest candidate to the previous one.",
"For example, if the mobile unit was last reported at 99 degrees W and the units digit of the longitude is now 0, the user is taken to be at 100 degrees W rather than, for example, 90 degrees or 110 degrees.",
"If location updates take place sufficiently frequently that the user's position cannot have changed by more than half a degree, the units digit of degrees may also be dispensed with, and the location given only in minutes and seconds of arc.",
"The more frequent the updates, the more digits can be dispensed with.",
"An alternative method of obtaining the coarse position location is interrogation of the cellular radio system's operating system to identify the cell in which the user is currently located.",
"Cell sizes can be up to about 40 km across (although they are often much smaller, so identifying the cell can identify the user's location to within 40 km, which identifies latitude to better than half a degree.",
"(1 degree of latitude=111 km).",
"The separation of lines of longitude varies with the cosine of the latitude but even at the Arctic Circle (66 degrees North) a 40 km resolution will identify longitude to the nearest whole degree (1 degree of longitude=111 km (cos latitude)=approximately 45 km at 66 degrees North).",
"By left-truncating the position data by omitting the degrees digits a basic position message would therefore consist of 10 decimal digits (minutes, seconds, and tenths of seconds).",
"Altitude data giving altitude in meters would require a further four digits, since all points on the Earth's surface lie within a range of 10,000 meters, but this data can also be left-truncated, as it is unlikely that any multi-level road system would exceed 100 meters in height (or if it did, that a GPS system would work effectively for any receiver on the lower levels).",
"This gives a total of twelve digits, which can be transmitted by DTMF in less than 2 seconds.",
"If the data is left-truncated as described above, the “coarse”",
"data is added by the interface controller 14 by reference to the previous position or to the cellular radio operating system.",
"When the computer 15 receives a location message, it stores the location and then searches its database for an overlay area within which that position lies.",
"The overlay areas are defined in the database by co-ordinates of latitude and longitude and have associated attributes which define messages which can be passed to mobile subscribers within the overlay area defined.",
"In some instances height (altitude) information, also available using satellite positioning systems, may be used, for example to distinguish between levels in a multi-level highway intersection.",
"When a DTMF location message has co-ordinates which fall inside an overlay area having an associated message, the message is then transmitted to the mobile part as a computer synthesised speech message, a DTMF coded message (to activate other subsystems) or as a high speed conventional data message.",
"If the mobile unit fell within the same overlay area at the previous location update, and the message associated with that overlay area is unchanged, the transmission of the message may be suspended.",
"The frequency at which location updates are requested by the system may be tailored to the size and nature of the current overlay area.",
"For example, an intricate road layout may comprise a large number of small overlay areas, requiring frequent location updates to ensure that a user does not miss an instruction by passing through its associated area between two updates.",
"However, a long stretch of road without junctions may be covered by a single overlay area, so less frequent updates are appropriate.",
"The speed with which a vehicle is likely to be moving, which will differ between urban, rural, and motorway environments may also be used as a factor in determining when the next location update should be requested.",
"As suggested above, there may be circumstances when a satellite positioning system may be unusable, for example in tunnels or built-up areas where a line-of-sight view of the satellites may be impossible to obtain.",
"Alternative arrangements for identifying and updating the mobile part's location which do not rely on a satellite receiver may be used, either on their own, or to interpolate between points where a satellite system can be used.",
"In one variant, a navigation system based on dead-reckoning may be used.",
"In such systems the user identifies his initial location and the on-board system measures the system's movement e.g. by magnetic bearing measurements, distance counters, and inertial navigation means such as gyrocompasses and accelerometers.",
"Such systems are self-contained, but require knowledge of the starting point.",
"This may be obtained, for example from a satellite positioning system.",
"In another variant, a method of location may be used which relies on the propagation characteristics of the cellular radio system used for communication with the central control station.",
"Examples of such systems are disclosed in German Patent specifications DE3825661 (Licentia Patent Verwaltungs) and DE 3516357 (Bosch), U.S. Pat. No. 4,210,913 (Newhouse), European Patent specification EP0320913 (Nokia), and International Patent applications WO92/13284 (Song) and WO 88/01061 (Ventana).",
"By comparison of signal strength or other characteristics of several cellular base stations, a position fix can be determined.",
"In this arrangement the location measurement may be made directly by the fixed system.",
"This allows the mobile part of the system to be embodied by a conventional cellular telephone, with inputs being provided by speech, or by DTMF tones generated by the keypad, and instructions to the user being transmitted by voice commands.",
"Examples of the kind of navigation information which may be stored in the database 17 will now be discussed, with reference to FIGS. 2 to 6 .",
"Briefly, FIG. 2 shows a junction J having four approach roads 21 , 22 , 23 , 24 ;",
"each having associated with it an overlay area 21 a , 22 a , 23 a , 24 a respectively.",
"In this figure, and all other figures illustrating road layouts, the roads are shown arranged for lefthand running, as used for example in the UK, Japan, Australia etc.",
"FIG. 3 shows part of a road network surrounding the junction J, including towns A, B, C, and a motorway M. Each of the roads 21 , 22 , 23 , 24 has an associated destination zone 21 z etc.",
"FIG. 4 shows a complex grade-separated junction interlinking four roads N, S, E, W. The junction has superimposed on it an overlay having twelve overlay areas, Na, Ni, Nd, Sa, Si, Sd, Ea, Ei, Ed, Wa, Wi, Wd.",
"FIG. 5 a shows a small region having a main road 33 and a side road 30 .",
"The main road 33 has two associated overlay areas 31 , 32 .",
"FIG. 5 b is similar to FIG. 5 a , but an obstruction X is present on the main road 33 , and the overlay area 32 has been subdivided into two overlay areas 32 a , 32 b , separated by the obstruction.",
"FIG. 6 shows an overlay comprising ten overlay areas 40 - 49 superimposed on a cellular radio coverage region comprising five cells 50 - 54 .",
"In greater detail, the road junction J (FIG.",
"2) has four approach roads 21 , 22 , 23 , 24 .",
"On each road, at the approach to the junction, an overlay area ( 21 a , 22 a , 23 a , 24 a ) is defined.",
"These overlay areas have directional information associated with them, giving turn instructions or other navigational information.",
"As shown in FIG. 3, the entire territory covered by the navigation system can be divided into four zones 21 z , 22 z , 23 z , 24 z , each comprising the set of all locations for which the corresponding road 21 , 22 , 23 , 24 should be taken from the junction J. In this particular example, road 24 leads directly into town A and is only used for local destinations (zone 24 z ), road 23 leads to town B (zone 23 z ), road 22 leads to town D (zone 22 z ) and road 21 leads to the motorway M, for all other destinations including town C and part of town A. These zones are defined differently for each junction: for example at junction J′ different directions are appropriate for towns A and C, so these towns fall in different zones with respect to the overlay areas at that junction.",
"The zones may even be defined differently for different overlay areas at the same junction.",
"For example, if U-turns are not possible at the junction J, any traffic approaching the junction J by road 22 and requiring town D (perhaps as the result of a previous error, or a change of plan) must be routed by way of roads 21 , M, and 25 .",
"Thus, for overlay area 22 a there are only three zones: 24 z , 23 z and the combined 21 z / 22 z , corresponding to the three permitted exits 21 , 23 , 24 .",
"The zones may be re-defined according to circumstances.",
"For example, when the motorway M is congested, the best route from junction J to town C may be by way of town B. In such circumstances, zones 21 z and 23 z are redefined so that town C now falls within zone 23 z .",
"It should be noted, however, that the total number of zones remains the number of exit routes from the relevant overlay area.",
"The overlay areas 21 a , 22 a , 23 a , and 24 a should be large enough to ensure that any vehicle approaching the junction gets at least one location update whilst within the relevant overlay area, and is thus sent the relevant turn instruction.",
"As shown in FIG. 2, these overlay areas are discrete, and may be considered equivalent to the coverage areas of the beacons of the prior art system discussed above.",
"They may, however, be made contiguous, as shown in FIGS. 4, 5 a , 5 b and 6 .",
"FIG. 4 shows a more complex, grade-separated junction, in which there are twelve overlay areas Each road N, E, S, W intersecting at the junction has a corresponding approach overlay area Na, Ea, Sa, Wa, (Wa shown shaded), and a depart overlay area Nd, Ed, Sd, Wd (Ed shown shaded).",
"There are also four intermediate overlay areas Ni, Ei, Si, Wi (Si shown shaded).",
"In the vicinity of the flyover F height (altitude) information obtainable from the GPS system can be used to determine which level, and therefore which overlay area, the user is currently in.",
"The approach and intermediate overlay areas each end at a decision point P 1 to P 8 .",
"In the database 17 each overlay area has direction information associated with it, providing instructions as to which fork to take at the associated decision point.",
"For example, the direction information associated with zone Si instructs users for destinations served by road N to go straight on at point P 1 , and users for destinations served by roads E, S, and W to turn left.",
"It will be seen that traffic using the intersection will pass through one approach overlay area, one departure overlay area, and may also pass through one or more intermediate overlay areas.",
"There may also be information associated with the departure overlay areas Nd, Sd, Ed, Wd, for example warning of hazards ahead.",
"The departure overlay areas may be continuous with approach overlay areas for the next junction in each direction.",
"As a user approaches the junction on road S, a location update identifies the user equipment as being within overlay area Sa.",
"If the co-ordinates of the user's destination are within the zone served by road W, the user is sent an instruction to turn left at point P 2 .",
"If the user obeys this instruction, he will enter overlay area Wd and on the next location update he will be sent information relevant to that overlay area (if any).",
"If the co-ordinates of the user's destination are within the zone served by road N, the user in overlay area Sa is instead sent an instruction to continue straight on at point P 2 .",
"If the user obeys this instruction, he will enter overlay area Si.",
"For a user in overlay area Si, if the co-ordinates of the user's destination are within the zone served by road N the user is sent an instruction to go straight on at point P 1 .",
"On obeying this instruction, he will enter the overlay area Nd and on the next location update he will be sent information relevant to that overlay area (if any).",
"If the co-ordinates of the destination of a user in overlay area Si are in the zone served by roads E, S, or W, the user will be sent an instruction to turn left at point P 1 .",
"On obeying this instruction, he will enter overlay area Wi.",
"Similar information is associated with the other overlay areas.",
"By being given appropriate instructions as the user negotiates a succession of junctions (decision points), the user can be directed to any destination.",
"It should be noted that all users who are to be directed to the same exit from the junction are given the same instruction, whatever their ultimate destination.",
"FIGS. 5 a and 5 b illustrate the reconfiguration of the overlay areas to meet changing circumstances.",
"Initially (FIG.",
"5 a ) an overlay area 31 is defined for the approach to a junction between a major road 33 and a side road 30 , and a second overlay area 32 is defined for that part of the major road 33 beyond the junction.",
"Information associated with the overlay area 31 includes turn information to instruct traffic for the zone served by the side road 30 to turn off.",
"Information may also be associated with the overlay area 32 .",
"In FIG. 5 b the major road 33 has been blocked at a point X. In order to accommodate this, the overlay area 32 has been subdivided into two overlay areas 32 a , 32 b .",
"The information (if any) associated with overlay area 32 b is the same as that previously associated with overlay area 32 .",
"Traffic in overlay area 32 a is given new information warning it of the hazard ahead.",
"The information associated with the overlay area 31 is modified, so that all traffic is now instructed to turn off onto the side road 30 .",
"(Effectively this means that the destination zones associated with the overlay area 31 are merged into one) FIG. 6 shows how the overlay areas may be defined for a road network.",
"In this example there is an overlay area 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 corresponding to each side of each section of road.",
"Information appropriate to each direction of travel on each section is Therefore available to users throughout the relevant section.",
"Superimposed on this overlay there is a cellular radio network, five cells of which ( 50 , 51 , 52 , 53 , 54 ) are shown.",
"The position of the user, as determined for example by a satellite positioning system, determines which overlay area is appropriate to the user.",
"The information is transmitted to the service control centre by means of the cellular radio network.",
"Handovers between cellular base stations occur in conventional manner at cell boundaries.",
"These handovers are, however, unrelated to the boundaries between the overlay areas 40 - 49 Although the described embodiment relates to the provision of route guidance information, other locality-dependant information may be provided as well, or instead, such as information about local facilities, tourist attractions, weather forecasts, public transport information, etc.",
"The term “guidance information”, as used in this specification, embraces any such information."
] |
BACKGROUND OF THE INVENTION
The present invention relates generally to automotive tools and specifically to a tool for attachment to an auto wheel assembly for purposes of camber adjustment.
Known to the art are various types of tools attachable to independently suspended wheels of an auto to impart corrective forces to a member or members of the wheel suspension system to restore desired wheel camber. Some of such tools impart corrective bending forces to a suspension member or members by means of a powered ram or cylinder.
A problem exists in correcting camber on autos utilizing a McPherson strut syspension member as found on the majority of foreign made autos. The above mentioned strut is widely used by both European and Japanese auto manufacturers and serves to provide, in one component, both suspension and motion dampening functions. The lower end of the above mentioned strut is somewhat susceptible however to bending upon forceful impact of the auto wheel with an obstruction, which bending results in incorrect wheel camber. In many instances, frame damage is also incurred, contributing to incorrect camber. While various camber adjusting tools have been proposed, none are known to be specifically directed toward camber adjustment of a McPherson suspension equipped auto nor can existing tools be readily modified for such use.
SUMMARY OF THE INVENTION
The present invention is embodied in a tool for attachment to the wheel plate of a McPherson strut suspension equipped auto to enable the imparting of corrective bending forces to the strut lower end.
The tool includes a base for attachment to the wheel plate, which base is apertured to receive the threaded wheel lugs or studs and also the projecting spindle hub. The lug receiving apertures in the base are slightly oversize to receive the most common lug patterns to render the tool usable on a wide range of autos. A base extension extends upwardly and outwardly from the base and carries an abutment assembly against which a powered component may be abutted for the application of bending forces to the wheel plate and associated suspension components. The powered component may utilize a strut mid portion as a support point when wheel camber is to be increased while a chain component permits opposite placement of the powered component relative to the tool base to enable camber corrections reducing wheel camber. The abutment assembly includes an adjustable fitting adjustable about a horizontal axis to best accomodate the type of powered component used and its relationship to the strut mid portion. Such powered components may be hydraulic or pneumatic cylinders or a mechanical instrumentality such as a jack.
Important objectives of the present tool include the provision of a single camber adjusting tool for use on most all autos utilizing a McPherson strut suspension component; the provsion of a tool for camber correction which does not require the disassembly of wheel suspension components but rather requires only the removal of wheel lug nuts and the wheel; the provision of a tool having an aperture for reception of the spindle hub to permit the attachment of a conventional sight guage thereon; the provision of a tool having a base apertured to receive most all lug patterns; the provision of a tool having an abutment assembly at its upper end which serves to receive a variety of powered components in various relationships which serve to impart corrective forces to the tool base; the provision of a tool of low cost, durable construction; the provision of a tool highly adaptable to use on several makes of automobiles with different makes and styles of power sources.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing:
FIG. 1 is a front elevational view of a McPherson strut suspension system with the present tool in place;
FIG. 2 is a side elevational view of the right hand side of FIG. 1; and
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2 and showing in broken lines optional placement of the power source for reducing wheel camber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference numeral 1 of the drawing indicates generally a suspension system for an automotive wheel assembly consisting of a tire and wheel which are normally carried by a wheel mounting member or plate 2 by means of lug studs 3. Other conventional suspension system components include a disc brake unit 4, disc brake rotor 5, lower arm 6, ball joint 7, McPherson strut 8, and knuckle 9 which carries the spindle hub H. The lower segment of said strut at X is susceptible to bending forces imparted thereto from impact of the wheel assembly against a road obstruction. In most instances, damage is slight permitting correction by the application of bending forces applied with the present tool. Corrections up to one and one-half degrees of camber may be made without strut impairment.
With attention now to the present invention, the tool includes a base at 12 which may be of channel construction for purposes of strength. The base web 13 is apertured at 13A to receive spindle hub H of the wheel suspension system and permit the mounting of a conventional sight guage G thereon. Spaced about aperture 13A is a series of lug receiving openings as at 14 each somewhat oversize or larger than the diameter of the lug stud to permit the reception of the lug studs of different autos. As the spacing and size of lug studs is very similar in the majority of autos manufactured outside of the United States the oversize apertures 14 accept most all lug stud arrangements to enable a single tool to be used on all but a small portion of foreign made autos. Spacers at S provide desired clearance of base 12 from wheel mounting member 2.
Extending upwardly from base 12 is a base extension 16 which is shown as comprising a pair of inclined arms secured at their lower ends to base 12 with a gusset provided at 17. The arms 16 carry at their outer ends an abutment assembly, generally at 18, which provides an adjustable abutment for the power source selected. Said abutment assembly includes locking means 19, shown as a threaded fastener, which enables slight inward displacement of the arm ends at 16A to close frictionally against the opposite ends of a fitting 20 to prevent rotation of same. In place on said fitting is an abutment 21 configured for abutting contact with the power source selected. Said fitting may include a stud (not shown) for engagement with that type of portable hydraulic cylinder having a corresponding socket in the cylinder base. An abutting surface is indicated at 21A which may be operatively adjusted by loosening locking means 19. The outer or rod end of the power source, shown as a hydraulic cylinder 22 is provided with a resilient pad 24 and abuts the McPherson strut at the intersection of the strut tubular portion and a conical spring guide 23 of the strut. The cylinder disposition in FIGS. 1 and 2 is for increasing wheel camber while in FIG. 3 the power source 22 has been reorientated on the tool to impart bending forces decreasing wheel camber. In the latter arrangement the power source is coupled by means of a chain loop 25 wrapped about the strut intersection with chain runs passing above and below fitting 20 and therepast to engage the rod end of cylinder while the opposite or base end of cylinder 22 reacts against repositioned abutment 21. A V-shaped fitting 26 may be utilized to assure chain-rod engagement.
With the tool in place, to adjust camber the operator notes the camber reading on the hub attached guage and actuates the power source via suitable valve controls (not shown) until the desired reading is indicated. In use the base of the tool is supported so as to permit a portion of the auto's weight approximately five percent to be supported by the base. Details of camber adjustment are believed to be apparent to one skilled in the art and accordingly are superfluous for present purposes.
While I have shown but one embodiment of the invention it will be apparent to those skilled in the art that the invention may be embodied still otherwise without departing from the spirit and scope of the claimed invention. | The tool disclosed includes a base for attachment to the wheel suspension system. Upright arms project from the tool base and carry an abutment assembly which is adjustable to support the end of different types of power cylinders in various operative relationships to the suspension system and which cylinders impart corrective bending forces to the suspension system. | Provide a concise summary of the essential information conveyed in the context. | [
"BACKGROUND OF THE INVENTION The present invention relates generally to automotive tools and specifically to a tool for attachment to an auto wheel assembly for purposes of camber adjustment.",
"Known to the art are various types of tools attachable to independently suspended wheels of an auto to impart corrective forces to a member or members of the wheel suspension system to restore desired wheel camber.",
"Some of such tools impart corrective bending forces to a suspension member or members by means of a powered ram or cylinder.",
"A problem exists in correcting camber on autos utilizing a McPherson strut syspension member as found on the majority of foreign made autos.",
"The above mentioned strut is widely used by both European and Japanese auto manufacturers and serves to provide, in one component, both suspension and motion dampening functions.",
"The lower end of the above mentioned strut is somewhat susceptible however to bending upon forceful impact of the auto wheel with an obstruction, which bending results in incorrect wheel camber.",
"In many instances, frame damage is also incurred, contributing to incorrect camber.",
"While various camber adjusting tools have been proposed, none are known to be specifically directed toward camber adjustment of a McPherson suspension equipped auto nor can existing tools be readily modified for such use.",
"SUMMARY OF THE INVENTION The present invention is embodied in a tool for attachment to the wheel plate of a McPherson strut suspension equipped auto to enable the imparting of corrective bending forces to the strut lower end.",
"The tool includes a base for attachment to the wheel plate, which base is apertured to receive the threaded wheel lugs or studs and also the projecting spindle hub.",
"The lug receiving apertures in the base are slightly oversize to receive the most common lug patterns to render the tool usable on a wide range of autos.",
"A base extension extends upwardly and outwardly from the base and carries an abutment assembly against which a powered component may be abutted for the application of bending forces to the wheel plate and associated suspension components.",
"The powered component may utilize a strut mid portion as a support point when wheel camber is to be increased while a chain component permits opposite placement of the powered component relative to the tool base to enable camber corrections reducing wheel camber.",
"The abutment assembly includes an adjustable fitting adjustable about a horizontal axis to best accomodate the type of powered component used and its relationship to the strut mid portion.",
"Such powered components may be hydraulic or pneumatic cylinders or a mechanical instrumentality such as a jack.",
"Important objectives of the present tool include the provision of a single camber adjusting tool for use on most all autos utilizing a McPherson strut suspension component;",
"the provsion of a tool for camber correction which does not require the disassembly of wheel suspension components but rather requires only the removal of wheel lug nuts and the wheel;",
"the provision of a tool having an aperture for reception of the spindle hub to permit the attachment of a conventional sight guage thereon;",
"the provision of a tool having a base apertured to receive most all lug patterns;",
"the provision of a tool having an abutment assembly at its upper end which serves to receive a variety of powered components in various relationships which serve to impart corrective forces to the tool base;",
"the provision of a tool of low cost, durable construction;",
"the provision of a tool highly adaptable to use on several makes of automobiles with different makes and styles of power sources.",
"BRIEF DESCRIPTION OF THE DRAWING In the accompanying drawing: FIG. 1 is a front elevational view of a McPherson strut suspension system with the present tool in place;",
"FIG. 2 is a side elevational view of the right hand side of FIG. 1;",
"and FIG. 3 is a sectional view taken along line 3--3 of FIG. 2 and showing in broken lines optional placement of the power source for reducing wheel camber.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Reference numeral 1 of the drawing indicates generally a suspension system for an automotive wheel assembly consisting of a tire and wheel which are normally carried by a wheel mounting member or plate 2 by means of lug studs 3.",
"Other conventional suspension system components include a disc brake unit 4, disc brake rotor 5, lower arm 6, ball joint 7, McPherson strut 8, and knuckle 9 which carries the spindle hub H. The lower segment of said strut at X is susceptible to bending forces imparted thereto from impact of the wheel assembly against a road obstruction.",
"In most instances, damage is slight permitting correction by the application of bending forces applied with the present tool.",
"Corrections up to one and one-half degrees of camber may be made without strut impairment.",
"With attention now to the present invention, the tool includes a base at 12 which may be of channel construction for purposes of strength.",
"The base web 13 is apertured at 13A to receive spindle hub H of the wheel suspension system and permit the mounting of a conventional sight guage G thereon.",
"Spaced about aperture 13A is a series of lug receiving openings as at 14 each somewhat oversize or larger than the diameter of the lug stud to permit the reception of the lug studs of different autos.",
"As the spacing and size of lug studs is very similar in the majority of autos manufactured outside of the United States the oversize apertures 14 accept most all lug stud arrangements to enable a single tool to be used on all but a small portion of foreign made autos.",
"Spacers at S provide desired clearance of base 12 from wheel mounting member 2.",
"Extending upwardly from base 12 is a base extension 16 which is shown as comprising a pair of inclined arms secured at their lower ends to base 12 with a gusset provided at 17.",
"The arms 16 carry at their outer ends an abutment assembly, generally at 18, which provides an adjustable abutment for the power source selected.",
"Said abutment assembly includes locking means 19, shown as a threaded fastener, which enables slight inward displacement of the arm ends at 16A to close frictionally against the opposite ends of a fitting 20 to prevent rotation of same.",
"In place on said fitting is an abutment 21 configured for abutting contact with the power source selected.",
"Said fitting may include a stud (not shown) for engagement with that type of portable hydraulic cylinder having a corresponding socket in the cylinder base.",
"An abutting surface is indicated at 21A which may be operatively adjusted by loosening locking means 19.",
"The outer or rod end of the power source, shown as a hydraulic cylinder 22 is provided with a resilient pad 24 and abuts the McPherson strut at the intersection of the strut tubular portion and a conical spring guide 23 of the strut.",
"The cylinder disposition in FIGS. 1 and 2 is for increasing wheel camber while in FIG. 3 the power source 22 has been reorientated on the tool to impart bending forces decreasing wheel camber.",
"In the latter arrangement the power source is coupled by means of a chain loop 25 wrapped about the strut intersection with chain runs passing above and below fitting 20 and therepast to engage the rod end of cylinder while the opposite or base end of cylinder 22 reacts against repositioned abutment 21.",
"A V-shaped fitting 26 may be utilized to assure chain-rod engagement.",
"With the tool in place, to adjust camber the operator notes the camber reading on the hub attached guage and actuates the power source via suitable valve controls (not shown) until the desired reading is indicated.",
"In use the base of the tool is supported so as to permit a portion of the auto's weight approximately five percent to be supported by the base.",
"Details of camber adjustment are believed to be apparent to one skilled in the art and accordingly are superfluous for present purposes.",
"While I have shown but one embodiment of the invention it will be apparent to those skilled in the art that the invention may be embodied still otherwise without departing from the spirit and scope of the claimed invention."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an ion pump, and more particularly to an ion pump that is made to a simpler design using better-suited materials than conventional ion pumps.
2. Description of the Prior Art
FIG. 1 shows an example of conventional ion pumps, which comprises a magnet 1 and a stainless steel pump casing 2, with part 2a of the latter extending into the magnetic field generated by the former. The part 2a contains a stainless steel anode 3 and a titanium cathode 4.
As a result of Penning discharge, titanium atoms are spattered and stick to the internal surface of the pump casing 2. The active titanium atoms adsorb gas molecules in the pump casing 2.
With the gas in the pump casing 2 thus eliminated or evacuated, a given vessel (not shown) communicating with the pump casing 2 is also evacuated to establish a high degree of vacuum therein.
Made of stainless steel and titanium, conventional ion pumps must, in application of heat treatment, be kept at a high temperature not lower than 450° C. for a long time (approximately 48 hours). Another problem is the extremely high cost of titanium cathodes.
SUMMARY OF THE INVENTION
Th object of this invention is to offer solutions to these problems. More specifically, the objects of this invention are to provide an ion vacuum pump that is made of better-suited materials, has a simpler structure, and functions more efficiently than the conventional ones.
In order to achieve the foregoing objects, an ion vacuum pump according to this invention comprises a pump casing inserted in a magnetic field, with an anode supported by insulators in the pump casing. Both the casing and anode are made of aluminum-based metals. The whole of the pump casing serves also as a cathode.
It is preferable that the aluminum-based metal of which the pump casing is made contains a trace of titanium, zirconium or magnesium.
With the low-cost aluminum-based metal pump casing the whole of which serves as a cathode, the ion pump of this invention performs efficient evacuation without using the costly titanium cathode that has been indispensable to the conventional ion pumps.
With the ion vacuum pump of this invention, not only the pump casing but also the anode is made of an aluminumbased metal. As a consequence, less gases are desorbed or extracted from the surface thereof during evacuation, which, in turn, permits lowering the temperature of baking, which is applied as a pretreatment, to as low a level as between approximately 120° and 150° C. and shortening the baking time to approximately 24 hours.
The ion vacuum pump of this invention requires only an anode in the pump casing because the pump casing itself serves as a cathode. This design permits reducing the distance between the two electrodes, whereby the required magnetic field can be generated with the use of a smaller magnet.
The ion vacuum pump according to this invention finds use in such applications as a particle accelerator and nuclear fusion reactor. Because the pump casing and anode are made of aluminum-based metals, radioactivity in the pump decays much more rapidly than in the conventional pumps made of stainless steel, which results in a safer working environment for the operators. The high thermal conductivity of aluminum-based metals assures prompt cooling and allows the pump to be used safely even in intensely heated places.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view schematically showing the structure of a conventional ion pump.
FIG. 2 is a cross-sectional view schematically showing the structure of an ion pump according to this invention.
FIG. 3 is a perspective view of the ion pump shown in FIG. 2.
FIG. 4 is a perspective view of an anode used therewith.
FIG. 5 is a perspective view showing another embodiment of the anode.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, preferred embodiments of this invention will be described hereinafter.
As illustrated in FIGS. 2 through 4, a pump casing 12 is placed in a magnetic field between the poles N and S of a permanent magnet 11. A high-voltage feedthrough 13 is attached to one end of the pump casing 12, and a flange 14 adapted for connection to an accelerator or other vacuum vessel is provided at an opening at the other end thereof.
The pump casing 12 is made of an aluminum-based metal. A billet is heated to approximately 500° C. and extruded into a seamless pipe that has an internal cross section 12a indicated by a broken line in FIG. 3. An end wall 12b having said high-voltage feedthrough 13 is welded to one end of the pipe and the flange 14 is formed at the other end.
In extruding the pump casing 12, a heater groove 15 and a longitudinal beam 16 adapted to carry a magnet are formed. An electric sheath heater 17 is put in the heater groove 15 and the permanent magnet 11 is bolted or otherwise fastened to the beam 16.
An anode 18 is supported in the pump casing 12 with ceramic insulators 19, 20 placed therebetween. A high-voltage wire 21 leading from the high-voltage feedthrough 13 to the anode 18 is contained in the insulator 19.
The anode 18 consists of a plurality of cylinders 18a fabricated from an aluminum-based metal sheet as shown in FIG. 4.
The anode 18 may also be formed by laying multiperforated sheets 18b of an aluminum-based metal one over another, with a thin spacer inserted therebetween, as shown in FIG. 5.
With the ion pump of this invention, the pump casing 12 serves also as a cathode, in other words, the entire pump casing functions as a cathode, and, therefore, is connected to a ground wire not shown.
Both the pump casing/cathode 12 and anode 18 can be made of either pure aluminum or an appropriate type of aluminum alloy. It is preferable for the aluminum-based metal of which the pump casing/cathode 12 which serves also as a cathode is made to contain a trace amount (0.1 to 1.0 percent by weight) of titanium, zirconium or magnesium.
The ion vacuum pump of this invention as aforedescribed is connected through the flange 14 to a vessel to be evacuated. While heating (at 120° to 150° C.) is effected by passing electricity through the sheath heater 17 for approximately 24 hours, the vessel is evacuated using an auxiliary pump not shown. By so doing, a vaccuum of approximately 10 -5 to 10 -7 torr is maintained. The hydro-oxides and adsorbed gases on the internal wall surfaces of the pump casing/cathode 12 and the surface of the anode 18 are extracted from the surfaces by being decomposed or vaporized as a result of the heating and evacuated by said auxiliary pump.
As the pump casing 12 and anode 18 are composed of aluminum-based metals whose thermal conductivities are high, the heating need not be continued over a prolonged period because the moisture contained in a film of aluminum oxide (Al 2 O 3 ) formed at the surface is thoroughly removed when heated to a temperature between approximately 120° and 150° C.
Aluminum-based metals have another advantage over stainless steel in that they release less gases.
Then, Penning discharge is conducted by applying a high d.c. voltage (approximately 5.5 kv) to the anode 18, with the result that the pump casing 12, which serves as the cathode, releases electrons which spiral in the magnetic field. On colliding with, for instance, nitrogen molecules in the pump casing 12, the electrons yield nitrogen ions and new electrons.
The positively charged ions of nitrogen thus formed collide with, and get absorbed by, the internal walls of the pump casing 12 that serves as the cathode. Consequently, atoms of aluminum and titanium (or zirconium or magnesium) contained in the pump casing 12 are adsorbed, which, however, stick to the surface of the anode 18 or the internal walls of the pump casing 12 later.
The active aluminum and titanium atoms, etc. sticking to the internal walls of the pump casing 12 as a result of spattering efficiently adsorb gas molecules in the pump casing 12. It has been experimentally confirmed that a vacuum as high as approximately 10 -10 torr can be attained easily through the elimination or evacuation of the internal gases. | An ion pump comprises a pump casing inserted in a magnetic field, with an anode supported by insulators in the pump casing. Both the pump casing and anode are made of alminum-based metals, and the pump casing serves also as a cathode, thereby the ion pump has a simpler structure and functions more efficiently than the conventional ones. | Concisely explain the essential features and purpose of the invention. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to an ion pump, and more particularly to an ion pump that is made to a simpler design using better-suited materials than conventional ion pumps.",
"Description of the Prior Art FIG. 1 shows an example of conventional ion pumps, which comprises a magnet 1 and a stainless steel pump casing 2, with part 2a of the latter extending into the magnetic field generated by the former.",
"The part 2a contains a stainless steel anode 3 and a titanium cathode 4.",
"As a result of Penning discharge, titanium atoms are spattered and stick to the internal surface of the pump casing 2.",
"The active titanium atoms adsorb gas molecules in the pump casing 2.",
"With the gas in the pump casing 2 thus eliminated or evacuated, a given vessel (not shown) communicating with the pump casing 2 is also evacuated to establish a high degree of vacuum therein.",
"Made of stainless steel and titanium, conventional ion pumps must, in application of heat treatment, be kept at a high temperature not lower than 450° C. for a long time (approximately 48 hours).",
"Another problem is the extremely high cost of titanium cathodes.",
"SUMMARY OF THE INVENTION Th object of this invention is to offer solutions to these problems.",
"More specifically, the objects of this invention are to provide an ion vacuum pump that is made of better-suited materials, has a simpler structure, and functions more efficiently than the conventional ones.",
"In order to achieve the foregoing objects, an ion vacuum pump according to this invention comprises a pump casing inserted in a magnetic field, with an anode supported by insulators in the pump casing.",
"Both the casing and anode are made of aluminum-based metals.",
"The whole of the pump casing serves also as a cathode.",
"It is preferable that the aluminum-based metal of which the pump casing is made contains a trace of titanium, zirconium or magnesium.",
"With the low-cost aluminum-based metal pump casing the whole of which serves as a cathode, the ion pump of this invention performs efficient evacuation without using the costly titanium cathode that has been indispensable to the conventional ion pumps.",
"With the ion vacuum pump of this invention, not only the pump casing but also the anode is made of an aluminumbased metal.",
"As a consequence, less gases are desorbed or extracted from the surface thereof during evacuation, which, in turn, permits lowering the temperature of baking, which is applied as a pretreatment, to as low a level as between approximately 120° and 150° C. and shortening the baking time to approximately 24 hours.",
"The ion vacuum pump of this invention requires only an anode in the pump casing because the pump casing itself serves as a cathode.",
"This design permits reducing the distance between the two electrodes, whereby the required magnetic field can be generated with the use of a smaller magnet.",
"The ion vacuum pump according to this invention finds use in such applications as a particle accelerator and nuclear fusion reactor.",
"Because the pump casing and anode are made of aluminum-based metals, radioactivity in the pump decays much more rapidly than in the conventional pumps made of stainless steel, which results in a safer working environment for the operators.",
"The high thermal conductivity of aluminum-based metals assures prompt cooling and allows the pump to be used safely even in intensely heated places.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view schematically showing the structure of a conventional ion pump.",
"FIG. 2 is a cross-sectional view schematically showing the structure of an ion pump according to this invention.",
"FIG. 3 is a perspective view of the ion pump shown in FIG. 2. FIG. 4 is a perspective view of an anode used therewith.",
"FIG. 5 is a perspective view showing another embodiment of the anode.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, preferred embodiments of this invention will be described hereinafter.",
"As illustrated in FIGS. 2 through 4, a pump casing 12 is placed in a magnetic field between the poles N and S of a permanent magnet 11.",
"A high-voltage feedthrough 13 is attached to one end of the pump casing 12, and a flange 14 adapted for connection to an accelerator or other vacuum vessel is provided at an opening at the other end thereof.",
"The pump casing 12 is made of an aluminum-based metal.",
"A billet is heated to approximately 500° C. and extruded into a seamless pipe that has an internal cross section 12a indicated by a broken line in FIG. 3. An end wall 12b having said high-voltage feedthrough 13 is welded to one end of the pipe and the flange 14 is formed at the other end.",
"In extruding the pump casing 12, a heater groove 15 and a longitudinal beam 16 adapted to carry a magnet are formed.",
"An electric sheath heater 17 is put in the heater groove 15 and the permanent magnet 11 is bolted or otherwise fastened to the beam 16.",
"An anode 18 is supported in the pump casing 12 with ceramic insulators 19, 20 placed therebetween.",
"A high-voltage wire 21 leading from the high-voltage feedthrough 13 to the anode 18 is contained in the insulator 19.",
"The anode 18 consists of a plurality of cylinders 18a fabricated from an aluminum-based metal sheet as shown in FIG. 4. The anode 18 may also be formed by laying multiperforated sheets 18b of an aluminum-based metal one over another, with a thin spacer inserted therebetween, as shown in FIG. 5. With the ion pump of this invention, the pump casing 12 serves also as a cathode, in other words, the entire pump casing functions as a cathode, and, therefore, is connected to a ground wire not shown.",
"Both the pump casing/cathode 12 and anode 18 can be made of either pure aluminum or an appropriate type of aluminum alloy.",
"It is preferable for the aluminum-based metal of which the pump casing/cathode 12 which serves also as a cathode is made to contain a trace amount (0.1 to 1.0 percent by weight) of titanium, zirconium or magnesium.",
"The ion vacuum pump of this invention as aforedescribed is connected through the flange 14 to a vessel to be evacuated.",
"While heating (at 120° to 150° C.) is effected by passing electricity through the sheath heater 17 for approximately 24 hours, the vessel is evacuated using an auxiliary pump not shown.",
"By so doing, a vaccuum of approximately 10 -5 to 10 -7 torr is maintained.",
"The hydro-oxides and adsorbed gases on the internal wall surfaces of the pump casing/cathode 12 and the surface of the anode 18 are extracted from the surfaces by being decomposed or vaporized as a result of the heating and evacuated by said auxiliary pump.",
"As the pump casing 12 and anode 18 are composed of aluminum-based metals whose thermal conductivities are high, the heating need not be continued over a prolonged period because the moisture contained in a film of aluminum oxide (Al 2 O 3 ) formed at the surface is thoroughly removed when heated to a temperature between approximately 120° and 150° C. Aluminum-based metals have another advantage over stainless steel in that they release less gases.",
"Then, Penning discharge is conducted by applying a high d.c. voltage (approximately 5.5 kv) to the anode 18, with the result that the pump casing 12, which serves as the cathode, releases electrons which spiral in the magnetic field.",
"On colliding with, for instance, nitrogen molecules in the pump casing 12, the electrons yield nitrogen ions and new electrons.",
"The positively charged ions of nitrogen thus formed collide with, and get absorbed by, the internal walls of the pump casing 12 that serves as the cathode.",
"Consequently, atoms of aluminum and titanium (or zirconium or magnesium) contained in the pump casing 12 are adsorbed, which, however, stick to the surface of the anode 18 or the internal walls of the pump casing 12 later.",
"The active aluminum and titanium atoms, etc.",
"sticking to the internal walls of the pump casing 12 as a result of spattering efficiently adsorb gas molecules in the pump casing 12.",
"It has been experimentally confirmed that a vacuum as high as approximately 10 -10 torr can be attained easily through the elimination or evacuation of the internal gases."
] |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 10/083,842 entitled “A Flexible and Plastic Radiopaque Laminate Composition,” filed on Mar. 18, 2005, the entire specification of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to laminate compositions. More specifically, the present invention relates to flexible and plastic laminate compositions that include a discrete and separate layer of a radiopaque material.
[0003] The use and manufacture of radiopaque materials compounded into plastic resins and then extruded into tubing or molded into shapes is well known. Radiopaque qualities are imparted to plastics through the dispersion of radiopaque materials into the thermoplastic resin. The resin is then extruded into tubes or molded into shapes that are desirable for use. In order for these resins to be radiopaque, the resins must be loaded with high percentages of radiopaque materials. This high percentage of loading can create structural and functional problems with the materials.
[0004] The use of a thin metal layer that can impart radiopaque qualities is also known. For example, ion implantation and vapor deposition processes can be utilized to deposit a thin layer of metal on the surface of medical devices. Electro-deposition processing techniques are also known that can apply a metal layer to the surface of medical devices. These types of processes are effective at producing a thin layer of radiopaque metal on the surface of the plastic. As a result, a high level of radiopacity for a given amount of material is expected. These types of processes are, however, costly and of limited use in the mass production of plastic medical devices.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a flexible plastic laminate composition with radiopaque properties. The laminate composition includes a single or multiple layers of a plastic material and a single or multiple layers of radiopaque or conductive materials wherein the radiopaque or conductive material forms a discreet and separate layer applied via a solvent between the layers of a plastic material. The use of a solvent allows the radiopaque material to be adhered to a surface of the plastic material upon evaporation of the solvent. This results in the formation of a uniform and thin layer of radiopaque material within the laminate composition such that desired radiopaque properties can be achieved.
[0006] The laminate composition can be formed into various geometries, such as tubular parts that can be cut to desired lengths to form compliant radiopaque marker bands. The radiopaque marker bands are flexible and made, in part, from a plastic material. This allows the marker bands to be readily applied to medical devices, such as catheters, for radiographic imaging. Alternatively, the laminate compositions can be utilized to form the catheter or other suitable medical device.
[0007] In an embodiment, the present invention provides a flexible laminate composition that includes one or more discrete and separate layers of a radiopaque material. The composition includes one or more plastic layers composed of a plastic material and one or more radiopaque layers composed of a radiopaque material wherein at least one of the radiopaque layers is applied via a solvent to at least one of the plastic layers.
[0008] In another embodiment, the present invention provides a method of manufacturing a flexible laminate composition. The method includes forming a radiopaque solution including a radiopaque material; and applying the radiopaque material via a solvent to a plastic layer composed of a plastic material; and forming a uniform layer of the radiopaque material on the plastic material. As a result, a uniform and thin layer of the radiopaque material can be readily formed such that a desired level of radiopaque properties associated with the laminate can be achieved.
[0009] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the figures.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 illustrates a laminate composition pursuant to an embodiment of the present invention.
[0011] FIG. 2 illustrates a radiopaque marker band pursuant to an embodiment of the present invention.
[0012] FIG. 3 illustrates a catheter with a radiopaque marker band pursuant to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention relates to laminate compositions. More specifically, the present invention relates to flexible and plastic laminate compositions that include a discrete and separate layer of a radiopaque material.
[0014] The laminate composition of the present invention includes a single or multiple layers of a plastic material and a single or multiple layers of radiopaque or conductive materials wherein the radiopaque or conductive material forms a discreet and separate layer applied via a solvent between the layers of plastic material. As a result, the laminate composition includes a uniform and thin layer of radiopaque material such that a desired and suitable level of radiopaque qualities can be achieved.
[0015] The laminate composition can be formed into various geometries, such as tubular parts that can be cut to desired lengths to form compliant radiopaque marker bands. The radiopaque marker bands are flexible and made, in part, from a plastic material. This allows the marker bands to be readily applied to medical devices, such as catheters, for radiographic imaging. Alternatively, the laminate compositions can be utilized to form the catheter or other suitable medical device.
[0016] The laminate composition can include any suitable type and amount of materials. As previously discussed, the laminate composition includes layers of radiopaque and plastic materials wherein the radiopaque material layers are applied via a solvent to the plastic material layers. The radiopaque material includes bismuth oxychloride, bismuth subcarbonate, bismuth trioxide, barium sulfate, tungsten, tantlium, platinum, silver, gold, copper, carbon, the like and combinations thereof.
[0017] The radiopaque material can include any suitable particle size such that it can be applied to the plastic material by adhering thereto with the use of a solvent, such as methyl ethyl ketone, tetrahydroform, dimethyl formamide, toluene, acetone, heptane, cyclohexane, the like and combinations thereof. Preferably, the radiopaque material has a particle size that ranges from about 2 microns to about 120 mesh screen size. In an embodiment, the radiopaque material is a perforated metal foil.
[0018] The plastic material can include any suitable type and amount of plastic material. In an embodiment, the plastic material includes a solution grade plastic coating resin, such as polyurethane, polyester, polyether, polycaprolactone, a copolymer of vinyl chloride and vinyl acetate, polyvinyl chloride, a silicone elastomer, the like and combinations thereof.
[0019] The plastic material can be made in any suitable manner. For example, the plastic material can be made from a solution grade plastic in a solvent that allows for the formation of different shapes. This can be conducted with the use of mandrels, forms or the like that are coated with the plastic solution. The solvent for the solution grade plastic can include, for example, methyl ethyl ketone, tetrahydrofuran, dimethylformamide, toluene, acetone, heptane, cyclohexane, the like, and combinations thereof.
[0020] As the solvent evaporates, the plastic is reconstituted on the form. When the form is removed, the plastic retains it shape and has the strength of the original material. The form can include any suitable type of shapes and sizes, such as a tubular part with a lubricous surface.
[0021] The radiopaque material is adhered through the application of an additional solvent or solvents to the surface of the formed plastic. The solvent or solvents create a tacky surface and thus cause the surface to flow and allow the adhesion and encapsulation of the radiopaque material. Once the solvent evaporates, the radiopaque material is retained on the surface of the plastic material thereby forming a uniform and thin layer of the radiopaque material.
[0022] Multiple applications of the plastic coating, solvent and radiopaque material result in a laminated plastic structure where the radiopaque material is not dispersed into the plastic. Instead, the radiopaque material is deposited as a uniform and thin layer lamination. The uniform thin layer of radiopaque material can enhance the ability of the laminate composition to block x-ray radiation as compared to conventional radiopaque materials, such as an aggregate of dispersed radiopaque materials in a molded or an extruded part. The use of the solvent allows the uniform thin layer of radiopaque material to be formed within the laminate composition with relative ease in operation, thus facilitating the manufacture of the radiopaque laminate in mass production.
[0023] FIGS. 1-3 provide graphical representations that illustrate various embodiments of the present invention. FIG. 1 illustrates a sectional view of a laminate composition 10 according to an embodiment. As shown, a radiopaque material 12 is applied between a first plastic layer 14 and a second plastic layer 16 . As previously discussed, the radiopaque material is applied to the plastic layers with the use of a solvent. The solvent produces a tacky surface such that the radiopaque material can effectively adhere upon evaporation of the solvent. This results in a uniform thin layer of radiopaque material within the laminate composition. The laminate composition can include multiple layers of plastic material and radiopaque material depending on the type of application.
[0024] As previously discussed, the laminate compositions of the present invention can be formed into any suitable types of configurations. As shown in FIG. 2 , the laminate composition 10 is formed into a radiopaque marker band 18 . The marker band 18 can be applied to a catheter 20 via RF bonding 22 , heat bonding, or other suitable technique to a part 24 of the catheter 20 as shown in FIG. 3 . Alternatively, the laminate composition can be formed into the catheter or other suitable type of medical device in any suitable manner.
[0025] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. | A flexible laminate composition and methods for manufacturing same are provided. The flexible laminate composition includes one or more discrete and separate layers of a radiopaque material wherein the radiopaque layer is applied via a solvent to a layer that is composed of a plastic material. The laminate composition can be formed into a radiopaque marker band that can be used with a medical device, such as a catheter, for radiographic imaging. The laminate composition as an alternative can also be utilized to form the catheter or other suitable medical device. | Summarize the patent information, clearly outlining the technical challenges and proposed solutions. | [
"CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional application of U.S. patent application Ser.",
"No. 10/083,842 entitled “A Flexible and Plastic Radiopaque Laminate Composition,” filed on Mar. 18, 2005, the entire specification of which is incorporated herein by reference.",
"BACKGROUND OF THE INVENTION [0002] The present invention relates to laminate compositions.",
"More specifically, the present invention relates to flexible and plastic laminate compositions that include a discrete and separate layer of a radiopaque material.",
"[0003] The use and manufacture of radiopaque materials compounded into plastic resins and then extruded into tubing or molded into shapes is well known.",
"Radiopaque qualities are imparted to plastics through the dispersion of radiopaque materials into the thermoplastic resin.",
"The resin is then extruded into tubes or molded into shapes that are desirable for use.",
"In order for these resins to be radiopaque, the resins must be loaded with high percentages of radiopaque materials.",
"This high percentage of loading can create structural and functional problems with the materials.",
"[0004] The use of a thin metal layer that can impart radiopaque qualities is also known.",
"For example, ion implantation and vapor deposition processes can be utilized to deposit a thin layer of metal on the surface of medical devices.",
"Electro-deposition processing techniques are also known that can apply a metal layer to the surface of medical devices.",
"These types of processes are effective at producing a thin layer of radiopaque metal on the surface of the plastic.",
"As a result, a high level of radiopacity for a given amount of material is expected.",
"These types of processes are, however, costly and of limited use in the mass production of plastic medical devices.",
"SUMMARY OF THE INVENTION [0005] The present invention relates to a flexible plastic laminate composition with radiopaque properties.",
"The laminate composition includes a single or multiple layers of a plastic material and a single or multiple layers of radiopaque or conductive materials wherein the radiopaque or conductive material forms a discreet and separate layer applied via a solvent between the layers of a plastic material.",
"The use of a solvent allows the radiopaque material to be adhered to a surface of the plastic material upon evaporation of the solvent.",
"This results in the formation of a uniform and thin layer of radiopaque material within the laminate composition such that desired radiopaque properties can be achieved.",
"[0006] The laminate composition can be formed into various geometries, such as tubular parts that can be cut to desired lengths to form compliant radiopaque marker bands.",
"The radiopaque marker bands are flexible and made, in part, from a plastic material.",
"This allows the marker bands to be readily applied to medical devices, such as catheters, for radiographic imaging.",
"Alternatively, the laminate compositions can be utilized to form the catheter or other suitable medical device.",
"[0007] In an embodiment, the present invention provides a flexible laminate composition that includes one or more discrete and separate layers of a radiopaque material.",
"The composition includes one or more plastic layers composed of a plastic material and one or more radiopaque layers composed of a radiopaque material wherein at least one of the radiopaque layers is applied via a solvent to at least one of the plastic layers.",
"[0008] In another embodiment, the present invention provides a method of manufacturing a flexible laminate composition.",
"The method includes forming a radiopaque solution including a radiopaque material;",
"and applying the radiopaque material via a solvent to a plastic layer composed of a plastic material;",
"and forming a uniform layer of the radiopaque material on the plastic material.",
"As a result, a uniform and thin layer of the radiopaque material can be readily formed such that a desired level of radiopaque properties associated with the laminate can be achieved.",
"[0009] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the figures.",
"BRIEF DESCRIPTION OF THE FIGURES [0010] FIG. 1 illustrates a laminate composition pursuant to an embodiment of the present invention.",
"[0011] FIG. 2 illustrates a radiopaque marker band pursuant to an embodiment of the present invention.",
"[0012] FIG. 3 illustrates a catheter with a radiopaque marker band pursuant to an embodiment of the present invention.",
"DETAILED DESCRIPTION OF THE INVENTION [0013] The present invention relates to laminate compositions.",
"More specifically, the present invention relates to flexible and plastic laminate compositions that include a discrete and separate layer of a radiopaque material.",
"[0014] The laminate composition of the present invention includes a single or multiple layers of a plastic material and a single or multiple layers of radiopaque or conductive materials wherein the radiopaque or conductive material forms a discreet and separate layer applied via a solvent between the layers of plastic material.",
"As a result, the laminate composition includes a uniform and thin layer of radiopaque material such that a desired and suitable level of radiopaque qualities can be achieved.",
"[0015] The laminate composition can be formed into various geometries, such as tubular parts that can be cut to desired lengths to form compliant radiopaque marker bands.",
"The radiopaque marker bands are flexible and made, in part, from a plastic material.",
"This allows the marker bands to be readily applied to medical devices, such as catheters, for radiographic imaging.",
"Alternatively, the laminate compositions can be utilized to form the catheter or other suitable medical device.",
"[0016] The laminate composition can include any suitable type and amount of materials.",
"As previously discussed, the laminate composition includes layers of radiopaque and plastic materials wherein the radiopaque material layers are applied via a solvent to the plastic material layers.",
"The radiopaque material includes bismuth oxychloride, bismuth subcarbonate, bismuth trioxide, barium sulfate, tungsten, tantlium, platinum, silver, gold, copper, carbon, the like and combinations thereof.",
"[0017] The radiopaque material can include any suitable particle size such that it can be applied to the plastic material by adhering thereto with the use of a solvent, such as methyl ethyl ketone, tetrahydroform, dimethyl formamide, toluene, acetone, heptane, cyclohexane, the like and combinations thereof.",
"Preferably, the radiopaque material has a particle size that ranges from about 2 microns to about 120 mesh screen size.",
"In an embodiment, the radiopaque material is a perforated metal foil.",
"[0018] The plastic material can include any suitable type and amount of plastic material.",
"In an embodiment, the plastic material includes a solution grade plastic coating resin, such as polyurethane, polyester, polyether, polycaprolactone, a copolymer of vinyl chloride and vinyl acetate, polyvinyl chloride, a silicone elastomer, the like and combinations thereof.",
"[0019] The plastic material can be made in any suitable manner.",
"For example, the plastic material can be made from a solution grade plastic in a solvent that allows for the formation of different shapes.",
"This can be conducted with the use of mandrels, forms or the like that are coated with the plastic solution.",
"The solvent for the solution grade plastic can include, for example, methyl ethyl ketone, tetrahydrofuran, dimethylformamide, toluene, acetone, heptane, cyclohexane, the like, and combinations thereof.",
"[0020] As the solvent evaporates, the plastic is reconstituted on the form.",
"When the form is removed, the plastic retains it shape and has the strength of the original material.",
"The form can include any suitable type of shapes and sizes, such as a tubular part with a lubricous surface.",
"[0021] The radiopaque material is adhered through the application of an additional solvent or solvents to the surface of the formed plastic.",
"The solvent or solvents create a tacky surface and thus cause the surface to flow and allow the adhesion and encapsulation of the radiopaque material.",
"Once the solvent evaporates, the radiopaque material is retained on the surface of the plastic material thereby forming a uniform and thin layer of the radiopaque material.",
"[0022] Multiple applications of the plastic coating, solvent and radiopaque material result in a laminated plastic structure where the radiopaque material is not dispersed into the plastic.",
"Instead, the radiopaque material is deposited as a uniform and thin layer lamination.",
"The uniform thin layer of radiopaque material can enhance the ability of the laminate composition to block x-ray radiation as compared to conventional radiopaque materials, such as an aggregate of dispersed radiopaque materials in a molded or an extruded part.",
"The use of the solvent allows the uniform thin layer of radiopaque material to be formed within the laminate composition with relative ease in operation, thus facilitating the manufacture of the radiopaque laminate in mass production.",
"[0023] FIGS. 1-3 provide graphical representations that illustrate various embodiments of the present invention.",
"FIG. 1 illustrates a sectional view of a laminate composition 10 according to an embodiment.",
"As shown, a radiopaque material 12 is applied between a first plastic layer 14 and a second plastic layer 16 .",
"As previously discussed, the radiopaque material is applied to the plastic layers with the use of a solvent.",
"The solvent produces a tacky surface such that the radiopaque material can effectively adhere upon evaporation of the solvent.",
"This results in a uniform thin layer of radiopaque material within the laminate composition.",
"The laminate composition can include multiple layers of plastic material and radiopaque material depending on the type of application.",
"[0024] As previously discussed, the laminate compositions of the present invention can be formed into any suitable types of configurations.",
"As shown in FIG. 2 , the laminate composition 10 is formed into a radiopaque marker band 18 .",
"The marker band 18 can be applied to a catheter 20 via RF bonding 22 , heat bonding, or other suitable technique to a part 24 of the catheter 20 as shown in FIG. 3 .",
"Alternatively, the laminate composition can be formed into the catheter or other suitable type of medical device in any suitable manner.",
"[0025] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art.",
"Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages.",
"It is therefore intended that such changes and modifications be covered by the appended claims."
] |
BACKGROUND
Certain filter materials have been suggested for incorporation into cigarette filters, including cotton, paper, cellulose, and certain synthetic fibers. However, such filter materials generally only remove particulate and condensable components from tobacco smoke. Thus, they are usually not optimal for the removal of certain gaseous components from tobacco smoke, e.g., volatile organic compounds.
SUMMARY
Cut tobacco filler, filter and paper compositions, cigarettes, methods for making cigarettes and methods for smoking cigarettes are provided which involve the use of a composite mesoporous/microporous material. In one embodiment, cut tobacco filler compositions are provided, which comprise tobacco, and a composite mesoporous/microporous material, wherein the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke.
In another embodiment, smoking articles are provided, which comprise a composite mesoporous/microporous material, wherein the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke. Examples of smoking articles include cigarettes, pipes, cigars and non-traditional cigarettes. Such smoking articles may comprise up to about 300 mg of the composite mesoporous/microporous material, or preferably greater than about 10 mg of the composite mesoporous/microporous material.
Examples of constituents in mainstream tobacco smoke that may be removed include, but are not limited to, aldehydes, carbon monoxide, 1,3-butadiene, isoprene, acrolein, acrylonitrile, hydrogen cyanide, o-toluidine, 2-naphtylamine, nitrogen oxide, benzene, N-nitrosonornicotine, phenol, catechol, benz(a)anthracene, and/or benzo(a)pyrene. Preferably, the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke through sorption and/or catalysis. The composite mesoporous/microporous material is present in an amount effective to remove some or all of at least one constituent from mainstream tobacco smoke; for example, preferably at least about 30% or more preferably at least about 50% of at least one constituent may be removed from mainstream tobacco smoke. Preferably, the composite mesoporous/microporous material is capable of selectively removing at least one constituent from tobacco smoke.
Preferably, the composite mesoporous/microporous material comprises mesopores having an average pore size from about 20 Å to about 500 Å. Preferably, the composite mesoporous/microporous material comprises a zeolite having an average pore size of less than about 20 Å. Examples of zeolite materials that may be used to make the composite mesoporous/microporous material include, but are not limited to, zeolites such as zeolite ZSM-5, zeolite A, zeolite X, zeolite Y, zeolite K-G, zeolite ZK-5, zeolite Beta, zeolite ZK-4, and mixtures thereof.
Preferably, the composite mesoporous/microporous material comprises channels interconnecting at least one mesoporous region and at least one microporous region. The mesopores of the composite mesoporous/microporous material may further comprise a carbon lining and/or be further functionalized with a surfactant. Alternatively, the composite mesoporous/microporous material may further comprise a metal or a metal oxide thereof. The metal or metal oxide thereof is preferably selected from one or more of a transition or lanthanide metal or a metalloid atom, e.g., such as those of Group IB-VIIIB, IIIA and IVA elements of the Periodic Table of Elements, and mixtures thereof, e.g., B, Al, Si, Ti, V, Mn, Fe, Co, Cu, Zn, Ge, Y, Zr, Nb, Mo, Rh, Pd, Ag, Ce, Hf, Ta, Re, Ir, Pt and Au. Particularly preferred metals are iron, copper, zinc, titanium, vanadium, silver, palladium, and/or manganese.
The composite mesoporous/microporous material may be dispersed in a cut tobacco filler, located in a paper wrapper and/or located in a filter portion. The filter portion may be a mono filter, a dual filter, a triple filter, a cavity filter, a recessed filter or a free-flow filter. The composite mesoporous/microporous material may be incorporated into one or more filter parts selected from the group consisting of: shaped paper insert, a plug, a space, cigarette filter paper, a cellulose acetate sleeve, a polypropylene sleeve, and a free-flow sleeve.
In yet another embodiment, methods of making a cigarette are provided, which comprise (i) adding at least one composite mesoporous/microporous material to a cut tobacco filler, wherein the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke; (ii) providing the cut tobacco filler comprising the composite mesoporous/microporous material to a cigarette making machine to form a tobacco column; and (iii) placing a paper wrapper around the tobacco column to form a tobacco rod of a cigarette.
In another embodiment, a method for making a cigarette comprises (i) providing a cut tobacco filler to a cigarette making machine to form a tobacco column; (ii) placing a paper wrapper around the tobacco column to form a tobacco rod; and (iii) attaching a cigarette filter to the tobacco rod using tipping paper to form the cigarette, wherein the cigarette filter comprises at least one composite mesoporous/microporous material capable of removing at least one constituent from mainstream tobacco smoke.
An embodiment further relates to methods for making a cigarette, which comprise (i) providing the cut tobacco filler to a cigarette making machine and forming a tobacco column; and (ii) placing a paper wrapper around the tobacco column to form a tobacco rod of the cigarette, wherein the paper wrapper comprises at least one composite mesoporous/microporous material that is capable of removing at least one constituent from sidestream tobacco smoke.
Another embodiment relates to methods for making a cigarette filter, comprising incorporating at least one composite mesoporous/microporous material that is capable of removing at least one constituent from mainstream tobacco smoke into a cigarette filter.
Yet another embodiment relates to methods of smoking a cigarette containing a composite mesoporous/microporous material, which comprises lighting the cigarette to form smoke and drawing the smoke through the cigarette, wherein during the smoking of the cigarette, the composite mesoporous/microporous material removes at least one constituent from mainstream tobacco smoke.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded perspective view of a cigarette incorporating one embodiment wherein folded paper containing a composite mesoporous/microporous material is inserted into a hollow portion of a tubular filter element of the cigarette.
FIG. 2 is partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in folded paper and inserted into a hollow portion of a first free-flow sleeve of a tubular filter element next to a second free-flow sleeve.
FIG. 3 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a plug-space-plug filter element.
FIG. 4 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a three-piece filter element having three plugs.
FIG. 5 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a four-piece filter element having a plug-space-plug arrangement and a hollow sleeve.
FIG. 6 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a three-part filter element having two plugs and a hollow sleeve.
FIG. 7 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a two-part filter element having two plugs.
FIG. 8 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a filter element which may be used in a smoking article.
DETAILED DESCRIPTION
Cut tobacco filler compositions, smoking articles such as cigarettes, methods for making cigarettes and methods for smoking cigarettes are provided which involve the use of a composite mesoporous/microporous material to remove one or more constituents from mainstream and sidestream tobacco smoke. The term “mainstream” smoke refers to the mixture of gases issuing through the mouth or filter end of a smoking article, e.g. the amount of smoke issuing or drawn from the mouth end of a cigarette during smoking of the cigarette.
Composite mesoporous/microporous material is used for selective and effective removal of certain selected constituents of mainstream tobacco smoke. Preferably, other constituents in mainstream smoke, i.e. such as those that contribute to flavor, will not be targeted for removal. By “removed” is meant that the concentration of at least some of at least one constituent in mainstream smoke is lowered. This can be accomplished by a variety of mechanisms. For example, the constituent may chemically react with the composite mesoporous/microporous material. Alternatively, the constituents may be sequestered within the pores of the composite mesoporous/microporous material, and thus removed from the tobacco smoke before reaching the smoker or being given off as second-hand smoke.
By “selective removal” is meant that certain constituents are substantially removed from mainstream smoke, while other constituents are not substantially removed. The term “selective” also encompasses “preferential” removal of certain constituents from mainstream smoke, i.e. where more than one constituent may be removed, but where one constituent is removed to a greater extent than another component.
The composite mesoporous/microporous material may remove one or more constituents from mainstream smoke through a combination of sorption and/or catalysis. The term “sorption” denotes filtration through absorption and/or adsorption. Sorption is intended to cover interactions on the outer surface of the composite mesoporous/microporous material, as well as interactions within the pores and channels of the sorbent. In other words, a sorbent is a substance that has the ability to condense or hold molecules of other substances on its surface and/or the ability to take up another substance, i.e. through penetration of the other substance into its inner structure or into its pores. The term “adsorption” also denotes filtration through physical sieving, i.e. capture of certain constituents in the pores of the composite mesoporous/microporous material. The term “sorbent” as used herein refers to either an adsorbent, an absorbent, or a substance that functions as both an adsorbent and an absorbent.
As used herein, the term “composite mesoporous/microporous material” covers a mesoporous molecular sieve material that is made from microporous starting materials or intermediate synthesis gel for microporous materials. The microporous material that makes up the composite mesoporous/microporous material product still retains microporous properties, i.e. an average pore size of about less than 20 Å, in the final composite mesoporous molecular sieve structure. Accordingly, the composite structure will have both microporous regions and mesoporous regions, which preferably have inter-connected channels. The composite mesoporous/microporous material preferably has increased catalytic ability, sorption, and/or selectivity as a result of its structure.
In a preferred embodiment, a modified procedure for preparing mesoporous molecular sieves may be used, where the microporous component is used as a source of silica to make mesoporous molecular sieves. Exemplary mesoporous silicates are described, for example, in patents relating to MCM-41 and MCM-48 and SBA-15; such as U.S. Pat. Nos. 5,108,725; 5,098,684 and 5,102,643, which are all hereby incorporated by reference in their entirety. See also, e.g., Shan, Z. et al., Studies in Surface Science and Catalysis 141:635-640 (2002). Typically, the microporous component, e.g. a semi-finished synthesis gel for microporous zeolites, is homogenously dispersed in a solvent such as water, along with silica sources such as tetraethyl orthosilicate (TEOS), along with organic amphiphilic surfactant templates that are suitable for the synthesis of mesoporous materials. Exemplary organic templates include but are not limited to, cetyltrimethylammonium bromide solution (cTAB) or block copolymes, such as: poly(ethylene glycol)-block-poly(propylene glycol)-block-poly(ethylene glycol). While not wishing to be bound by theory, it is believed that the zeolite microcrystalline particles organize into arrays along the organic template, which leads to the synthesis of the mesoporous molecular sieves under certain pH value and temperature. The resulting solid product is filtered and dried. The organic templates are typically removed through calcination, to generate a mesoporous porosity, which is linked to the microporous channels associated with the zeolite.
The composite mesoporous/microporous material, as described above, may be provided along the length of a tobacco rod by distributing the composite mesoporous/microporous material in the form of a powder on the tobacco or incorporating it into the cut tobacco filler tobacco using any suitable method. For instance, the composite mesoporous/microporous material may be provided to the cut tobacco filler in the form of a dry powder or in a dispersion with a suitable solvent. In a preferred method, the composite mesoporous/microporous material in the form of a dry powder is dusted on the cut tobacco filler tobacco. The composite mesoporous/microporous material may also be present in the form of a solution and sprayed on the cut tobacco filler. Alternatively, the tobacco may be coated with a solution containing the composite mesoporous/microporous material. The composite mesoporous/microporous material may also be added to the cut tobacco filler stock supplied to the cigarette making machine or added to a tobacco column prior to wrapping cigarette paper around the cigarette rod.
Any conventional or modified cigarette making technique may be used to incorporate the composite mesoporous/microporous material. The resulting cigarettes can be manufactured to any known specifications using standard or modified cigarette making techniques and equipment. Typically, the cut tobacco filler composition is optionally combined with other cigarette additives, and provided to a cigarette making machine to produce a tobacco rod, which is then wrapped in cigarette paper, and optionally tipped with filters.
Any suitable tobacco mixture may be used for the cut tobacco filler. Examples of suitable types of tobacco materials include flue-cured, Burley, Md. or Oriental tobaccos, the rare or specialty tobaccos, and blends thereof. The tobacco material can be provided in the form of tobacco lamina; processed tobacco materials such as volume expanded or puffed tobacco, processed tobacco stems such as cut-rolled or cut-puffed stems, reconstituted tobacco materials; or blends thereof. The cut filler may include tobacco substitutes.
In cigarette manufacture, the tobacco is normally employed in the form of cut filler, i.e. in the form of shreds or strands cut into widths ranging from about 1/10 inch to about 1/20 inch or even 1/40 inch. The lengths of the strands range from between about 0.25 inches to about 3.0 inches. The cigarettes may further comprise one or more flavorants or other additives, e.g. burn additives, combustion modifying agents, coloring agents, binders, etc.
The cigarettes may range from about 50 mm to about 120 mm in length. Generally, a regular cigarette is about 70 mm long, a “King Size” is about 85 mm long, a “Super King Size” is about 100 mm long, and a “Long” is usually about 120 mm in length. The circumference is from about 15 mm to about 30 mm in circumference, and preferably around 25 mm. The packing density is typically between the range of about 100 mg/cm 3 to about 300 mg/cm 3 , and preferably 150 mg/cm 3 to about 275 mg/cm 3 .
“Smoking” of a cigarette includes the heating or combustion of the cigarette to form smoke, and drawing the smoke through the smoking article. Generally, smoking of a cigarette involves lighting one end of the cigarette and drawing the cigarette smoke through the mouth end of the cigarette, while the tobacco contained therein undergoes a combustion reaction. However, the cigarette may also be smoked by other means. For example, the cigarette may be smoked by heating the cigarette and/or heating using electrical heater means, as described in commonly-assigned U.S. Pat. Nos. 6,053,176; 5,934,289, 5,591,368 or 5,322,075, for example.
Any conventional or modified method of making cigarette filters may be used to incorporate the composite mesoporous/microporous material. For example, various cigarette filter arrangements and methods for making filters are described in commonly-assigned U.S. Pat. No. 6,209,547, which is hereby incorporated in its entirety.
FIG. 1 illustrates a cigarette 2 having a tobacco rod 4 , a filter portion 6 , and a mouthpiece filter plug 8 . As shown, a composite mesoporous/microporous material can be loaded onto folded paper 10 inserted into a hollow cavity such as the interior of a free-flow sleeve 12 forming part of the filter portion 6 .
FIG. 2 shows a cigarette 2 having a tobacco rod 4 and a filter portion 6 , wherein the folded paper 10 is located in the hollow cavity of a first free-flow sleeve 13 located between the mouthpiece filter 8 and a second free-flow sleeve 15 . The paper 10 can be used in forms other than as a folded sheet. For instance, the paper 10 can be deployed as one or more individual strips, a wound roll, etc. In whichever form, a desired amount of a composite mesoporous/microporous material can be provided in the cigarette filter portion by a combination of the coated amount of reagent/area of the paper and/or the total area of coated paper employed in the filter (e.g., higher amounts of a composite mesoporous/microporous material can be provided simply by using larger pieces of coated paper). In the cigarettes shown in FIGS. 1 and 2 , the tobacco rod 4 and the filter portion 6 are joined together with tipping paper 14 . In both cigarettes, the filter portion 6 may be held together by filter overwrap 11 .
A composite mesoporous/microporous material can be incorporated into the filter paper in a number of ways. For example, a composite mesoporous/microporous material can be mixed with water to form a slurry. The slurry can then be coated onto pre-formed filter paper and allowed to dry. The filter paper can then be incorporated into the filter portion of a cigarette in the manner shown in FIGS. 8 and 9 . Alternatively, the dried paper can be wrapped into a plug shape and inserted into a filter portion of the cigarette. For example, the paper can be wrapped into a plug shape and inserted as a plug into the interior of a free-flow filter element such as a polypropylene or cellulose acetate sleeve. In another arrangement, the paper can comprise an inner liner of such a free-flow filter element.
Alternatively and preferably, a composite mesoporous/microporous material is added to the filter paper during the paper-making process. For example, a composite mesoporous/microporous material can be mixed with bulk cellulose to form a cellulose pulp mixture. The mixture can be then formed into filter paper according to any conventional or modified methods.
In another preferred embodiment, a composite mesoporous/microporous material is incorporated into the fibrous material of the cigarette filter portion itself. Such filter materials include, but are not limited to, fibrous filter materials including paper such as tipping paper or plugs of fibers such as cellulose acetate fibers and polypropylene fibers. This embodiment is illustrated in FIG. 3 , which shows a cigarette 2 comprised of a tobacco rod 4 and a filter portion 6 in the form of a plug-space-plug filter having a mouthpiece filter 8 , a plug 16 , and a space 18 . The plug 16 can comprise a tube or solid piece of material such as polypropylene or cellulose acetate fibers. The tobacco rod 4 and the filter portion 6 are joined together with tipping paper 14 . The filter portion 6 may include a filter overwrap 11 . The filter overwrap 11 containing traditional fibrous filter material and a composite mesoporous/microporous material can be incorporated in or on the filter overwrap 11 such as by being coated thereon. Alternatively, a composite mesoporous/microporous material can be incorporated in the mouthpiece filter 8 , in the plug 16 , and/or in the space 18 . Moreover, a composite mesoporous/microporous material can be incorporated in any element of the filter portion of a cigarette. For example, the filter portion may consist only of the mouthpiece filter 8 and a composite mesoporous/microporous material can be incorporated in the mouthpiece filter 8 and/or in the tipping paper 14 .
FIG. 4 shows a cigarette 2 comprised of a tobacco rod 4 and filter portion 6 . This arrangement is similar to that of FIG. 3 except the space 18 is filled with granules of a composite mesoporous/microporous material or a plug 15 made of material such as fibrous polypropylene or cellulose acetate containing a composite mesoporous/microporous material. As in the previous embodiment, the plug 16 can be hollow or solid and the tobacco rod 4 and filter portion 6 are joined together with tipping paper 14 . There is also a filter overwrap 11 .
FIG. 5 shows a cigarette 2 comprised of a tobacco rod 4 and a filter portion 6 wherein the filter portion 6 includes a mouthpiece filter 8 , a filter overwrap 11 , tipping paper 14 to join the tobacco rod 4 and filter portion 6 , a space 18 , a plug 16 , and a hollow sleeve 20 . A composite mesoporous/microporous material can be incorporated into one or more elements of the filter portion 6 . For instance, a composite mesoporous/microporous material can be incorporated into the sleeve 20 or granules of a composite mesoporous/microporous material can be filled into the space within the sleeve 20 . If desired, the plug 16 and sleeve 20 can be made of material such as fibrous polypropylene or cellulose acetate containing a composite mesoporous/microporous material. As in the previous embodiment, the plug 16 can be hollow or solid.
FIGS. 6 and 7 show further modifications of the filter portion 6 . In FIG. 6 , cigarette 2 is comprised of a tobacco rod 4 and filter portion 6 . The filter portion 6 includes a mouthpiece filter 8 , a filter overwrap 11 , a plug 22 , and a sleeve 20 , and a composite mesoporous/microporous material can be incorporated in one or more of these filter elements. In FIG. 7 , the filter portion 6 includes a mouthpiece filter 8 and a plug 24 , and a composite mesoporous/microporous material can be incorporated in one or more of these filter elements. Like the plug 16 , the plugs 22 and 24 can be solid or hollow. In the cigarettes shown in FIGS. 6 and 7 , the tobacco rod 4 and filter portion 6 are joined together by tipping paper 14 .
Various techniques can be used to apply a composite mesoporous/microporous material to filter fibers or other substrate supports. For example, a composite mesoporous/microporous material can be added to the filter fibers before they are formed into a filter cartridge, e.g., a tip for a cigarette. A composite mesoporous/microporous material can be added to the filter fibers, for example, in the form of a dry powder or a slurry. If a composite mesoporous/microporous material is applied in the form of a slurry, the fibers are allowed to dry before they are formed into a filter cartridge.
In another preferred embodiment, a composite mesoporous/microporous material is employed in a hollow portion of a cigarette filter. For example, some cigarette filters have a plug/space/plug configuration in which the plugs comprise a fibrous filter material and the space is simply a void between the two filter plugs. That void can be filled with a composite mesoporous/microporous material. An example of this embodiment is shown in FIG. 3 . The composite mesoporous/microporous material can be in granular form or can be loaded onto a suitable support such as a fiber or thread.
In another embodiment, the composite mesoporous/microporous material is employed in a filter portion of a cigarette for use with a smoking device as described in commonly-assigned U.S. Pat. No. 5,692,525, the entire content of which is hereby incorporated by reference. FIG. 8 illustrates one type of construction of a cigarette 100 which can be used with an electrical smoking device. As shown, the cigarette 100 includes a tobacco rod 60 and a filter portion 62 joined by tipping paper 64 . The filter portion 62 preferably contains a tubular free-flow filter element 102 and a mouthpiece filter plug 104 . The free-flow filter element 102 and mouthpiece filter plug 104 may be joined together as a combined plug 110 with plug wrap 112 . The tobacco rod 60 can have various forms incorporating one or more of the following items: an overwrap 71 , another tubular free-flow filter element 74 , a cylindrical tobacco plug 80 preferably wrapped in a plug wrap 84 , a tobacco web 66 comprising a base web 68 and tobacco flavor material 70 , and a void space 91 . The free-flow filter element 74 provides structural definition and support at the tipped end 72 of the tobacco rod 60 . At the free end 78 of the tobacco rod 60 , the tobacco web 66 together with overwrap 71 are wrapped about cylindrical tobacco plug 80 . Various modifications can be made to a filter arrangement for such a cigarette incorporating a composite mesoporous/microporous material of the invention.
In such a cigarette, a composite mesoporous/microporous material can be incorporated in various ways such as by being loaded onto paper or other substrate material which is fitted into the passageway of the tubular free-flow filter element 102 therein. It may also be deployed as a liner or a plug in the interior of the tubular free-flow filter element 102 . Alternatively, a composite mesoporous/microporous material can be incorporated into the fibrous wall portions of the tubular free-flow filter element 102 itself. For instance, the tubular free-flow filter element or sleeve 102 can be made of suitable materials such as polypropylene or cellulose acetate fibers and a composite mesoporous/microporous material can be mixed with such fibers prior to or as part of the sleeve forming process.
In another embodiment, a composite mesoporous/microporous material can be incorporated into the mouthpiece filter plug 104 instead of in the element 102 . However, as in the previously described embodiments, a composite mesoporous/microporous material may be incorporated into more than one constituent of a filter portion such as by being incorporated into the mouthpiece filter plug 104 and into the tubular free-flow filter element 102 . The filter portion 62 of FIG. 8 can also be modified to create a void space into which a composite mesoporous/microporous material can be inserted.
As explained above, the composite mesoporous/microporous material can be incorporated in various support materials. When a composite mesoporous/microporous material is used in filter paper, the composite mesoporous/microporous material can be incorporated in or formed into particles having average particle size of up to 100 μm, preferably less than 30 μm. When the composite mesoporous/microporous material is used in granular form, larger particles may be used. Such particles can be formed by using a binding material, such as clay, alumina, silica, as commonly used for catalyst production, and preferably have a mesh size of from 20 to 60 mesh (850 to 250 microns, U.S. Standard, ASTM E11), and more preferably from 35 to 60 mesh (500 to 250 microns). To form such particles, larger particles of the composite mesoporous/microporous material with binding material can be broken up into smaller particles having a desired size by any suitable technique, such as milling. The smaller particles can be separated to produce a desired particle size range by any suitable technique, such as sieving.
While the invention has been described with reference to preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and scope of the invention as defined by the claims appended hereto.
All of the above-mentioned references are herein incorporated by reference in their entirety to the same extent as if each individual reference was specifically and individually indicated to be incorporated herein by reference in its entirety. | Cut filler compositions, cigarettes, methods for making cigarettes and methods for smoking cigarettes are provided, which involve the use of a composite mesoporous/microporous material. The composite material is capable of removing at least one constituent from tobacco smoke, preferably selectively. The composite material may also be used for removing at least one constituent from tobacco smoke through sorption and/or catalysis. The composite material comprises channels interconnecting at least one mesoporous region and at least one microporous region. The mesopores of the composite material may further comprise a carbon lining and/or be further functionalized with a surfactant. Alternatively, the composite material may further comprise a metal, a metal oxide, or mixtures thereof. | Concisely explain the essential features and purpose of the concept presented in the passage. | [
"BACKGROUND Certain filter materials have been suggested for incorporation into cigarette filters, including cotton, paper, cellulose, and certain synthetic fibers.",
"However, such filter materials generally only remove particulate and condensable components from tobacco smoke.",
"Thus, they are usually not optimal for the removal of certain gaseous components from tobacco smoke, e.g., volatile organic compounds.",
"SUMMARY Cut tobacco filler, filter and paper compositions, cigarettes, methods for making cigarettes and methods for smoking cigarettes are provided which involve the use of a composite mesoporous/microporous material.",
"In one embodiment, cut tobacco filler compositions are provided, which comprise tobacco, and a composite mesoporous/microporous material, wherein the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke.",
"In another embodiment, smoking articles are provided, which comprise a composite mesoporous/microporous material, wherein the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke.",
"Examples of smoking articles include cigarettes, pipes, cigars and non-traditional cigarettes.",
"Such smoking articles may comprise up to about 300 mg of the composite mesoporous/microporous material, or preferably greater than about 10 mg of the composite mesoporous/microporous material.",
"Examples of constituents in mainstream tobacco smoke that may be removed include, but are not limited to, aldehydes, carbon monoxide, 1,3-butadiene, isoprene, acrolein, acrylonitrile, hydrogen cyanide, o-toluidine, 2-naphtylamine, nitrogen oxide, benzene, N-nitrosonornicotine, phenol, catechol, benz(a)anthracene, and/or benzo(a)pyrene.",
"Preferably, the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke through sorption and/or catalysis.",
"The composite mesoporous/microporous material is present in an amount effective to remove some or all of at least one constituent from mainstream tobacco smoke;",
"for example, preferably at least about 30% or more preferably at least about 50% of at least one constituent may be removed from mainstream tobacco smoke.",
"Preferably, the composite mesoporous/microporous material is capable of selectively removing at least one constituent from tobacco smoke.",
"Preferably, the composite mesoporous/microporous material comprises mesopores having an average pore size from about 20 Å to about 500 Å.",
"Preferably, the composite mesoporous/microporous material comprises a zeolite having an average pore size of less than about 20 Å.",
"Examples of zeolite materials that may be used to make the composite mesoporous/microporous material include, but are not limited to, zeolites such as zeolite ZSM-5, zeolite A, zeolite X, zeolite Y, zeolite K-G, zeolite ZK-5, zeolite Beta, zeolite ZK-4, and mixtures thereof.",
"Preferably, the composite mesoporous/microporous material comprises channels interconnecting at least one mesoporous region and at least one microporous region.",
"The mesopores of the composite mesoporous/microporous material may further comprise a carbon lining and/or be further functionalized with a surfactant.",
"Alternatively, the composite mesoporous/microporous material may further comprise a metal or a metal oxide thereof.",
"The metal or metal oxide thereof is preferably selected from one or more of a transition or lanthanide metal or a metalloid atom, e.g., such as those of Group IB-VIIIB, IIIA and IVA elements of the Periodic Table of Elements, and mixtures thereof, e.g., B, Al, Si, Ti, V, Mn, Fe, Co, Cu, Zn, Ge, Y, Zr, Nb, Mo, Rh, Pd, Ag, Ce, Hf, Ta, Re, Ir, Pt and Au.",
"Particularly preferred metals are iron, copper, zinc, titanium, vanadium, silver, palladium, and/or manganese.",
"The composite mesoporous/microporous material may be dispersed in a cut tobacco filler, located in a paper wrapper and/or located in a filter portion.",
"The filter portion may be a mono filter, a dual filter, a triple filter, a cavity filter, a recessed filter or a free-flow filter.",
"The composite mesoporous/microporous material may be incorporated into one or more filter parts selected from the group consisting of: shaped paper insert, a plug, a space, cigarette filter paper, a cellulose acetate sleeve, a polypropylene sleeve, and a free-flow sleeve.",
"In yet another embodiment, methods of making a cigarette are provided, which comprise (i) adding at least one composite mesoporous/microporous material to a cut tobacco filler, wherein the composite mesoporous/microporous material is capable of removing at least one constituent from tobacco smoke;",
"(ii) providing the cut tobacco filler comprising the composite mesoporous/microporous material to a cigarette making machine to form a tobacco column;",
"and (iii) placing a paper wrapper around the tobacco column to form a tobacco rod of a cigarette.",
"In another embodiment, a method for making a cigarette comprises (i) providing a cut tobacco filler to a cigarette making machine to form a tobacco column;",
"(ii) placing a paper wrapper around the tobacco column to form a tobacco rod;",
"and (iii) attaching a cigarette filter to the tobacco rod using tipping paper to form the cigarette, wherein the cigarette filter comprises at least one composite mesoporous/microporous material capable of removing at least one constituent from mainstream tobacco smoke.",
"An embodiment further relates to methods for making a cigarette, which comprise (i) providing the cut tobacco filler to a cigarette making machine and forming a tobacco column;",
"and (ii) placing a paper wrapper around the tobacco column to form a tobacco rod of the cigarette, wherein the paper wrapper comprises at least one composite mesoporous/microporous material that is capable of removing at least one constituent from sidestream tobacco smoke.",
"Another embodiment relates to methods for making a cigarette filter, comprising incorporating at least one composite mesoporous/microporous material that is capable of removing at least one constituent from mainstream tobacco smoke into a cigarette filter.",
"Yet another embodiment relates to methods of smoking a cigarette containing a composite mesoporous/microporous material, which comprises lighting the cigarette to form smoke and drawing the smoke through the cigarette, wherein during the smoking of the cigarette, the composite mesoporous/microporous material removes at least one constituent from mainstream tobacco smoke.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partially exploded perspective view of a cigarette incorporating one embodiment wherein folded paper containing a composite mesoporous/microporous material is inserted into a hollow portion of a tubular filter element of the cigarette.",
"FIG. 2 is partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in folded paper and inserted into a hollow portion of a first free-flow sleeve of a tubular filter element next to a second free-flow sleeve.",
"FIG. 3 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a plug-space-plug filter element.",
"FIG. 4 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a three-piece filter element having three plugs.",
"FIG. 5 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a four-piece filter element having a plug-space-plug arrangement and a hollow sleeve.",
"FIG. 6 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a three-part filter element having two plugs and a hollow sleeve.",
"FIG. 7 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a two-part filter element having two plugs.",
"FIG. 8 is a partially exploded perspective view of another embodiment wherein a composite mesoporous/microporous material is incorporated in a filter element which may be used in a smoking article.",
"DETAILED DESCRIPTION Cut tobacco filler compositions, smoking articles such as cigarettes, methods for making cigarettes and methods for smoking cigarettes are provided which involve the use of a composite mesoporous/microporous material to remove one or more constituents from mainstream and sidestream tobacco smoke.",
"The term “mainstream”",
"smoke refers to the mixture of gases issuing through the mouth or filter end of a smoking article, e.g. the amount of smoke issuing or drawn from the mouth end of a cigarette during smoking of the cigarette.",
"Composite mesoporous/microporous material is used for selective and effective removal of certain selected constituents of mainstream tobacco smoke.",
"Preferably, other constituents in mainstream smoke, i.e. such as those that contribute to flavor, will not be targeted for removal.",
"By “removed”",
"is meant that the concentration of at least some of at least one constituent in mainstream smoke is lowered.",
"This can be accomplished by a variety of mechanisms.",
"For example, the constituent may chemically react with the composite mesoporous/microporous material.",
"Alternatively, the constituents may be sequestered within the pores of the composite mesoporous/microporous material, and thus removed from the tobacco smoke before reaching the smoker or being given off as second-hand smoke.",
"By “selective removal”",
"is meant that certain constituents are substantially removed from mainstream smoke, while other constituents are not substantially removed.",
"The term “selective”",
"also encompasses “preferential”",
"removal of certain constituents from mainstream smoke, i.e. where more than one constituent may be removed, but where one constituent is removed to a greater extent than another component.",
"The composite mesoporous/microporous material may remove one or more constituents from mainstream smoke through a combination of sorption and/or catalysis.",
"The term “sorption”",
"denotes filtration through absorption and/or adsorption.",
"Sorption is intended to cover interactions on the outer surface of the composite mesoporous/microporous material, as well as interactions within the pores and channels of the sorbent.",
"In other words, a sorbent is a substance that has the ability to condense or hold molecules of other substances on its surface and/or the ability to take up another substance, i.e. through penetration of the other substance into its inner structure or into its pores.",
"The term “adsorption”",
"also denotes filtration through physical sieving, i.e. capture of certain constituents in the pores of the composite mesoporous/microporous material.",
"The term “sorbent”",
"as used herein refers to either an adsorbent, an absorbent, or a substance that functions as both an adsorbent and an absorbent.",
"As used herein, the term “composite mesoporous/microporous material”",
"covers a mesoporous molecular sieve material that is made from microporous starting materials or intermediate synthesis gel for microporous materials.",
"The microporous material that makes up the composite mesoporous/microporous material product still retains microporous properties, i.e. an average pore size of about less than 20 Å, in the final composite mesoporous molecular sieve structure.",
"Accordingly, the composite structure will have both microporous regions and mesoporous regions, which preferably have inter-connected channels.",
"The composite mesoporous/microporous material preferably has increased catalytic ability, sorption, and/or selectivity as a result of its structure.",
"In a preferred embodiment, a modified procedure for preparing mesoporous molecular sieves may be used, where the microporous component is used as a source of silica to make mesoporous molecular sieves.",
"Exemplary mesoporous silicates are described, for example, in patents relating to MCM-41 and MCM-48 and SBA-15;",
"such as U.S. Pat. Nos. 5,108,725;",
"5,098,684 and 5,102,643, which are all hereby incorporated by reference in their entirety.",
"See also, e.g., Shan, Z. et al.",
", Studies in Surface Science and Catalysis 141:635-640 (2002).",
"Typically, the microporous component, e.g. a semi-finished synthesis gel for microporous zeolites, is homogenously dispersed in a solvent such as water, along with silica sources such as tetraethyl orthosilicate (TEOS), along with organic amphiphilic surfactant templates that are suitable for the synthesis of mesoporous materials.",
"Exemplary organic templates include but are not limited to, cetyltrimethylammonium bromide solution (cTAB) or block copolymes, such as: poly(ethylene glycol)-block-poly(propylene glycol)-block-poly(ethylene glycol).",
"While not wishing to be bound by theory, it is believed that the zeolite microcrystalline particles organize into arrays along the organic template, which leads to the synthesis of the mesoporous molecular sieves under certain pH value and temperature.",
"The resulting solid product is filtered and dried.",
"The organic templates are typically removed through calcination, to generate a mesoporous porosity, which is linked to the microporous channels associated with the zeolite.",
"The composite mesoporous/microporous material, as described above, may be provided along the length of a tobacco rod by distributing the composite mesoporous/microporous material in the form of a powder on the tobacco or incorporating it into the cut tobacco filler tobacco using any suitable method.",
"For instance, the composite mesoporous/microporous material may be provided to the cut tobacco filler in the form of a dry powder or in a dispersion with a suitable solvent.",
"In a preferred method, the composite mesoporous/microporous material in the form of a dry powder is dusted on the cut tobacco filler tobacco.",
"The composite mesoporous/microporous material may also be present in the form of a solution and sprayed on the cut tobacco filler.",
"Alternatively, the tobacco may be coated with a solution containing the composite mesoporous/microporous material.",
"The composite mesoporous/microporous material may also be added to the cut tobacco filler stock supplied to the cigarette making machine or added to a tobacco column prior to wrapping cigarette paper around the cigarette rod.",
"Any conventional or modified cigarette making technique may be used to incorporate the composite mesoporous/microporous material.",
"The resulting cigarettes can be manufactured to any known specifications using standard or modified cigarette making techniques and equipment.",
"Typically, the cut tobacco filler composition is optionally combined with other cigarette additives, and provided to a cigarette making machine to produce a tobacco rod, which is then wrapped in cigarette paper, and optionally tipped with filters.",
"Any suitable tobacco mixture may be used for the cut tobacco filler.",
"Examples of suitable types of tobacco materials include flue-cured, Burley, Md.",
"or Oriental tobaccos, the rare or specialty tobaccos, and blends thereof.",
"The tobacco material can be provided in the form of tobacco lamina;",
"processed tobacco materials such as volume expanded or puffed tobacco, processed tobacco stems such as cut-rolled or cut-puffed stems, reconstituted tobacco materials;",
"or blends thereof.",
"The cut filler may include tobacco substitutes.",
"In cigarette manufacture, the tobacco is normally employed in the form of cut filler, i.e. in the form of shreds or strands cut into widths ranging from about 1/10 inch to about 1/20 inch or even 1/40 inch.",
"The lengths of the strands range from between about 0.25 inches to about 3.0 inches.",
"The cigarettes may further comprise one or more flavorants or other additives, e.g. burn additives, combustion modifying agents, coloring agents, binders, etc.",
"The cigarettes may range from about 50 mm to about 120 mm in length.",
"Generally, a regular cigarette is about 70 mm long, a “King Size”",
"is about 85 mm long, a “Super King Size”",
"is about 100 mm long, and a “Long”",
"is usually about 120 mm in length.",
"The circumference is from about 15 mm to about 30 mm in circumference, and preferably around 25 mm.",
"The packing density is typically between the range of about 100 mg/cm 3 to about 300 mg/cm 3 , and preferably 150 mg/cm 3 to about 275 mg/cm 3 .",
"“Smoking”",
"of a cigarette includes the heating or combustion of the cigarette to form smoke, and drawing the smoke through the smoking article.",
"Generally, smoking of a cigarette involves lighting one end of the cigarette and drawing the cigarette smoke through the mouth end of the cigarette, while the tobacco contained therein undergoes a combustion reaction.",
"However, the cigarette may also be smoked by other means.",
"For example, the cigarette may be smoked by heating the cigarette and/or heating using electrical heater means, as described in commonly-assigned U.S. Pat. Nos. 6,053,176;",
"5,934,289, 5,591,368 or 5,322,075, for example.",
"Any conventional or modified method of making cigarette filters may be used to incorporate the composite mesoporous/microporous material.",
"For example, various cigarette filter arrangements and methods for making filters are described in commonly-assigned U.S. Pat. No. 6,209,547, which is hereby incorporated in its entirety.",
"FIG. 1 illustrates a cigarette 2 having a tobacco rod 4 , a filter portion 6 , and a mouthpiece filter plug 8 .",
"As shown, a composite mesoporous/microporous material can be loaded onto folded paper 10 inserted into a hollow cavity such as the interior of a free-flow sleeve 12 forming part of the filter portion 6 .",
"FIG. 2 shows a cigarette 2 having a tobacco rod 4 and a filter portion 6 , wherein the folded paper 10 is located in the hollow cavity of a first free-flow sleeve 13 located between the mouthpiece filter 8 and a second free-flow sleeve 15 .",
"The paper 10 can be used in forms other than as a folded sheet.",
"For instance, the paper 10 can be deployed as one or more individual strips, a wound roll, etc.",
"In whichever form, a desired amount of a composite mesoporous/microporous material can be provided in the cigarette filter portion by a combination of the coated amount of reagent/area of the paper and/or the total area of coated paper employed in the filter (e.g., higher amounts of a composite mesoporous/microporous material can be provided simply by using larger pieces of coated paper).",
"In the cigarettes shown in FIGS. 1 and 2 , the tobacco rod 4 and the filter portion 6 are joined together with tipping paper 14 .",
"In both cigarettes, the filter portion 6 may be held together by filter overwrap 11 .",
"A composite mesoporous/microporous material can be incorporated into the filter paper in a number of ways.",
"For example, a composite mesoporous/microporous material can be mixed with water to form a slurry.",
"The slurry can then be coated onto pre-formed filter paper and allowed to dry.",
"The filter paper can then be incorporated into the filter portion of a cigarette in the manner shown in FIGS. 8 and 9 .",
"Alternatively, the dried paper can be wrapped into a plug shape and inserted into a filter portion of the cigarette.",
"For example, the paper can be wrapped into a plug shape and inserted as a plug into the interior of a free-flow filter element such as a polypropylene or cellulose acetate sleeve.",
"In another arrangement, the paper can comprise an inner liner of such a free-flow filter element.",
"Alternatively and preferably, a composite mesoporous/microporous material is added to the filter paper during the paper-making process.",
"For example, a composite mesoporous/microporous material can be mixed with bulk cellulose to form a cellulose pulp mixture.",
"The mixture can be then formed into filter paper according to any conventional or modified methods.",
"In another preferred embodiment, a composite mesoporous/microporous material is incorporated into the fibrous material of the cigarette filter portion itself.",
"Such filter materials include, but are not limited to, fibrous filter materials including paper such as tipping paper or plugs of fibers such as cellulose acetate fibers and polypropylene fibers.",
"This embodiment is illustrated in FIG. 3 , which shows a cigarette 2 comprised of a tobacco rod 4 and a filter portion 6 in the form of a plug-space-plug filter having a mouthpiece filter 8 , a plug 16 , and a space 18 .",
"The plug 16 can comprise a tube or solid piece of material such as polypropylene or cellulose acetate fibers.",
"The tobacco rod 4 and the filter portion 6 are joined together with tipping paper 14 .",
"The filter portion 6 may include a filter overwrap 11 .",
"The filter overwrap 11 containing traditional fibrous filter material and a composite mesoporous/microporous material can be incorporated in or on the filter overwrap 11 such as by being coated thereon.",
"Alternatively, a composite mesoporous/microporous material can be incorporated in the mouthpiece filter 8 , in the plug 16 , and/or in the space 18 .",
"Moreover, a composite mesoporous/microporous material can be incorporated in any element of the filter portion of a cigarette.",
"For example, the filter portion may consist only of the mouthpiece filter 8 and a composite mesoporous/microporous material can be incorporated in the mouthpiece filter 8 and/or in the tipping paper 14 .",
"FIG. 4 shows a cigarette 2 comprised of a tobacco rod 4 and filter portion 6 .",
"This arrangement is similar to that of FIG. 3 except the space 18 is filled with granules of a composite mesoporous/microporous material or a plug 15 made of material such as fibrous polypropylene or cellulose acetate containing a composite mesoporous/microporous material.",
"As in the previous embodiment, the plug 16 can be hollow or solid and the tobacco rod 4 and filter portion 6 are joined together with tipping paper 14 .",
"There is also a filter overwrap 11 .",
"FIG. 5 shows a cigarette 2 comprised of a tobacco rod 4 and a filter portion 6 wherein the filter portion 6 includes a mouthpiece filter 8 , a filter overwrap 11 , tipping paper 14 to join the tobacco rod 4 and filter portion 6 , a space 18 , a plug 16 , and a hollow sleeve 20 .",
"A composite mesoporous/microporous material can be incorporated into one or more elements of the filter portion 6 .",
"For instance, a composite mesoporous/microporous material can be incorporated into the sleeve 20 or granules of a composite mesoporous/microporous material can be filled into the space within the sleeve 20 .",
"If desired, the plug 16 and sleeve 20 can be made of material such as fibrous polypropylene or cellulose acetate containing a composite mesoporous/microporous material.",
"As in the previous embodiment, the plug 16 can be hollow or solid.",
"FIGS. 6 and 7 show further modifications of the filter portion 6 .",
"In FIG. 6 , cigarette 2 is comprised of a tobacco rod 4 and filter portion 6 .",
"The filter portion 6 includes a mouthpiece filter 8 , a filter overwrap 11 , a plug 22 , and a sleeve 20 , and a composite mesoporous/microporous material can be incorporated in one or more of these filter elements.",
"In FIG. 7 , the filter portion 6 includes a mouthpiece filter 8 and a plug 24 , and a composite mesoporous/microporous material can be incorporated in one or more of these filter elements.",
"Like the plug 16 , the plugs 22 and 24 can be solid or hollow.",
"In the cigarettes shown in FIGS. 6 and 7 , the tobacco rod 4 and filter portion 6 are joined together by tipping paper 14 .",
"Various techniques can be used to apply a composite mesoporous/microporous material to filter fibers or other substrate supports.",
"For example, a composite mesoporous/microporous material can be added to the filter fibers before they are formed into a filter cartridge, e.g., a tip for a cigarette.",
"A composite mesoporous/microporous material can be added to the filter fibers, for example, in the form of a dry powder or a slurry.",
"If a composite mesoporous/microporous material is applied in the form of a slurry, the fibers are allowed to dry before they are formed into a filter cartridge.",
"In another preferred embodiment, a composite mesoporous/microporous material is employed in a hollow portion of a cigarette filter.",
"For example, some cigarette filters have a plug/space/plug configuration in which the plugs comprise a fibrous filter material and the space is simply a void between the two filter plugs.",
"That void can be filled with a composite mesoporous/microporous material.",
"An example of this embodiment is shown in FIG. 3 .",
"The composite mesoporous/microporous material can be in granular form or can be loaded onto a suitable support such as a fiber or thread.",
"In another embodiment, the composite mesoporous/microporous material is employed in a filter portion of a cigarette for use with a smoking device as described in commonly-assigned U.S. Pat. No. 5,692,525, the entire content of which is hereby incorporated by reference.",
"FIG. 8 illustrates one type of construction of a cigarette 100 which can be used with an electrical smoking device.",
"As shown, the cigarette 100 includes a tobacco rod 60 and a filter portion 62 joined by tipping paper 64 .",
"The filter portion 62 preferably contains a tubular free-flow filter element 102 and a mouthpiece filter plug 104 .",
"The free-flow filter element 102 and mouthpiece filter plug 104 may be joined together as a combined plug 110 with plug wrap 112 .",
"The tobacco rod 60 can have various forms incorporating one or more of the following items: an overwrap 71 , another tubular free-flow filter element 74 , a cylindrical tobacco plug 80 preferably wrapped in a plug wrap 84 , a tobacco web 66 comprising a base web 68 and tobacco flavor material 70 , and a void space 91 .",
"The free-flow filter element 74 provides structural definition and support at the tipped end 72 of the tobacco rod 60 .",
"At the free end 78 of the tobacco rod 60 , the tobacco web 66 together with overwrap 71 are wrapped about cylindrical tobacco plug 80 .",
"Various modifications can be made to a filter arrangement for such a cigarette incorporating a composite mesoporous/microporous material of the invention.",
"In such a cigarette, a composite mesoporous/microporous material can be incorporated in various ways such as by being loaded onto paper or other substrate material which is fitted into the passageway of the tubular free-flow filter element 102 therein.",
"It may also be deployed as a liner or a plug in the interior of the tubular free-flow filter element 102 .",
"Alternatively, a composite mesoporous/microporous material can be incorporated into the fibrous wall portions of the tubular free-flow filter element 102 itself.",
"For instance, the tubular free-flow filter element or sleeve 102 can be made of suitable materials such as polypropylene or cellulose acetate fibers and a composite mesoporous/microporous material can be mixed with such fibers prior to or as part of the sleeve forming process.",
"In another embodiment, a composite mesoporous/microporous material can be incorporated into the mouthpiece filter plug 104 instead of in the element 102 .",
"However, as in the previously described embodiments, a composite mesoporous/microporous material may be incorporated into more than one constituent of a filter portion such as by being incorporated into the mouthpiece filter plug 104 and into the tubular free-flow filter element 102 .",
"The filter portion 62 of FIG. 8 can also be modified to create a void space into which a composite mesoporous/microporous material can be inserted.",
"As explained above, the composite mesoporous/microporous material can be incorporated in various support materials.",
"When a composite mesoporous/microporous material is used in filter paper, the composite mesoporous/microporous material can be incorporated in or formed into particles having average particle size of up to 100 μm, preferably less than 30 μm.",
"When the composite mesoporous/microporous material is used in granular form, larger particles may be used.",
"Such particles can be formed by using a binding material, such as clay, alumina, silica, as commonly used for catalyst production, and preferably have a mesh size of from 20 to 60 mesh (850 to 250 microns, U.S. Standard, ASTM E11), and more preferably from 35 to 60 mesh (500 to 250 microns).",
"To form such particles, larger particles of the composite mesoporous/microporous material with binding material can be broken up into smaller particles having a desired size by any suitable technique, such as milling.",
"The smaller particles can be separated to produce a desired particle size range by any suitable technique, such as sieving.",
"While the invention has been described with reference to preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art.",
"Such variations and modifications are to be considered within the purview and scope of the invention as defined by the claims appended hereto.",
"All of the above-mentioned references are herein incorporated by reference in their entirety to the same extent as if each individual reference was specifically and individually indicated to be incorporated herein by reference in its entirety."
] |
CROSS-REFERENCED TO RELATED APPLICATIONS
This Application claims the benefit of pending U.S. Provisional Application No. 60/038,630, filed on Feb. 19, 1997.
FIELD OF THE INVENTION
This invention relates to a molding system and method for making injection molded dental appliances such as dentures, retainers, prostheses and similar appliances. The invention also relates to a means for dispensing materials which may limit operator exposure to harmful chemicals.
SCOPE OF THE PRIOR ART
Conventional molded dental appliances and methods of making them are widely practiced by dental laboratories. Most molded dental appliances are constructed in a dental flask containing a mold, also called an investment, of the appliance to be formed. The investment is made of plaster or other investment material and is molded around a wax model of the desired appliance, a wax-up, which is embedded in the dental flask. The wax-up may include items such as retainer wires or artificial teeth. Once the investment has hardened, the wax is removed from the dental flask, creating a cavity in the investment of the shape of the desired appliance. The uncured appliance material is then introduced by hand or by conventional injection methods. In conventional methods of packing, approximately three to four tons of force is required in order to squeeze out excess appliance material. After packing, the material is cured in the flask by conventional means such as by conduction heating, thereby forming a dental appliance of the desired shape.
The use of conventional molding systems and methods poses several problems for the practitioner. Often, too much material is added to the investment cavity, resulting in overpacking of the flask. Also, the high pressures can cause distortion of metal frameworks. In addition, when applied to partial dentures, tooth movement frequently occurs, requiring time-consuming reconstruction. Additionally, the material may undergo shrinkage during curing. Overpacking, excess pressure and shrinkage can all result in inaccurately dimensioned dental appliances. In addition, opening and subsequent addition or subtraction of material to the dental flask can cause a variety of significant problems, including but not limited to nonuniform or incomplete curing, the entrapment of air bubbles within the appliance, dislodging of embedded items such as teeth or retaining wires, premature appliance fractures (due to nonuniform preparation of materials), and inaccurately dimensioned appliances.
In addition to the problems disclosed above, conventional methods of mixing the materials may expose the operator to potentially harmful fumes and chemicals. For instance, many dental appliances are created using resins, such as acrylic, urethane or epoxy resins. A number of these resins are currently believed to pose a risk of cancer to exposed persons, and all may be harmful if absorbed through the skin or lungs or ingested, or if fumes emitted from the resins are inhaled. For example, in a conventional acrylic resin preparation of the type generally used in dentistry, the resin material is prepared on a benchtop by combining a fine, loose powder polymer with a liquid monomer and mixing by hand with a small stick or spatula until uniform. The polymer powder readily disperses into the air, and may be inhaled by the operator or absorbed through the skin. The liquid monomer is volatile, and may be inhaled in its gaseous state. In addition, the possibility of spillage of the liquid monomer is a constant threat to the operator. Moreover, upon combination of the powder and the liquid, a chemical reaction causes the immediate release of fumes, which may also be harmful to the operator if inhaled. In another example, epoxy resins are generally formed from two or more thick liquid components which are hand mixed on a benchtop, the process of which also releases potentially harmful vapors. In addition, as with virtually all commercially available uncured resins, mixed but uncured acrylic or epoxy material may be harmful and irritating if contacted with skin.
Moreover, conventional molding systems further cause an economic disadvantage to operators in that the flasks and attendant equipment used for each type of material are different. For instance, traditional flasks and injector modules for forming heat-curable appliances are different than traditional flasks and injector modules used for forming microwave-curable appliances. Thus, operators must purchase entirely separate equipment if they are to have the desired freedom to use both types of materials.
Thus, there is a need for an improved dental injection molding system which minimizes inaccurately dimensioned appliances, which protects operators from exposure to potentially dangerous fumes and chemicals and which allows operators the freedom to use at least some of the same equipment with more than one type of material.
As will become apparent from a detailed reading of the description, the system of the invention offers significant advantages over the prior art systems described above, most significantly including a system for pressurized and continuous injection in a closed system even during curing, which greatly minimizes the risk of inaccurately formed or non-uniform appliances. In addition, the injection system of the invention can accommodate conduction heat and microwave curing, both under pressure and without pressure. Lastly, use of the dispensing system of the invention will minimize operator exposure to harmful fumes and chemicals, regardless of the chemistry used to make the material. Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a pressurized dental injection molding system whereby material may be continuously pressurized in a mold up to the point of cure of the material.
It is a further object of the invention to provide a system for making injection molded dental appliances that can compensate for shrinkage or overfilling or underfilling.
It is also an object of the invention to provide a system for making injection molded dental appliances which at least partly vents the injector module and flask during injection.
It is yet another object of the present invention to provide an injection module for making injection molded dental appliances that may be used with both conduction heating and microwave curable material.
It is still another object of the present invention to provide a dispensing system that minimizes operator exposure to chemicals and vapors.
The invention includes a system and method for making injection molded dental appliance apparatuses having an injector module removably attached to a dental flask, a press and a controlled compression means, wherein the press and compression means introduce pressure into the dental flask and the injector module, which pressure may or may not be maintained during curing of the appliance. The invention also includes a system for dispensing dental appliance chemicals having at least one chemical dispensing apparatus and a bag; whereby a separate dispensing apparatus is used for each chemical and the chemicals are dispensed directly into the bag and mixed in the bag.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic view of a dental injection molding system apparatus made in accordance with the principles of the invention, featuring a press, an assembled flask, an injector module and a compression device.
FIG. 2 is an exploded view of a flask and an injector module made according to the invention.
FIG. 3 is a schematic diagram of an assembled flask and sprue former of the invention.
FIG. 4 depicts the material dispensing system of the invention.
FIG. 5 shows a separated flask of the invention containing a formed mold for an appliance made in accordance with the principles of the invention.
FIG. 6 shows insertion of appliance material into an injector module of the invention.
FIG. 7 illustrates the continuous injection apparatus of the invention whereby the appliance is microwave cured under continuous pressure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a preferred embodiment of an injection molding system made in accordance with the principles of the present invention. The system includes a press 2 , a compression device 8 , a flask 4 , and an injector module 6 .
The press 2 includes a vertically moveable platform 10 , a compression plate 12 , and opposing first 14 and second 16 vertical platform posts running from the underside of compression plate 12 through platform 10 to compression device 8 . The compression plate 12 is bolted to the platform posts 14 and 16 respectively by first and second bolting means 18 and 20 . A press piston 19 connected to the compression device allows the platform 10 to be raised or lowered along first 18 and second 20 platform posts.
The compression device of the preferred embodiment illustrated in FIG. 1 includes a controller means for controlling various factors, such as pressure, speed and time. The compression device further includes a plurality of switches and visual and audible indicators, including a pressure indicator 22 , a cycle completion indicator 24 , stop and start buttons ( 28 and 30 respectively) and a selector switch 32 . The compression device 8 further contains a compression means that is housed within the compression device. The compression means may be any means of raising and lowering platform 10 with press piston 19 , which means are known in the art and which include an electronic controller for controlling factors such as pressure and speed of injection.
FIGS. 1-3 illustrate a preferred embodiment of a microwavable flask 4 and injector module 6 of the invention, which flask 4 includes a bottom section 34 , a center spacer section 36 and a top section 38 , each section having a plurality of bolt holes 44 through which a plurality of bolts 42 are inserted upon assembly of the flask sections.
The bottom section 34 also includes a knockout plate 50 , which fits into opening 51 and assists in separation of the sections upon completion of the method of the invention. Impressed into bottom section 34 is a bottom cavity 46 in which a cast and wax-up is inserted. The cast and wax-up and methods of their making are well known to practitioners of the art, and all of those methods are suitable for use with the dental flask and injector module of the invention.
The center spacer section 36 includes a spacer plate having an outer edge 48 and an inner edge 49 , wherein the outer edge is shaped to be in registry with the outer edge of bottom 34 and top 38 sections, and the inner edge is shaped to be in registry with the edges of the bottom cavity 46 of the bottom section.
The top section 38 includes two vent openings 52 and 56 , and one sprue former opening 54 , into which a bushing 58 is inserted, although the number of vents, sprue former openings and bushings may vary in other embodiments of the invention. When the flask sections are assembled in registry with one another as illustrated in FIGS. 2 b and 3 , each set of bolt holes 44 (one set in each of the three sections 34 , 36 and 38 ) are in registry with one another. Although the embodiment illustrated here shows three bolt holes, other embodiments with more or less than three bolt holes in dental flask 4 are contemplated to be within the scope of this invention. The bushing 58 includes an opening 60 , which fits into sprue former opening 54 . In another embodiment, the top section includes a top plate for use with pressureless curing The top plate includes a slide valve (not shown) that is closed when curing without the injector module is desired by the operator. The dental flask illustrated in FIG. 2 is constructed from material which is microwave conducting and which can withstand injection pressures of at least 3000 lbs. Other embodiments of the flask of the invention include a flask for use with conduction heating which can withstand injection pressures of at least 3000 lbs. and which is compatible with the injection methods of the invention.
The injector module 6 (used to inject the curable material into the appliance mold within the flask) is then assembled and attached to the reassembled flask 4 . In the preferred embodiment of a microwavable flask 4 and injector module 6 as illustrated in FIG. 2 a, the injector module 6 includes a plate 68 , upon which is mounted a tubular injection cylinder 70 having a cavity 71 and with a plurality of bolt holes 44 in registry with those previously described. The injection cylinder 70 and plate 68 further have an injection orifice (not shown) which is constructed to be in alignment with the sprue opening in the dental flask. Disposed about the outside of the injection cylinder is a threaded pressure retaining band 72 . The injection cylinder cavity 71 is designed to accommodate a solid cylindrical piston 74 , having a piston cap 76 with a patterned exterior edge ridge 78 , and top 80 and bottom 82 surfaces. This piston 74 is fitted to be removably inserted into the injection cylinder cavity 71 up to the bottom surface 82 of the piston cap 76 . The injection cylinder 70 may further includes a tubular pressure cap 84 with a substantially flat cover 86 , which includes a spring mechanism 85 and pressure retaining ring 90 which is threaded on the interior surface 92 to be compatible with the pressure retaining band 72 on the injection cylinder 70 . The pressure cap 84 and the pressure retaining ring are used for curing under pressure, as illustrated in FIG. 2 . At least one view hole 88 disposed in the side wall of the pressure cap 84 . Disposed about the exterior surface of the pressure cap 84 is a pressure retaining ring 90 . In another embodiment of the injector module used for pressureless curing, no pressure cap or pressure retaining ring are used. In the embodiments described herein, the injector module is constructed of a metal which does not conduct microwaves. The universal metal injector is a novel feature of the invention which may be used to inject material into both microwave flasks and conduction heating flasks, and may be used for pressured or pressureless curing. If used with pressure cap 84 , the injector module applies continuous pressure and venting of the material during injection and either microwave or conduction heat cure, and holds the material in the injector in an uncured state while exposed to microwaves.
One preferred method of using the injection system to make molded dental appliances includes the steps of assembling the dental flask, creating an investment, or mold, for the desired appliance, attaching the injector module, preparing the curable material, injecting the curable material into the flask using the compression device of the invention, curing the curable material under pressure or without pressure, disassembling the flask and finally releasing the finished appliance.
The dental flask of the preferred embodiment illustrated in FIGS. 1-3 and 5 - 7 is assembled by first inserting knockout plate 50 into the bottom section 34 of dental flask 4 . Investment material is then prepared according to known methods and placed into the cavity 46 of the bottom section 34 . A cast and wax-up which have been formed in accordance with methods well known in the art are positioned in the assembled bottom cavity 46 of the bottom section 34 . The center section 36 is then positioned upon the bottom section 34 such that the bolt holes 44 in each of the two sections are in registry. Additional investment material is then added to the flask on top of the cast and wax-up.
Once the flask is filled with investment material, the flask is reassembled. The reassambled flask may include either a top section for use with continuous pressurized injection during curing, or it may be reassembled with a top section for pressureless curing, as described above. The top section 38 is then positioned such that the bolt holes 44 of the top section are in registry with the bolt holes 44 of the bottom and center sections ( 34 and 36 respectively). Bolts 42 which extend from the top section into the bottom section of the flask are then inserted into the bolt holes and hand tightened. Vent openings 52 and 56 allow excess investment to be released from the assembled flask upon tightening of the bolts 42 , which vent openings 52 and 56 subsequently become sealed by solidification of the investment material. Prior to the hardening of the investment, the sprue former 62 is then positioned in the sprue former opening 54 such that the sprue former contacts the wax-up, thus forming the passage 63 in the investment material through which curable material is injected (as illustrated in FIG. 5 ). Once the investment is hardened, the sprue former 62 is removed. The cast and wax -up in the invested flask is then heated for a time sufficient to soften the wax. The top section 38 then separated from the bottom 34 and center 36 sections and the wax is removed, leaving a cavity in the investment as shown in FIG. 5 . This cavity forms the mold for the appliance which is subsequently filled with uncured material as described below. The flask sections are then reassembled but not bolted.
In order to attach injector module 6 to reassembled flask 4 , the plate 68 with injection cylinder 70 is aligned with dental flask 4 so that bolt holes 44 in plate 68 are in registry with bolt holes 44 in dental flask 4 . The bolts 42 are then inserted into bolt holes 44 and hand tightened. The bolts are then tightened using press 2 and compression device 8 of the invention. This step involves placing the dental flask 4 with attached plate 68 and injection cylinder 70 on platform 10 so that the cavity 71 of the injection cylinder 70 is facing the lower surface of the compression plate 12 . The various controls on the compression device 8 are then used to raise the platform 10 and compress the flask so that the bolts 42 may be tightened. Once platform 10 stops rising, bolts 42 are tightened, and platform 10 is lowered.
Once the dental flask 4 and injection cylinder 6 are assembled and bolted together as described above, the material may be prepared using the dispensing system of the invention. The dispensing system illustrated in FIG. 4 depicts preparation of an acrylic resin material, and includes a powder dispenser 98 with lever 100 , a cup 102 , a funnel 104 , a funnel stand 106 , a stopper 108 , a liquid dispenser 110 with a lever 116 , and a container 96 , such as the bag illustrated in the preferred embodiment shown in FIGS. 4 d - 4 f. The dispensing system may also include an umbrella 112 , as shown in FIG. 6, which may be used to seal the container 96 . The container 96 may be any container which will not degrade when filled with the material, which is capable of being closed and which is thin enough to allow the operator to assess through touch the consistence of the material.
The powder dispenser lever 100 is used to dispense a measured amount of polymer powder into the cup 102 . (FIGS. 4 a and b ). The powder is then poured into funnel 104 , a spout 118 of which is blocked by the stopper 108 , and which funnel 104 is held upright by use of the funnel stand 106 (FIG. 4 c ). The container 96 is then disposed around a nozzle 114 of the liquid dispenser 110 , and an appropriate amount of liquid monomer is then dispensed into container 96 by movement of lever 116 (FIG. 4 d ). The container 96 containing the liquid monomer is placed below funnel spout 118 and stopper 108 is removed, causing powder to flow into container 96 (FIG. 4 e ). The top portion of the filled container 96 is then closed and the contents gently mixed by hand (FIG. 4 f ). The use of the material dispensing apparatus and the method described above minimizes aerosolized powder and exposure to potentially harmful vapors, and reduces the risk of operator exposure to potentially harmful chemicals and vapors. This particular embodiment illustrates preparation of an acrylic resin compound, but it is understood that any powder/liquid or liquid/liquid combination may be used with the dispensing apparatus of the invention, provided the material resulting from the mixed components is sufficiently viscous for use with the mold and injector module of the invention.
Once the container 96 containing the material is prepared, the filled container 96 is placed into the injection cylinder cavity 71 such that the empty top of container 96 extends out of the top of the injection cylinder 70 . If an umbrella 112 is used, the top of the container 96 may then be threaded through an opening 116 in the umbrella 112 and the umbrella 112 pushed down until it reaches the material, as shown in FIG. 6, with the empty top of the container 96 extending through the opening 116 of umbrella 112 . The top of the container is then folded and the filled container 96 is inserted into the cavity 71 of the injection cylinder 70 . The injector piston 74 is then inserted into the injection cylinder cavity 71 , thus compressing the filled container 96 .
If the continuous pressure embodiment of the injector module is used, the pressure cap 84 is placed over the piston 74 , with the piston cap ridge 78 visible through the pressure cap view hole 88 . The pressure retaining ring 90 is then disposed around the piston cap 76 , with the interior surface 92 of the ring 90 removably resting upon the lower rim 120 of the pressure cap.
In yet another embodiment of the system, the dispensing system may not be used and the material may be loaded directly into the injector module without use of a container.
The assembled dental flask 4 and filled injector module 6 are then placed on platform 10 of press 2 so that in the pressureless embodiment, the top of piston 74 is facing the lower surface of the compression plate 12 , and in the pressured embodiment, the top of pressure cap 86 is facing the lower surface of the compression plate 12 . The compression device is then activated to cause injection of the material into the investment through the injection orifice in the injector module, by pressure applied to the injector module 6 and dental flask 4 . In the continuous pressure embodiment of the invention, once the injection is substantially completed, the pressure retaining ring 90 is tightened about the pressure retaining band 72 , thus causing spring mechanism 85 to exert pressure on the piston 74 , which creates pressure in the dental flask 4 . Upon completion of injection, the flask and injector module are removed from the press.
The pressurized dental flask 4 with attached injector module 6 is then cured, for instance by microwave as shown in FIG. 7 . Until the point of cure (hardening) of the material, the pressure in the dental flask 4 allows for continued injection of uncured material at a constant pressure as necessary to fill void spaces within the investment without causing overfilling of the investment. In addition, the continuous pressure exerted on the appliance minimizes distortion of the appliance due to shrinkage during polymerization, or cure, of the material.
In the pressureless injection system of the invention, the injection of material into the flask is as described above, but after injection, the slide valve on the top section of the flask is closed to seal the material within the flask, and the injector module 6 is removed. The flask is then cured as described above.
After cure, the dental flask 4 is cooled. In the pressurized embodiment, the pressure retaining ring 90 , pressure cap 86 , piston 74 and bag 96 are removed from the injection cylinder 70 prior to cooling. The cured appliance is removed and finished in the conventional manner.
It should be understood that various changes and modifications to the preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be within the scope of the claims. | The invention includes a system and method for making injection molded dental appliance apparatuses having an injector module removably attached to a dental flask, a press and a controlled compression apparatus, wherein the press and compression apparatus introduce pressure into the dental flask and the injector module, which pressure may or may not be maintained during curing of the appliance. The invention also includes a system for dispensing dental appliance chemicals having at least one chemical dispensing apparatus and a mixing container; whereby a separate dispensing apparatus is used for each chemical and the chemicals are dispensed and mixed in the same container. | Summarize the key points of the given patent document. | [
"CROSS-REFERENCED TO RELATED APPLICATIONS This Application claims the benefit of pending U.S. Provisional Application No. 60/038,630, filed on Feb. 19, 1997.",
"FIELD OF THE INVENTION This invention relates to a molding system and method for making injection molded dental appliances such as dentures, retainers, prostheses and similar appliances.",
"The invention also relates to a means for dispensing materials which may limit operator exposure to harmful chemicals.",
"SCOPE OF THE PRIOR ART Conventional molded dental appliances and methods of making them are widely practiced by dental laboratories.",
"Most molded dental appliances are constructed in a dental flask containing a mold, also called an investment, of the appliance to be formed.",
"The investment is made of plaster or other investment material and is molded around a wax model of the desired appliance, a wax-up, which is embedded in the dental flask.",
"The wax-up may include items such as retainer wires or artificial teeth.",
"Once the investment has hardened, the wax is removed from the dental flask, creating a cavity in the investment of the shape of the desired appliance.",
"The uncured appliance material is then introduced by hand or by conventional injection methods.",
"In conventional methods of packing, approximately three to four tons of force is required in order to squeeze out excess appliance material.",
"After packing, the material is cured in the flask by conventional means such as by conduction heating, thereby forming a dental appliance of the desired shape.",
"The use of conventional molding systems and methods poses several problems for the practitioner.",
"Often, too much material is added to the investment cavity, resulting in overpacking of the flask.",
"Also, the high pressures can cause distortion of metal frameworks.",
"In addition, when applied to partial dentures, tooth movement frequently occurs, requiring time-consuming reconstruction.",
"Additionally, the material may undergo shrinkage during curing.",
"Overpacking, excess pressure and shrinkage can all result in inaccurately dimensioned dental appliances.",
"In addition, opening and subsequent addition or subtraction of material to the dental flask can cause a variety of significant problems, including but not limited to nonuniform or incomplete curing, the entrapment of air bubbles within the appliance, dislodging of embedded items such as teeth or retaining wires, premature appliance fractures (due to nonuniform preparation of materials), and inaccurately dimensioned appliances.",
"In addition to the problems disclosed above, conventional methods of mixing the materials may expose the operator to potentially harmful fumes and chemicals.",
"For instance, many dental appliances are created using resins, such as acrylic, urethane or epoxy resins.",
"A number of these resins are currently believed to pose a risk of cancer to exposed persons, and all may be harmful if absorbed through the skin or lungs or ingested, or if fumes emitted from the resins are inhaled.",
"For example, in a conventional acrylic resin preparation of the type generally used in dentistry, the resin material is prepared on a benchtop by combining a fine, loose powder polymer with a liquid monomer and mixing by hand with a small stick or spatula until uniform.",
"The polymer powder readily disperses into the air, and may be inhaled by the operator or absorbed through the skin.",
"The liquid monomer is volatile, and may be inhaled in its gaseous state.",
"In addition, the possibility of spillage of the liquid monomer is a constant threat to the operator.",
"Moreover, upon combination of the powder and the liquid, a chemical reaction causes the immediate release of fumes, which may also be harmful to the operator if inhaled.",
"In another example, epoxy resins are generally formed from two or more thick liquid components which are hand mixed on a benchtop, the process of which also releases potentially harmful vapors.",
"In addition, as with virtually all commercially available uncured resins, mixed but uncured acrylic or epoxy material may be harmful and irritating if contacted with skin.",
"Moreover, conventional molding systems further cause an economic disadvantage to operators in that the flasks and attendant equipment used for each type of material are different.",
"For instance, traditional flasks and injector modules for forming heat-curable appliances are different than traditional flasks and injector modules used for forming microwave-curable appliances.",
"Thus, operators must purchase entirely separate equipment if they are to have the desired freedom to use both types of materials.",
"Thus, there is a need for an improved dental injection molding system which minimizes inaccurately dimensioned appliances, which protects operators from exposure to potentially dangerous fumes and chemicals and which allows operators the freedom to use at least some of the same equipment with more than one type of material.",
"As will become apparent from a detailed reading of the description, the system of the invention offers significant advantages over the prior art systems described above, most significantly including a system for pressurized and continuous injection in a closed system even during curing, which greatly minimizes the risk of inaccurately formed or non-uniform appliances.",
"In addition, the injection system of the invention can accommodate conduction heat and microwave curing, both under pressure and without pressure.",
"Lastly, use of the dispensing system of the invention will minimize operator exposure to harmful fumes and chemicals, regardless of the chemistry used to make the material.",
"Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.",
"SUMMARY OF THE INVENTION It is an object of the invention to provide a pressurized dental injection molding system whereby material may be continuously pressurized in a mold up to the point of cure of the material.",
"It is a further object of the invention to provide a system for making injection molded dental appliances that can compensate for shrinkage or overfilling or underfilling.",
"It is also an object of the invention to provide a system for making injection molded dental appliances which at least partly vents the injector module and flask during injection.",
"It is yet another object of the present invention to provide an injection module for making injection molded dental appliances that may be used with both conduction heating and microwave curable material.",
"It is still another object of the present invention to provide a dispensing system that minimizes operator exposure to chemicals and vapors.",
"The invention includes a system and method for making injection molded dental appliance apparatuses having an injector module removably attached to a dental flask, a press and a controlled compression means, wherein the press and compression means introduce pressure into the dental flask and the injector module, which pressure may or may not be maintained during curing of the appliance.",
"The invention also includes a system for dispensing dental appliance chemicals having at least one chemical dispensing apparatus and a bag;",
"whereby a separate dispensing apparatus is used for each chemical and the chemicals are dispensed directly into the bag and mixed in the bag.",
"BRIEF DESCRIPTION OF THE FIGURES FIG. 1 is a schematic view of a dental injection molding system apparatus made in accordance with the principles of the invention, featuring a press, an assembled flask, an injector module and a compression device.",
"FIG. 2 is an exploded view of a flask and an injector module made according to the invention.",
"FIG. 3 is a schematic diagram of an assembled flask and sprue former of the invention.",
"FIG. 4 depicts the material dispensing system of the invention.",
"FIG. 5 shows a separated flask of the invention containing a formed mold for an appliance made in accordance with the principles of the invention.",
"FIG. 6 shows insertion of appliance material into an injector module of the invention.",
"FIG. 7 illustrates the continuous injection apparatus of the invention whereby the appliance is microwave cured under continuous pressure.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 illustrates a preferred embodiment of an injection molding system made in accordance with the principles of the present invention.",
"The system includes a press 2 , a compression device 8 , a flask 4 , and an injector module 6 .",
"The press 2 includes a vertically moveable platform 10 , a compression plate 12 , and opposing first 14 and second 16 vertical platform posts running from the underside of compression plate 12 through platform 10 to compression device 8 .",
"The compression plate 12 is bolted to the platform posts 14 and 16 respectively by first and second bolting means 18 and 20 .",
"A press piston 19 connected to the compression device allows the platform 10 to be raised or lowered along first 18 and second 20 platform posts.",
"The compression device of the preferred embodiment illustrated in FIG. 1 includes a controller means for controlling various factors, such as pressure, speed and time.",
"The compression device further includes a plurality of switches and visual and audible indicators, including a pressure indicator 22 , a cycle completion indicator 24 , stop and start buttons ( 28 and 30 respectively) and a selector switch 32 .",
"The compression device 8 further contains a compression means that is housed within the compression device.",
"The compression means may be any means of raising and lowering platform 10 with press piston 19 , which means are known in the art and which include an electronic controller for controlling factors such as pressure and speed of injection.",
"FIGS. 1-3 illustrate a preferred embodiment of a microwavable flask 4 and injector module 6 of the invention, which flask 4 includes a bottom section 34 , a center spacer section 36 and a top section 38 , each section having a plurality of bolt holes 44 through which a plurality of bolts 42 are inserted upon assembly of the flask sections.",
"The bottom section 34 also includes a knockout plate 50 , which fits into opening 51 and assists in separation of the sections upon completion of the method of the invention.",
"Impressed into bottom section 34 is a bottom cavity 46 in which a cast and wax-up is inserted.",
"The cast and wax-up and methods of their making are well known to practitioners of the art, and all of those methods are suitable for use with the dental flask and injector module of the invention.",
"The center spacer section 36 includes a spacer plate having an outer edge 48 and an inner edge 49 , wherein the outer edge is shaped to be in registry with the outer edge of bottom 34 and top 38 sections, and the inner edge is shaped to be in registry with the edges of the bottom cavity 46 of the bottom section.",
"The top section 38 includes two vent openings 52 and 56 , and one sprue former opening 54 , into which a bushing 58 is inserted, although the number of vents, sprue former openings and bushings may vary in other embodiments of the invention.",
"When the flask sections are assembled in registry with one another as illustrated in FIGS. 2 b and 3 , each set of bolt holes 44 (one set in each of the three sections 34 , 36 and 38 ) are in registry with one another.",
"Although the embodiment illustrated here shows three bolt holes, other embodiments with more or less than three bolt holes in dental flask 4 are contemplated to be within the scope of this invention.",
"The bushing 58 includes an opening 60 , which fits into sprue former opening 54 .",
"In another embodiment, the top section includes a top plate for use with pressureless curing The top plate includes a slide valve (not shown) that is closed when curing without the injector module is desired by the operator.",
"The dental flask illustrated in FIG. 2 is constructed from material which is microwave conducting and which can withstand injection pressures of at least 3000 lbs.",
"Other embodiments of the flask of the invention include a flask for use with conduction heating which can withstand injection pressures of at least 3000 lbs.",
"and which is compatible with the injection methods of the invention.",
"The injector module 6 (used to inject the curable material into the appliance mold within the flask) is then assembled and attached to the reassembled flask 4 .",
"In the preferred embodiment of a microwavable flask 4 and injector module 6 as illustrated in FIG. 2 a, the injector module 6 includes a plate 68 , upon which is mounted a tubular injection cylinder 70 having a cavity 71 and with a plurality of bolt holes 44 in registry with those previously described.",
"The injection cylinder 70 and plate 68 further have an injection orifice (not shown) which is constructed to be in alignment with the sprue opening in the dental flask.",
"Disposed about the outside of the injection cylinder is a threaded pressure retaining band 72 .",
"The injection cylinder cavity 71 is designed to accommodate a solid cylindrical piston 74 , having a piston cap 76 with a patterned exterior edge ridge 78 , and top 80 and bottom 82 surfaces.",
"This piston 74 is fitted to be removably inserted into the injection cylinder cavity 71 up to the bottom surface 82 of the piston cap 76 .",
"The injection cylinder 70 may further includes a tubular pressure cap 84 with a substantially flat cover 86 , which includes a spring mechanism 85 and pressure retaining ring 90 which is threaded on the interior surface 92 to be compatible with the pressure retaining band 72 on the injection cylinder 70 .",
"The pressure cap 84 and the pressure retaining ring are used for curing under pressure, as illustrated in FIG. 2 .",
"At least one view hole 88 disposed in the side wall of the pressure cap 84 .",
"Disposed about the exterior surface of the pressure cap 84 is a pressure retaining ring 90 .",
"In another embodiment of the injector module used for pressureless curing, no pressure cap or pressure retaining ring are used.",
"In the embodiments described herein, the injector module is constructed of a metal which does not conduct microwaves.",
"The universal metal injector is a novel feature of the invention which may be used to inject material into both microwave flasks and conduction heating flasks, and may be used for pressured or pressureless curing.",
"If used with pressure cap 84 , the injector module applies continuous pressure and venting of the material during injection and either microwave or conduction heat cure, and holds the material in the injector in an uncured state while exposed to microwaves.",
"One preferred method of using the injection system to make molded dental appliances includes the steps of assembling the dental flask, creating an investment, or mold, for the desired appliance, attaching the injector module, preparing the curable material, injecting the curable material into the flask using the compression device of the invention, curing the curable material under pressure or without pressure, disassembling the flask and finally releasing the finished appliance.",
"The dental flask of the preferred embodiment illustrated in FIGS. 1-3 and 5 - 7 is assembled by first inserting knockout plate 50 into the bottom section 34 of dental flask 4 .",
"Investment material is then prepared according to known methods and placed into the cavity 46 of the bottom section 34 .",
"A cast and wax-up which have been formed in accordance with methods well known in the art are positioned in the assembled bottom cavity 46 of the bottom section 34 .",
"The center section 36 is then positioned upon the bottom section 34 such that the bolt holes 44 in each of the two sections are in registry.",
"Additional investment material is then added to the flask on top of the cast and wax-up.",
"Once the flask is filled with investment material, the flask is reassembled.",
"The reassambled flask may include either a top section for use with continuous pressurized injection during curing, or it may be reassembled with a top section for pressureless curing, as described above.",
"The top section 38 is then positioned such that the bolt holes 44 of the top section are in registry with the bolt holes 44 of the bottom and center sections ( 34 and 36 respectively).",
"Bolts 42 which extend from the top section into the bottom section of the flask are then inserted into the bolt holes and hand tightened.",
"Vent openings 52 and 56 allow excess investment to be released from the assembled flask upon tightening of the bolts 42 , which vent openings 52 and 56 subsequently become sealed by solidification of the investment material.",
"Prior to the hardening of the investment, the sprue former 62 is then positioned in the sprue former opening 54 such that the sprue former contacts the wax-up, thus forming the passage 63 in the investment material through which curable material is injected (as illustrated in FIG. 5 ).",
"Once the investment is hardened, the sprue former 62 is removed.",
"The cast and wax -up in the invested flask is then heated for a time sufficient to soften the wax.",
"The top section 38 then separated from the bottom 34 and center 36 sections and the wax is removed, leaving a cavity in the investment as shown in FIG. 5 .",
"This cavity forms the mold for the appliance which is subsequently filled with uncured material as described below.",
"The flask sections are then reassembled but not bolted.",
"In order to attach injector module 6 to reassembled flask 4 , the plate 68 with injection cylinder 70 is aligned with dental flask 4 so that bolt holes 44 in plate 68 are in registry with bolt holes 44 in dental flask 4 .",
"The bolts 42 are then inserted into bolt holes 44 and hand tightened.",
"The bolts are then tightened using press 2 and compression device 8 of the invention.",
"This step involves placing the dental flask 4 with attached plate 68 and injection cylinder 70 on platform 10 so that the cavity 71 of the injection cylinder 70 is facing the lower surface of the compression plate 12 .",
"The various controls on the compression device 8 are then used to raise the platform 10 and compress the flask so that the bolts 42 may be tightened.",
"Once platform 10 stops rising, bolts 42 are tightened, and platform 10 is lowered.",
"Once the dental flask 4 and injection cylinder 6 are assembled and bolted together as described above, the material may be prepared using the dispensing system of the invention.",
"The dispensing system illustrated in FIG. 4 depicts preparation of an acrylic resin material, and includes a powder dispenser 98 with lever 100 , a cup 102 , a funnel 104 , a funnel stand 106 , a stopper 108 , a liquid dispenser 110 with a lever 116 , and a container 96 , such as the bag illustrated in the preferred embodiment shown in FIGS. 4 d - 4 f. The dispensing system may also include an umbrella 112 , as shown in FIG. 6, which may be used to seal the container 96 .",
"The container 96 may be any container which will not degrade when filled with the material, which is capable of being closed and which is thin enough to allow the operator to assess through touch the consistence of the material.",
"The powder dispenser lever 100 is used to dispense a measured amount of polymer powder into the cup 102 .",
"(FIGS.",
"4 a and b ).",
"The powder is then poured into funnel 104 , a spout 118 of which is blocked by the stopper 108 , and which funnel 104 is held upright by use of the funnel stand 106 (FIG.",
"4 c ).",
"The container 96 is then disposed around a nozzle 114 of the liquid dispenser 110 , and an appropriate amount of liquid monomer is then dispensed into container 96 by movement of lever 116 (FIG.",
"4 d ).",
"The container 96 containing the liquid monomer is placed below funnel spout 118 and stopper 108 is removed, causing powder to flow into container 96 (FIG.",
"4 e ).",
"The top portion of the filled container 96 is then closed and the contents gently mixed by hand (FIG.",
"4 f ).",
"The use of the material dispensing apparatus and the method described above minimizes aerosolized powder and exposure to potentially harmful vapors, and reduces the risk of operator exposure to potentially harmful chemicals and vapors.",
"This particular embodiment illustrates preparation of an acrylic resin compound, but it is understood that any powder/liquid or liquid/liquid combination may be used with the dispensing apparatus of the invention, provided the material resulting from the mixed components is sufficiently viscous for use with the mold and injector module of the invention.",
"Once the container 96 containing the material is prepared, the filled container 96 is placed into the injection cylinder cavity 71 such that the empty top of container 96 extends out of the top of the injection cylinder 70 .",
"If an umbrella 112 is used, the top of the container 96 may then be threaded through an opening 116 in the umbrella 112 and the umbrella 112 pushed down until it reaches the material, as shown in FIG. 6, with the empty top of the container 96 extending through the opening 116 of umbrella 112 .",
"The top of the container is then folded and the filled container 96 is inserted into the cavity 71 of the injection cylinder 70 .",
"The injector piston 74 is then inserted into the injection cylinder cavity 71 , thus compressing the filled container 96 .",
"If the continuous pressure embodiment of the injector module is used, the pressure cap 84 is placed over the piston 74 , with the piston cap ridge 78 visible through the pressure cap view hole 88 .",
"The pressure retaining ring 90 is then disposed around the piston cap 76 , with the interior surface 92 of the ring 90 removably resting upon the lower rim 120 of the pressure cap.",
"In yet another embodiment of the system, the dispensing system may not be used and the material may be loaded directly into the injector module without use of a container.",
"The assembled dental flask 4 and filled injector module 6 are then placed on platform 10 of press 2 so that in the pressureless embodiment, the top of piston 74 is facing the lower surface of the compression plate 12 , and in the pressured embodiment, the top of pressure cap 86 is facing the lower surface of the compression plate 12 .",
"The compression device is then activated to cause injection of the material into the investment through the injection orifice in the injector module, by pressure applied to the injector module 6 and dental flask 4 .",
"In the continuous pressure embodiment of the invention, once the injection is substantially completed, the pressure retaining ring 90 is tightened about the pressure retaining band 72 , thus causing spring mechanism 85 to exert pressure on the piston 74 , which creates pressure in the dental flask 4 .",
"Upon completion of injection, the flask and injector module are removed from the press.",
"The pressurized dental flask 4 with attached injector module 6 is then cured, for instance by microwave as shown in FIG. 7 .",
"Until the point of cure (hardening) of the material, the pressure in the dental flask 4 allows for continued injection of uncured material at a constant pressure as necessary to fill void spaces within the investment without causing overfilling of the investment.",
"In addition, the continuous pressure exerted on the appliance minimizes distortion of the appliance due to shrinkage during polymerization, or cure, of the material.",
"In the pressureless injection system of the invention, the injection of material into the flask is as described above, but after injection, the slide valve on the top section of the flask is closed to seal the material within the flask, and the injector module 6 is removed.",
"The flask is then cured as described above.",
"After cure, the dental flask 4 is cooled.",
"In the pressurized embodiment, the pressure retaining ring 90 , pressure cap 86 , piston 74 and bag 96 are removed from the injection cylinder 70 prior to cooling.",
"The cured appliance is removed and finished in the conventional manner.",
"It should be understood that various changes and modifications to the preferred embodiments described herein will be apparent to those skilled in the art.",
"Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.",
"It is therefore intended that such changes and modifications be within the scope of the claims."
] |
This is a continuation-in-part of U.S. application. Ser. No. 06/933,170 filed Nov. 21, 1986, now U.S. Pat. No. 4,738,526, granted Apr. 21, 1988
BACKGROUND OF THE INVENTION
Portrait photography, to a significant extent, has depended upon the imagination of the photographer. A creative portrait photographer selects and captures qualities in and features of his or her subject that make the picture artistic rather than common place. Classically, the photographer positions the portrait subject in a multitude of poses and takes one or more proof negative photographs of each pose. Proof prints of each photo are then prepared and submitted to the subject for consideration. In a follow-up visit between the photographer and the portrait subject the proof prints are reviewed and selection is made with respect to one or more of the photos. Finally, the portrait subject receives finished prints and/or enlargements of the selected photo or photos. The entire portrait photography process is time consuming for both the photographer and the subject and, if a first set of proof prints does not yield an acceptable photo, the process of photography and preparation of proof prints must be repeated.
It is an object of the present invention to provide an improved system for accomplishing high quality portrait photography over a relatively short time period including a single photographer-subject photography session with final photo selection by the portrait subject.
It is a further object of the invention to provide an improved automated system for accomplishing high quality portrait photography during a single photographer-subject session including in-session selection of one or more photos by the portrait subject for finishing as photo prints and/or enlargements.
It is a still further object of the invention to provide an improved automated system for high quality portrait photography which permits subject photographing, photo pose selection and final print and/or enlargement within a period of approximately one hour.
It is yet another object of the invention to provide a unique method for accomplishing high quality portrait photography during a one-hour session in a photography studio including subject multiple frame photographing, photo pose comparison and selection and final print and/or enlargement production and delivery.
Other objects and advantages of the invention will be apparent from the following summary and detailed description of the invention, taken with the accompanying drawing.
SUMMARY OF THE INVENTION
The present invention relates to a method and system (including a unique arrangement of computer and photographic apparatus) for automated or computer-aided portrait photography. The method and system utilize a fully automatic, between-the-lens 35mm automatic camera including latest auto-wind, auto focus and auto-exposure features. A beam splitter behind the camera lens captures a part of the image-forming light reflected from the portrait subject to provide a video pickup charge coupled device (CCD) with an exact color video image of the subject as seen by the camera. On the outside of the camera housing a flat screen video viewfinder is provided which permits the operator (portrait photographer) to view the image which is being received by the video pickup device. The camera and overall system components are interfaced with and connected to a microprocessor and are controlled by the flash circuitry of the camera. When the operator is satisfied with the subject's appearance and pose (as seen through the video viewfinder), press-button action trips the camera shutter for exposure of a frame of film, actuates the flash circuitry of the camera firing flash lighting apparatus and directs (through the microprocessor) the electronic storage (via solid state memory) of a video image identical to the image captured by the camera film.
In accordance with the unique system of the invention, the stored video image can be outputed (by wireless transmission means) to a video portrait viewer (CRT screen) for subject viewing. The video portrait viewer can also be utilized as a means for displaying to the portrait subjects (particularly children) attention-getting images (static or live) of animals, toys, etc. during the pose preparation periods of portrait photographic sessions. In addition, the portrait viewer (via microprocessor direction) can be utilized to display a multiplicity of the captured (stored) video images (each representing a film frame) for subject comparison and selection. Thus, immediately following the taking of a number of portrait photographs, the entire group of stored video images can be displayed in sub-groups (2, 4, 6, etc. images), manipulated for side-by-side comparison and reduced in preference for final selection. The overall auto-portrait system of the invention may also include a color portrait printer (microprocessor directed) for the production of frame printouts as an aid in the photo proofing and selection process with the protrait subject.
The microprocessor is used to check out and direct all functions of the system including film loading, film advance, flash actuation, auto-focus, and image alignment and selection. With regard to the video portrait viewer and the one or more electronic flash units of the system, the microprocessor directs the wireless transmission of video image information to the viewer and flash actuation and timing information to the flash units.
The camera module also includes a slide projection unit for projecting appropriate background images and/or scenery against a high gain reflection screen positioned as a backdrop behind the portrait subject. In operation, the background images or scenery are projected onto the reflective front-coated surface of a beam slitter located within the camera in front of the camera lens and are thereby front projected to the reflection screen. Image-forming light reflected from the portrait subject and background light reflected from the screen enter the camera through its front opening, pass through the front beam splitter to and through the camera lens, and thereafter pass in part through the behind-the-lens beam splitter to the camera shutter and in part are reflected to the video pickup CCD device. The front projector includes means for bar code reading of slide identification and computer verification information that the slide used for background projection purposes is appropriate in accordance with desired photographic affects, as-well-as, a slide positioner so that the slide is correctly oriented.
The system and methodolgy of the present invention combines the latest automatic 35mm camera technology and microprocessor image information reception, manipulation, storage and regeneration technology for high quality automated or computer-aided, one-session, portrait photography, proofing and product delivery. Development of the portrait film and printing of selected photographic prints and enlargemants is carried out via well known high speed (one-hour or less) developing/printing apparatus and systems. The system also permits automated order processing and billing with printouts, as-well-as film frame and video frame image identification means.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will become apparent hereinafter from the following detailed description of the invention taken in conjunction with the accompanying drawings wherein:
FIG. 1 comprises a top view of the layout of equipment utilized and interacting to accomplish automated portrait photography as a system in accordance with the invention together with block diagramatic presention of the relationships of internal equipment components and functions of the principal items of equipment of the system;
FIG. 2 is a side sectional schematic representation of the camera module utilized inthe automated, computer-aided portrait photographic system of the invention;
FIG. 3 is an enlarged side sectional view of the front projector portion of the camera module of FIG. 2;
FIG. 4 is a top view of the rotatable slide table of the front projector portion of the camera module;
FIG. 5 is a top plan view of a background or scenery slide mount designed for use with the front projector of the camera module in accordance with the invention; and
FIG. 6 is an underside view of the background slide mount of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, a preferred embodiment of the invention is illustrated in FIG. 1 and includes a layout of equipment utilized and interacting for automated portrait photography as a system together with a block diagramatic showing of the relationship of the principal equipment modules and their components and functions. Numeral 8 represents in general an auto-portrait studio according to the invention. The studio consists of basic equipment components including: camera module 10, microprocessor 40, wireless video portrait viewer 50, wireless lighting units 60, a computer-directed printer 70 and a high reflection backdrop screen 80. These equipment components, as situated in FIG. 1, are centered about a portrait subject S located in front of reflection screen 80 facing the camera module 10 and in viewing alignment with the video portrait viewer 50. As shown in FIG. 1, the microprocessor 40 is positioned below the camera module 10.
The camera module 10 is shown in the side sectional schematic representation of the module in FIG. 2. The camera 11, located within camera module housing 12, is an automatic 35mm long length camera including latest auto-wind, auto-focus and auto-exposure features. The camera also includes as basic components: film compartment 13 including a bulk film delivery cartridge 14, film 15 and a film take-up cartridge 16; shutter mechanism 17; and front camera lens L 1 . Built into the camera structure (behind the lens L 1 ) is a beam splitter 18 which is essentially a flat glass lens which is silver coated on its front surface 18a. The beam splitter 18 is positioned to receive image-forming light (passing through camera lens L 1 ) and reflect a part of the image-forming light through a fiied lens L 2 to a mirror 20 and through relay lens L 3 to a video pickup or CCD array device 21. The principal portion of the image-forming light (passing through lens L 1 ) passes through the beam splitter 18 and (upon the opening of shutter 17) is received by film 15 with the image captured thereon by the film's light-sensitive coating.
The camera module 10 is also specially equipped with a built-in front projector 22 which includes a tungsten halide previewing lamp 23a and an electronic discharge flash lamp 23b which fully illuminates a 35mm slide 24 of background or scenery subject matter at the instant of film exposure. The slide subject matter is projected through projector lens L 4 to a beam splitter 25 which is silver coated on its front surface 25a. The beam splitter 25 is positioned to receive the background (scenery) image-forming light and reflect same through the front opening 26 of the camera module 10 for projection to the reflection backdrop screen 80 situated behind the portrait subject (see FIG. 1). The background image-forming light is reflected back from the screen 80 to the front opening 26 of the camera module 10 and, together with the image-forming light from the portrait subject S, passes: through the beam splitter 25; to and through camera lens L 1 ; and to and through (in part) the behind-the-lens beam splitter 18. As previously indicated, a part of the image-forming light from the portrait subject and a part of the background (scenery) image-forming light is reflected by beam splitter 18 through field lens L 2 to mirror 20 and through relay lens L 3 to the video pickup CCD device 21.
The front projector 22 is designed to accept only specially prepared slide mounts for the portrait background (scenery) slides. Thus, each slide mount 27 (see FIGS. 5 and 6) for each slide 24 has a single eccentrically rounded corner 27a and a bar code strip 27b on the underside of mount 27 (see FIG. 6). As shown in FIG. 3, the front projector 22 includes a slide verifier section 28 with a built-in bar code reading device 28a for reading the bar code strips 27b on slide mounts 27 through reader port 28b of verifier section 28. A selection of background slides 24 are carried by a rotatable slide table 29 (see FIGS. 3 and 4) which includes a central hub portion 30 around which the slides 24 are positioned over table ports 29a on support ledges 29b which surround the ports 29a. The inner course of each support ledge 29b includes a reader port 30a which, upon rotation of slide table 29 to position a slide over projection lamps 23a and 23b of the projector 22 in alignment with projector lens L 4 , corresponds with reader port 28b of the slide verifiear section 28 and permits the reading of the bar code strip 27b on the underside of the slide. The rotatable slide table 29 is mounted to the upper wall 22a of the front projector 22 by a pivot connector 31. The rotation of slide table 29 of the front projector may be by hand by the camera operator or may be accomplished by an electrical drive mechanism (not shown) as directed by keyboard instruction of the microprocessor associated with the camera in the auto-portrait system. The focusing of lens L 4 of the front projector may also be directed by keyboard and microprocessor control.
The camera module 10 (as shown in FIG. 1) has as part of its structure, on the outside of housing 12, a flat screen video viewfinder 33. Alternatively the viewfinder 33 may be a handheld unit with video screen and limited keyboard interconnected to the camera module and microprocessor by appropriate electric cable or by wireless communication. The video viewfinder 33, under microprocessor control and direction in cooperation with the camera's video pickup CCD device 21, permits the operator (portrait photographer) to see the image of the portrait subject as viewed by the camera 11 prior to the firing of the camera to expose a frame of film. Through the video viewfinder the operator can direct adjustment of the subject's pose position and expression. The camera's internal battery power supply and operating circuitry drive all functions of the camera including the electronic exposure flash unit 23b of the front projector 22. Activation of the camera circuitry functions, along with other functions of the interrelated microprocessor 40, wireless video video portrait viewer 50 and wireless lighting system 60, for accomplishing auto-portrait photography in accordance with the invention, are initiated by push button 32 of the camera module 10.
The microprocessor 40 of the present auto-portrait system may be of any of the well-known commercially available types. It is used in the system, through its interface with the camera module 10, to check and control all camera control functions 41 including film loading and rewind, film advance, electronic flash, front projector operation and auto-focus. The microprocessor 40 also acts and interacts within the auto-portrait system to provide lighting control 42 and to receive the output of the camera's video pickup CCD device 21. Thus, the portrait subject's image a seen by the video pickup device of the camera is relayed to the video viewfinder 33 of the camera for operator viewing and, upon activation of the camera circuitry (shutter opening and film capture of a portrait photograph on film), the subject's portrait video image is captured by the microprocessor's memory store 43. Upon operator direction (through an infrared keyboard arrangement, not show) the portrait video image may be retrieved from the microprocessor's memory store and displayed by wireless (or cable) transmission on the CRT screen of the video portrait viewer 50. Display on the viewer 50 may be as a single full-screen portrait image (viewer funtion 51) or in a multiple display arrangement (viewer function 52) at reduced size along with other portrait images captured during the photographic portrait session for comparison and selection purposes. During multiple display, the several images may be shifted in their display arrangement and reduced in number as the selection process proceeds.
The microprocessor 40 also receives for storage, retrieval and display purposes (under keyboard direction), via the portrait viewer 50, single images or video tape live images and programs for gaining the attention of the protrait subject and for promoting special photographic expressions from children (subject pleaser function 53) during child portrait photography sessions. As previously indicated, the transmission of a single captured video image (function 51), multiple displayed images (function 52) or subject pleaser imagery (function 53) may be by wireless transmission (function 44) under the direction of the operator via the microprocessor. The wireless transmission systems involve the use of a transmitting antenna T associated with the microprocessor and a receiving antenna R 1 associated with the video portrait viewer 50. Alternatively, the transmission of imagery may also be conducted by direct cable connection between the microprocessor 40 and the video portrait viewer 50.
Film roll and frame identification date, corresponding video image identification and retrieval information, and customer order processing and billing information (function 45) is also handled by the microprocessor 40 and ordered out or printed out through operator keyboard direction. Thus, video images captured during the photography session can be printed out for comparison and selection purposes via electronic printer 70 and the order processing and billing information is generated by the same printer at the conclusion of the session.
The auto-portrait system of the invention also includes special lighting apparatus 60. The lighting apparatus, as shown in FIG. 1, comprises compact rechargeab;e flash lighting (function 61), fired by remote control through the wireless transmission of light firing signals under microprocessor direction. The subject lighting units 60 have built in spill-control louvers which reduce or eliminate background pickup and assure professional lighting with a minimum of lighting expertise on the part of the operator. Although cable connection between the electronic flash devices 61 and the microprocessor is entirely within the realm of the autoportrait system, wireless control through the mechanism of transmission antenna T and reception antennae R 2 at the light stations is preferred so that floor areas between the microprocessor 40 and the lighting units 60 are free of communication cables. The same non-obstruction philosophy applies with respect to communication between the microprocessor and the video portrait viewer 50. As previously indicated, the screen 80, which acts as a backdrop with respect to camera-subject alignment for receiving projected background and scenery, has a high reflection surface. Although the camera module has its own internal power source via batteries (expendable or rechargeable), the microprocessor 40 is provided with its power via power line 37. Where wireless lighting 60 is provided, the electronic flash units 61 included in such lighting are energized by rechargeable batteries.
In operation of the auto-portrait photo studio of the present invention, the portrait subject is positioned appropriatel in alignment with the camera module 10 in front of the reflective background screen 80. Usually the portrait subject will be seated for subject comfort and for ease in promoting appropriate pose orientation and development of a pleasing expression. Through operator (portrait photographer) control the camera module 10 is aligned properly with the portrait subject and determination is made as to the nature of the background scenery to be utilized. Subject alignment of the camera module is accomplished by the operator's viewing of the portrait subject through the video view finder 33 associated with the camera module. The subject's attention is held or attracted to the video portrait viewer 50 in accordance with instructions and imagery or programmed video material generated by the microprocessor 40 by operator command and inputted by keyboard operation.
At the time of operator decision as to desired subject pos and expression, the push-button 32 of the camera is depressed whereby the camera circuitry (in cooperation with the microprocessor): (i) actuates the flash projection of background scenery to background screen 80 by the front projector 22 of the camera; (ii) actuates flash lighting of the portrait subject by electronic flash units 60; (iii) opens the shutter 17 of the camera for the admission of image-forming light from the portrait subject to the light-sensitive surface of a film frame within the camera; and (iv) simultaneously records within the microprocessor's memory a video image of the portrait subject as picked up by the video charged coupled device 21 of the camera in sequence from the behind-the-lens beam splitter 18, field lens L 2 , mirror 20 and relay lens L 3 . The video image captured by the microprocessor is an exact replica of the photographic image of the portrait subject captured on a frame of the ftured by the microprocessor is an exact replica of the photographic image of the portrait subject captured on a frame of the film within the camera. In accordance with the invention, the captured video image can be retrieved from the microprocessor's memory store for manipulation, display and/or printout as required by the operator and in accordance with the portrait subject's desire. Thus, the entire process of portrait photography, including proof review and selection, can be accomplished in a matter of minutes by the system of the present invention. Coupled with the technology and equipment of fast film development and printing (one hour or less, the entire portrait photography process, as automated by the invention, can be accomplished in an extremely short period of time with delivery of high quality prints and enlargements to the portrait subject in less than several hours from the time of commencement of the portrait photography session.
While the invention has been described in connection with particular structural embodiments of an auto-portrait studio and camera module, variances and modifications in the embodiments will be apparent to those skilled in the art. Accordingly, such modifications are to be included within the spirit and scope of the invention sa defined by the following claims. | A dual function electronic recording portrait camera that divides the image-forming light reflected from a portrait subject and received through the front lens of the camera into a first optical image portion which passed, upon shutter opening, to a frame of photographic film for recording thereon as a photographic image and into a second optical image portion which is passed to a video charge coupled device with an electronic image array for conversion to an electronic image. The electronic image is viewed before and at the instant of shutter opening through a video display unit associated with the camera and the electronic image is recorded in the memory of a microprocessor associated with the camera at the instant of shutter opening. The recorded electronic image corresponds exactly to the photographic image recorded on film and the electronic image may be recalled from the memory of the microprocessor for video display and review by the camera operator and the portrait subject. Based upon the review of a number of video-displayed, electronically-recorded poses of the portrait subject, selection of one or more preferred poses can be made prior to development of film containing frames of photographic images corresponding exactly to the displayed electronic images. | Briefly describe the main idea outlined in the provided context. | [
"This is a continuation-in-part of U.S. application.",
"Ser.",
"No. 06/933,170 filed Nov. 21, 1986, now U.S. Pat. No. 4,738,526, granted Apr. 21, 1988 BACKGROUND OF THE INVENTION Portrait photography, to a significant extent, has depended upon the imagination of the photographer.",
"A creative portrait photographer selects and captures qualities in and features of his or her subject that make the picture artistic rather than common place.",
"Classically, the photographer positions the portrait subject in a multitude of poses and takes one or more proof negative photographs of each pose.",
"Proof prints of each photo are then prepared and submitted to the subject for consideration.",
"In a follow-up visit between the photographer and the portrait subject the proof prints are reviewed and selection is made with respect to one or more of the photos.",
"Finally, the portrait subject receives finished prints and/or enlargements of the selected photo or photos.",
"The entire portrait photography process is time consuming for both the photographer and the subject and, if a first set of proof prints does not yield an acceptable photo, the process of photography and preparation of proof prints must be repeated.",
"It is an object of the present invention to provide an improved system for accomplishing high quality portrait photography over a relatively short time period including a single photographer-subject photography session with final photo selection by the portrait subject.",
"It is a further object of the invention to provide an improved automated system for accomplishing high quality portrait photography during a single photographer-subject session including in-session selection of one or more photos by the portrait subject for finishing as photo prints and/or enlargements.",
"It is a still further object of the invention to provide an improved automated system for high quality portrait photography which permits subject photographing, photo pose selection and final print and/or enlargement within a period of approximately one hour.",
"It is yet another object of the invention to provide a unique method for accomplishing high quality portrait photography during a one-hour session in a photography studio including subject multiple frame photographing, photo pose comparison and selection and final print and/or enlargement production and delivery.",
"Other objects and advantages of the invention will be apparent from the following summary and detailed description of the invention, taken with the accompanying drawing.",
"SUMMARY OF THE INVENTION The present invention relates to a method and system (including a unique arrangement of computer and photographic apparatus) for automated or computer-aided portrait photography.",
"The method and system utilize a fully automatic, between-the-lens 35mm automatic camera including latest auto-wind, auto focus and auto-exposure features.",
"A beam splitter behind the camera lens captures a part of the image-forming light reflected from the portrait subject to provide a video pickup charge coupled device (CCD) with an exact color video image of the subject as seen by the camera.",
"On the outside of the camera housing a flat screen video viewfinder is provided which permits the operator (portrait photographer) to view the image which is being received by the video pickup device.",
"The camera and overall system components are interfaced with and connected to a microprocessor and are controlled by the flash circuitry of the camera.",
"When the operator is satisfied with the subject's appearance and pose (as seen through the video viewfinder), press-button action trips the camera shutter for exposure of a frame of film, actuates the flash circuitry of the camera firing flash lighting apparatus and directs (through the microprocessor) the electronic storage (via solid state memory) of a video image identical to the image captured by the camera film.",
"In accordance with the unique system of the invention, the stored video image can be outputed (by wireless transmission means) to a video portrait viewer (CRT screen) for subject viewing.",
"The video portrait viewer can also be utilized as a means for displaying to the portrait subjects (particularly children) attention-getting images (static or live) of animals, toys, etc.",
"during the pose preparation periods of portrait photographic sessions.",
"In addition, the portrait viewer (via microprocessor direction) can be utilized to display a multiplicity of the captured (stored) video images (each representing a film frame) for subject comparison and selection.",
"Thus, immediately following the taking of a number of portrait photographs, the entire group of stored video images can be displayed in sub-groups (2, 4, 6, etc.",
"images), manipulated for side-by-side comparison and reduced in preference for final selection.",
"The overall auto-portrait system of the invention may also include a color portrait printer (microprocessor directed) for the production of frame printouts as an aid in the photo proofing and selection process with the protrait subject.",
"The microprocessor is used to check out and direct all functions of the system including film loading, film advance, flash actuation, auto-focus, and image alignment and selection.",
"With regard to the video portrait viewer and the one or more electronic flash units of the system, the microprocessor directs the wireless transmission of video image information to the viewer and flash actuation and timing information to the flash units.",
"The camera module also includes a slide projection unit for projecting appropriate background images and/or scenery against a high gain reflection screen positioned as a backdrop behind the portrait subject.",
"In operation, the background images or scenery are projected onto the reflective front-coated surface of a beam slitter located within the camera in front of the camera lens and are thereby front projected to the reflection screen.",
"Image-forming light reflected from the portrait subject and background light reflected from the screen enter the camera through its front opening, pass through the front beam splitter to and through the camera lens, and thereafter pass in part through the behind-the-lens beam splitter to the camera shutter and in part are reflected to the video pickup CCD device.",
"The front projector includes means for bar code reading of slide identification and computer verification information that the slide used for background projection purposes is appropriate in accordance with desired photographic affects, as-well-as, a slide positioner so that the slide is correctly oriented.",
"The system and methodolgy of the present invention combines the latest automatic 35mm camera technology and microprocessor image information reception, manipulation, storage and regeneration technology for high quality automated or computer-aided, one-session, portrait photography, proofing and product delivery.",
"Development of the portrait film and printing of selected photographic prints and enlargemants is carried out via well known high speed (one-hour or less) developing/printing apparatus and systems.",
"The system also permits automated order processing and billing with printouts, as-well-as film frame and video frame image identification means.",
"BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other objects, features and advantages of the invention will become apparent hereinafter from the following detailed description of the invention taken in conjunction with the accompanying drawings wherein: FIG. 1 comprises a top view of the layout of equipment utilized and interacting to accomplish automated portrait photography as a system in accordance with the invention together with block diagramatic presention of the relationships of internal equipment components and functions of the principal items of equipment of the system;",
"FIG. 2 is a side sectional schematic representation of the camera module utilized inthe automated, computer-aided portrait photographic system of the invention;",
"FIG. 3 is an enlarged side sectional view of the front projector portion of the camera module of FIG. 2;",
"FIG. 4 is a top view of the rotatable slide table of the front projector portion of the camera module;",
"FIG. 5 is a top plan view of a background or scenery slide mount designed for use with the front projector of the camera module in accordance with the invention;",
"and FIG. 6 is an underside view of the background slide mount of FIG. 5. DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings, a preferred embodiment of the invention is illustrated in FIG. 1 and includes a layout of equipment utilized and interacting for automated portrait photography as a system together with a block diagramatic showing of the relationship of the principal equipment modules and their components and functions.",
"Numeral 8 represents in general an auto-portrait studio according to the invention.",
"The studio consists of basic equipment components including: camera module 10, microprocessor 40, wireless video portrait viewer 50, wireless lighting units 60, a computer-directed printer 70 and a high reflection backdrop screen 80.",
"These equipment components, as situated in FIG. 1, are centered about a portrait subject S located in front of reflection screen 80 facing the camera module 10 and in viewing alignment with the video portrait viewer 50.",
"As shown in FIG. 1, the microprocessor 40 is positioned below the camera module 10.",
"The camera module 10 is shown in the side sectional schematic representation of the module in FIG. 2. The camera 11, located within camera module housing 12, is an automatic 35mm long length camera including latest auto-wind, auto-focus and auto-exposure features.",
"The camera also includes as basic components: film compartment 13 including a bulk film delivery cartridge 14, film 15 and a film take-up cartridge 16;",
"shutter mechanism 17;",
"and front camera lens L 1 .",
"Built into the camera structure (behind the lens L 1 ) is a beam splitter 18 which is essentially a flat glass lens which is silver coated on its front surface 18a.",
"The beam splitter 18 is positioned to receive image-forming light (passing through camera lens L 1 ) and reflect a part of the image-forming light through a fiied lens L 2 to a mirror 20 and through relay lens L 3 to a video pickup or CCD array device 21.",
"The principal portion of the image-forming light (passing through lens L 1 ) passes through the beam splitter 18 and (upon the opening of shutter 17) is received by film 15 with the image captured thereon by the film's light-sensitive coating.",
"The camera module 10 is also specially equipped with a built-in front projector 22 which includes a tungsten halide previewing lamp 23a and an electronic discharge flash lamp 23b which fully illuminates a 35mm slide 24 of background or scenery subject matter at the instant of film exposure.",
"The slide subject matter is projected through projector lens L 4 to a beam splitter 25 which is silver coated on its front surface 25a.",
"The beam splitter 25 is positioned to receive the background (scenery) image-forming light and reflect same through the front opening 26 of the camera module 10 for projection to the reflection backdrop screen 80 situated behind the portrait subject (see FIG. 1).",
"The background image-forming light is reflected back from the screen 80 to the front opening 26 of the camera module 10 and, together with the image-forming light from the portrait subject S, passes: through the beam splitter 25;",
"to and through camera lens L 1 ;",
"and to and through (in part) the behind-the-lens beam splitter 18.",
"As previously indicated, a part of the image-forming light from the portrait subject and a part of the background (scenery) image-forming light is reflected by beam splitter 18 through field lens L 2 to mirror 20 and through relay lens L 3 to the video pickup CCD device 21.",
"The front projector 22 is designed to accept only specially prepared slide mounts for the portrait background (scenery) slides.",
"Thus, each slide mount 27 (see FIGS. 5 and 6) for each slide 24 has a single eccentrically rounded corner 27a and a bar code strip 27b on the underside of mount 27 (see FIG. 6).",
"As shown in FIG. 3, the front projector 22 includes a slide verifier section 28 with a built-in bar code reading device 28a for reading the bar code strips 27b on slide mounts 27 through reader port 28b of verifier section 28.",
"A selection of background slides 24 are carried by a rotatable slide table 29 (see FIGS. 3 and 4) which includes a central hub portion 30 around which the slides 24 are positioned over table ports 29a on support ledges 29b which surround the ports 29a.",
"The inner course of each support ledge 29b includes a reader port 30a which, upon rotation of slide table 29 to position a slide over projection lamps 23a and 23b of the projector 22 in alignment with projector lens L 4 , corresponds with reader port 28b of the slide verifiear section 28 and permits the reading of the bar code strip 27b on the underside of the slide.",
"The rotatable slide table 29 is mounted to the upper wall 22a of the front projector 22 by a pivot connector 31.",
"The rotation of slide table 29 of the front projector may be by hand by the camera operator or may be accomplished by an electrical drive mechanism (not shown) as directed by keyboard instruction of the microprocessor associated with the camera in the auto-portrait system.",
"The focusing of lens L 4 of the front projector may also be directed by keyboard and microprocessor control.",
"The camera module 10 (as shown in FIG. 1) has as part of its structure, on the outside of housing 12, a flat screen video viewfinder 33.",
"Alternatively the viewfinder 33 may be a handheld unit with video screen and limited keyboard interconnected to the camera module and microprocessor by appropriate electric cable or by wireless communication.",
"The video viewfinder 33, under microprocessor control and direction in cooperation with the camera's video pickup CCD device 21, permits the operator (portrait photographer) to see the image of the portrait subject as viewed by the camera 11 prior to the firing of the camera to expose a frame of film.",
"Through the video viewfinder the operator can direct adjustment of the subject's pose position and expression.",
"The camera's internal battery power supply and operating circuitry drive all functions of the camera including the electronic exposure flash unit 23b of the front projector 22.",
"Activation of the camera circuitry functions, along with other functions of the interrelated microprocessor 40, wireless video video portrait viewer 50 and wireless lighting system 60, for accomplishing auto-portrait photography in accordance with the invention, are initiated by push button 32 of the camera module 10.",
"The microprocessor 40 of the present auto-portrait system may be of any of the well-known commercially available types.",
"It is used in the system, through its interface with the camera module 10, to check and control all camera control functions 41 including film loading and rewind, film advance, electronic flash, front projector operation and auto-focus.",
"The microprocessor 40 also acts and interacts within the auto-portrait system to provide lighting control 42 and to receive the output of the camera's video pickup CCD device 21.",
"Thus, the portrait subject's image a seen by the video pickup device of the camera is relayed to the video viewfinder 33 of the camera for operator viewing and, upon activation of the camera circuitry (shutter opening and film capture of a portrait photograph on film), the subject's portrait video image is captured by the microprocessor's memory store 43.",
"Upon operator direction (through an infrared keyboard arrangement, not show) the portrait video image may be retrieved from the microprocessor's memory store and displayed by wireless (or cable) transmission on the CRT screen of the video portrait viewer 50.",
"Display on the viewer 50 may be as a single full-screen portrait image (viewer funtion 51) or in a multiple display arrangement (viewer function 52) at reduced size along with other portrait images captured during the photographic portrait session for comparison and selection purposes.",
"During multiple display, the several images may be shifted in their display arrangement and reduced in number as the selection process proceeds.",
"The microprocessor 40 also receives for storage, retrieval and display purposes (under keyboard direction), via the portrait viewer 50, single images or video tape live images and programs for gaining the attention of the protrait subject and for promoting special photographic expressions from children (subject pleaser function 53) during child portrait photography sessions.",
"As previously indicated, the transmission of a single captured video image (function 51), multiple displayed images (function 52) or subject pleaser imagery (function 53) may be by wireless transmission (function 44) under the direction of the operator via the microprocessor.",
"The wireless transmission systems involve the use of a transmitting antenna T associated with the microprocessor and a receiving antenna R 1 associated with the video portrait viewer 50.",
"Alternatively, the transmission of imagery may also be conducted by direct cable connection between the microprocessor 40 and the video portrait viewer 50.",
"Film roll and frame identification date, corresponding video image identification and retrieval information, and customer order processing and billing information (function 45) is also handled by the microprocessor 40 and ordered out or printed out through operator keyboard direction.",
"Thus, video images captured during the photography session can be printed out for comparison and selection purposes via electronic printer 70 and the order processing and billing information is generated by the same printer at the conclusion of the session.",
"The auto-portrait system of the invention also includes special lighting apparatus 60.",
"The lighting apparatus, as shown in FIG. 1, comprises compact rechargeab;e flash lighting (function 61), fired by remote control through the wireless transmission of light firing signals under microprocessor direction.",
"The subject lighting units 60 have built in spill-control louvers which reduce or eliminate background pickup and assure professional lighting with a minimum of lighting expertise on the part of the operator.",
"Although cable connection between the electronic flash devices 61 and the microprocessor is entirely within the realm of the autoportrait system, wireless control through the mechanism of transmission antenna T and reception antennae R 2 at the light stations is preferred so that floor areas between the microprocessor 40 and the lighting units 60 are free of communication cables.",
"The same non-obstruction philosophy applies with respect to communication between the microprocessor and the video portrait viewer 50.",
"As previously indicated, the screen 80, which acts as a backdrop with respect to camera-subject alignment for receiving projected background and scenery, has a high reflection surface.",
"Although the camera module has its own internal power source via batteries (expendable or rechargeable), the microprocessor 40 is provided with its power via power line 37.",
"Where wireless lighting 60 is provided, the electronic flash units 61 included in such lighting are energized by rechargeable batteries.",
"In operation of the auto-portrait photo studio of the present invention, the portrait subject is positioned appropriatel in alignment with the camera module 10 in front of the reflective background screen 80.",
"Usually the portrait subject will be seated for subject comfort and for ease in promoting appropriate pose orientation and development of a pleasing expression.",
"Through operator (portrait photographer) control the camera module 10 is aligned properly with the portrait subject and determination is made as to the nature of the background scenery to be utilized.",
"Subject alignment of the camera module is accomplished by the operator's viewing of the portrait subject through the video view finder 33 associated with the camera module.",
"The subject's attention is held or attracted to the video portrait viewer 50 in accordance with instructions and imagery or programmed video material generated by the microprocessor 40 by operator command and inputted by keyboard operation.",
"At the time of operator decision as to desired subject pos and expression, the push-button 32 of the camera is depressed whereby the camera circuitry (in cooperation with the microprocessor): (i) actuates the flash projection of background scenery to background screen 80 by the front projector 22 of the camera;",
"(ii) actuates flash lighting of the portrait subject by electronic flash units 60;",
"(iii) opens the shutter 17 of the camera for the admission of image-forming light from the portrait subject to the light-sensitive surface of a film frame within the camera;",
"and (iv) simultaneously records within the microprocessor's memory a video image of the portrait subject as picked up by the video charged coupled device 21 of the camera in sequence from the behind-the-lens beam splitter 18, field lens L 2 , mirror 20 and relay lens L 3 .",
"The video image captured by the microprocessor is an exact replica of the photographic image of the portrait subject captured on a frame of the ftured by the microprocessor is an exact replica of the photographic image of the portrait subject captured on a frame of the film within the camera.",
"In accordance with the invention, the captured video image can be retrieved from the microprocessor's memory store for manipulation, display and/or printout as required by the operator and in accordance with the portrait subject's desire.",
"Thus, the entire process of portrait photography, including proof review and selection, can be accomplished in a matter of minutes by the system of the present invention.",
"Coupled with the technology and equipment of fast film development and printing (one hour or less, the entire portrait photography process, as automated by the invention, can be accomplished in an extremely short period of time with delivery of high quality prints and enlargements to the portrait subject in less than several hours from the time of commencement of the portrait photography session.",
"While the invention has been described in connection with particular structural embodiments of an auto-portrait studio and camera module, variances and modifications in the embodiments will be apparent to those skilled in the art.",
"Accordingly, such modifications are to be included within the spirit and scope of the invention sa defined by the following claims."
] |
[0001] This application is a continuation of U.S. patent application Ser. No. 14/733,774, filed Jun. 8, 2015, which is a continuation of U.S. patent application Ser. No. 13/806,834, filed Mar. 18, 2013 (now U.S. Pat. No. 9,059,532), which is a 371 nationalization of Application No. PCT/IS2011/050010 filed Jun. 24, 2011, which claims the benefit of priority of U.S. Provisional Application No. 61/358,472, filed Jun. 25, 2010, the entirety of which are each incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is within the field of medical devices, in particular biometric devices for measuring biosignals, and relates particularly to electrodes for such devices and in particular electrode belts and connectors for such belts.
BACKGROUND
[0003] Electrode belts are known, both for direct contact galvanic electrodes for measure cardiography signals and inductive belts used in respiratory inductive plethysmography. Prior art belts have various types of connectors, for transmitting the received signal to the respective device. There remains a need for improved belt connectors that are reliable and easy to use and maintain.
SUMMARY
[0004] The disclosure provides a belt connector for electrically connecting an electrode belt to a biometric device to be carried on a human or animal body. The belt connector is preferably made from one single piece which can be economically manufactured in order to function as a single-use consumable, to be used with a matching biometric device. The belt connector comprises a molded plastic frame having a front side and a rear side, the frame having a receiving hole, having radial flexibility to function as a female snap button fastener for receiving and fastening on the front side of the frame a male snap protrusion. The belt connector further comprises fastening means for fastening to the frame a belt end of the electrode belt, and a member adjacent to the snap fastener receiving hole to engage an electrode wire end electrically connected to the belt such that the wire end is in electrical contact with the hole, either by extending into the hole or coming in electrical contact e.g. through a bridging conductor, with a conducting male snap fastener inserted in the receiving hole.
[0005] The belt connector and belt should be configured such that a person wearing the belt under operation is insulated from current running through the belt, in order to meet existing standards for medical devices. The belt connector of the present disclosure is configured accordingly, and in a preferred embodiment, the belt connector comprises a shield member which is arranged on the rear side of the frame to electrically shield the wire end from the rear side exterior of the belt connector.
[0006] The belt connector preferably comprises a cover enclosing the connector and wire end. The cover may suitably include a pre-perforated hole overlapping the hole of the frame, or in other embodiments is made from such material that can readily be perforated by pressing the connector onto a male fastener which fits the receiving hole of the frame.
[0007] The belt end is fixedly engaged with the connector and the electrode wire connected to the connector such that the electrode wire is in electrical contact with the female snap fastener hole and thereby comes in electrical contact with a conducting male snap fastener inserted in the hole.
[0008] Preferably the belt end is engaged with the connector in a fashion allowing adjustment of the length of the belt.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIGS. 1A, 1B, 1C, and 1D illustrate a belt connector according to a first embodiment.
[0010] FIG. 1A shows a prospective top view according to the first embodiment.
[0011] FIG. 1B shows a prospective bottom view according to the first embodiment.
[0012] FIG. 1C shows a top plan view according to the first embodiment.
[0013] FIG. 1D shows a bottom plan view according to the first embodiment.
[0014] FIGS. 2A, 2B, and 2C illustrate a belt connector and connected belt according to a second embodiment.
[0015] FIG. 2A shows a prospective top view according to the second embodiment.
[0016] FIG. 2B shows a prospective bottom view according to the second embodiment.
[0017] FIG. 2C shows a prospective top view according to the second embodiment.
[0018] FIG. 3A shows a top plan view according to another embodiment.
[0019] FIG. 3B shows a prospective top view according to the embodiment of FIG. 3A .
DETAILED DESCRIPTION
[0020] The disclosed belt connector is suitable for various types of electrode belts, such as for cardiographic measurements, both in clinical settings or for training purposes, but also for belts such as RIP (respiratory inductive plethysmography) belts.
[0021] As mentioned above, the belt connector is intended for electrically connecting an electrode belt to a biometric device, the term biometric device in this context includes any devices for receiving electrical biosignals as well as extension cables, intermediate devices, connecting boxes, etc. or other means for receiving and transmitting the biosignals.
[0022] The belt connector is preferably made from any of various suitable non-conducting plastic materials, such as but not limited to ABS (acrylonitrile butadiene styrene), PC/ABS, polyethylene, e.g. low density polyethylene (LDPE) or high density polyethylene (HDPE), or derivatives such as polyethylene terephthalate (PET) or polyfluoroethylene (PTFE), or more preferably polypropylene, polyvinyl chloride, or polyamide (nylon). In other embodiments the connector is made from paper based material or other material from natural fibers.
[0023] The electrode belt is generally a flexible belt such as commonly used in respiratory inductance plethysmography (RIP) devices today. Such electrode belt is preferably a flexible textile belt where an electrode wire is interwoven in the belt or can be laminated between two layers, typically in a zig-zag fashion to allow longitudinal elasticity.
[0024] The molded frame of the connector has a front side and a rear side, which are defined as follows: the front side of the frame faces the biometric device which is fastened onto the connector for operation and the rear side faces away from the device. In the presently preferred embodiment the rear side of the connector faces the body of the patient when mounted, i.e. the belt connector comes between the patient and the biometric device. However, the biometric device can also be configured such that the device faces the patient and the belt connectors lie on top of the device, i.e. connect to the device on the face of the device facing away from the patient, thus in such embodiment the front side of the connectors face the patient and the rear side face away from the patient.
[0025] The frame has a receiving hole with radial flexibility to function as a female snap button fastener for receiving and fastening on the front side of the frame a male snap protrusion. A mating biometric device will thus have a corresponding mating male snap fastener which can be fastened securely onto the belt connector. The hole can preferably be shaped circular or semi-circular but may in other embodiments have any other suitable shape, such as a general elongated shape shaped by two parallel members, suitably including guiding members to ensure proper positioning of the mating male snap member, a square opening, or the like.
[0026] The radial flexibility of the hole can in one embodiment be achieved by one or more slot extending from the hole. The embodiment shown if FIGS. 1 and 2 shows two slots extending across from each other in the belt direction. The one or more slot are preferably formed by at least one elongated member having flexibility transverse to its longitudinal axis (e.g. by being sufficiently thin), thus imparting flexibility to the width of the hole. Preferably the hole is between two elongated members where one or both have sufficient and suitable flexibility to provide a snap fastener hole with suitable fastening strength.
[0027] As mentioned, the belt connector comprises a member adjacent to the snap fastener receiving hole to engage an electrode wire coming from the belt end. This wire must come in electrical contact with the receiving hole, either by extending into the hole or coming in electrical contact with the hole e.g. through a bridging conductor. In one embodiment, the wire end is crimped onto the member such the crimping tubing fixes the wire and conducts and connects electrically the wire to the receiving hole, such that thus the wire and the belt is in electrical contact with a conducting male snap fastener inserted in the receiving hole.
[0028] The slot mentioned above can also function to provide an additional opening for a mating male projection on the biometric device. By this arrangement it is assured that the device cannot be incorrectly fastened, and the device will not fit any generic non-proprietary belts having connectors with female fasteners but without the correctly shaped and placed extended hole.
[0029] The connector frame has in another embodiment a separate further hole, not joined to the main fastener and electrical connection hole, where the further hole can mate with a corresponding male projection on the biometric device. Alternatively, the biometric device can have a female hole for mating with a corresponding male projection on the belt connector.
[0030] The connector frame further comprises fastening means for fastening to the frame a belt end of an electrode belt. The fastening means can in one embodiment comprise a slot with a row of teeth, pins or hooks, transverse to the belt direction, to engage a belt end. The slot preferably allows to insert through it a loop of the belt such that the belt length is adjusted and fixed, but preferably so that a user can later re-adjust the length.
[0031] In another embodiment, the fastening means comprise a ridge member, which can be a flat or sharp elongated ridge or ridge or row comprising pins or hooks, which ridge lies transverse to the belt direction and to which a belt end can be fastened onto with heat melting or gluing. Alternatively, the ridge member can have pins hooks that grab onto the belt fabric without need of heating.
[0032] Preferably, the frame has also an adjustment slot for user adjustment of the belt, which can configured with either of the two described fastening means, the adjustment slot having a row of teeth, pins or hooks transverse to the belt direction, through which adjustment slot a loop of the belt can be inserted, which hooks onto the teeth/pins when pulled on, such that the length of the belt can be readily adjusted but also secured in the desired adjusted length.
[0033] As shown in the embodiment of FIGS. 3A and 3B , the connector will preferably include a cover 21 substantially or essentially fully enclosing the frame 3 , which cover 21 either includes a pre-made hole 22 overlapping the receiving hole 6 of the frame, or can be readily perforated 23 by pressing the connector onto a male fastener which fits the receiving hole 6 of the frame 3 . A suitable cover can be arranged by a suitably sized paper, plastic or fabric sticker (foldable sheet with glue on one side) which sticker is folded over the frame after the belt end has been fastened and the wire end electrically connected to the receiving hole, or the cover can be from but not limited to a paper envelope, a plastic envelope and a textile envelope, which envelope is suitably fastened by gluing, sewing or the like.
[0034] In the embodiments where the biometric device has a further male projecting member which fits within the slot of the frame or within a separate mating hole, the cover is suitably arranged with corresponding openings for such hole or slot for receiving such mating male member, and the cover may also have a suitable hole allowing the protrusion of a male protruding member being a part of the frame which fits in a mating receiving hole or slot on the mating biometric device.
[0035] In a preferred embodiment, the connector comprises a shield member which is arranged on the rear side of the frame to electrically shield the wire from the rear side exterior of the belt connector. The shield member is in one embodiment a sheet member extending from the frame, which sheet member is configured to be folded over onto the rear side of the frame to cover the hole and engaged wire. Such shield member molded in one piece with the frame with enough 30 strength but suitably flexible to allow folding at least once without braking allows the use of a cover enclosing the frame, which cover need not be electrically insulating, as the shield insulates the only part of the connector which could conduct electrical current of the connector, except through the hole.
[0036] In another aspect, the present disclosure sets forth a process for making an electrode belt with biometric belt connectors, comprising:
placing an end of a flexible electrode belt with an incorporated wire onto a belt connector as defined above, in the suitable direction in which it is to be fastened onto the connector, such that a portion of the belt end extends beyond the ridge member or row of pins, pressing a heat element ultrasonic hot body or other means of heat transfer onto the belt and ridge member, and through the action of the heat, shearing an end piece of the belt but leaving intact the incorporated wire, thus revealing an end of the wire, through the action of heat from the heat element, fastening by heat melting the belt to the ridge, and fastening the wire end to a member adjacent to the hole of the connector frame, such that the end is in electrical contact with the hole and comes in electrical contact with a conducting male snap fastener inserted in the hole.
[0041] The process further preferably comprises enclosing the connector frame with the fastened belt end and connected wire with a cover such as suitably a cover as described above.
[0042] FIGS. 1A, 1B, 1C, and 1D illustrate a belt connector according to a first embodiment. FIG. 1A shows a prospective top view according to the first embodiment.
[0043] FIG. 1B shows a prospective bottom view according to the first embodiment. FIG. 1C shows a top plan view according to the first embodiment. FIG. 1D shows a bottom plan view according to the first embodiment.
[0044] FIGS. 2A, 2B, and 2C illustrate a belt connector and connected belt according to a second embodiment.
[0045] FIG. 2A shows a prospective top view according to the second embodiment.
[0046] FIG. 2B shows a prospective bottom view according to the second embodiment.
[0047] FIG. 2C shows a prospective top view according to the second embodiment.
[0048] As seen in the first and second embodiments of FIGS. 1A, 1B, 1C, and 1D and FIGS. 2A, 2B , and 2 C, respectively, a biometric belt connector ( 1 ) is electrically connected to an electrode belt ( 2 ). The connector ( 1 ) may comprise a molded plastic frame ( 3 ) having a front side ( 4 ) and a rear side ( 5 ), a shaped circular or semi-circular hole ( 6 ) with radial flexibility to function as a female snap button fastener, fastening means ( 7 ) which comprise a ridge member ( 12 ). According to the first embodiment, the ridge member ( 12 ) may include a series of buts which are provided transverse to the belt direction and to which the belt end can be fastened onto with heat melting or gluing. The frame ( 3 ) may include two members ( 8 , 13 ) adjacent to the hole ( 6 ), the two members ( 8 , 13 ) forming a slot ( 11 ) extending from the hole and a second slot ( 15 ) across from the first slot ( 11 ).
[0049] The elongated members and slots provide the hole with sufficient flexibility (i.e. elasticity in the width of the hole) to function as a female snap fastener. The member ( 13 ) also functions to engage an electrode wire end ( 9 ) from the belt end electrically connecting the belt with the hole and which comes in electrical contact with a conducting male snap fastener inserted in the hole. The connector further comprises a belt slot ( 14 ) with teeth members or pins ( 17 ), through which slot a loop of the belt ( 2 ) can be inserted such that it is held by the teeth/pins when pulled back, to adjust the length of the belt.
[0050] The connector further comprises a shield member ( 10 ) which may be molded in one piece with the frame ( 3 ) and joined to the frame with foldable hinges ( 16 ) such that the shield member can be folded over to cover the rear side of the hole and wire end. | A belt connector is provided. The belt connector is configured to electrically connect a conductor of an electrode belt to a male portion of a snap connector electrode connected to a biometric device. The belt connector includes a frame, a fastener, and an engaging member. The frame includes a receiving hole having radial flexibility. The receiving hole is configured to receive and fasten the frame to a protrusion of the male portion of the snap connector electrode. The fastener is configured to fasten the frame to a first end of the electrode belt. The engaging member is adjacent to the receiving hole and engages the conductor of the electrode belt by the conductor passing through the receiving hole. When the male portion of the snap connector electrode penetrates the receiving hole, the conductor is forced into contact with a lateral surface of the male portion of the snap connector electrode. | Provide a concise summary of the essential information conveyed in the given context. | [
"[0001] This application is a continuation of U.S. patent application Ser.",
"No. 14/733,774, filed Jun. 8, 2015, which is a continuation of U.S. patent application Ser.",
"No. 13/806,834, filed Mar. 18, 2013 (now U.S. Pat. No. 9,059,532), which is a 371 nationalization of Application No. PCT/IS2011/050010 filed Jun. 24, 2011, which claims the benefit of priority of U.S. Provisional Application No. 61/358,472, filed Jun. 25, 2010, the entirety of which are each incorporated herein by reference.",
"FIELD OF THE DISCLOSURE [0002] The present disclosure is within the field of medical devices, in particular biometric devices for measuring biosignals, and relates particularly to electrodes for such devices and in particular electrode belts and connectors for such belts.",
"BACKGROUND [0003] Electrode belts are known, both for direct contact galvanic electrodes for measure cardiography signals and inductive belts used in respiratory inductive plethysmography.",
"Prior art belts have various types of connectors, for transmitting the received signal to the respective device.",
"There remains a need for improved belt connectors that are reliable and easy to use and maintain.",
"SUMMARY [0004] The disclosure provides a belt connector for electrically connecting an electrode belt to a biometric device to be carried on a human or animal body.",
"The belt connector is preferably made from one single piece which can be economically manufactured in order to function as a single-use consumable, to be used with a matching biometric device.",
"The belt connector comprises a molded plastic frame having a front side and a rear side, the frame having a receiving hole, having radial flexibility to function as a female snap button fastener for receiving and fastening on the front side of the frame a male snap protrusion.",
"The belt connector further comprises fastening means for fastening to the frame a belt end of the electrode belt, and a member adjacent to the snap fastener receiving hole to engage an electrode wire end electrically connected to the belt such that the wire end is in electrical contact with the hole, either by extending into the hole or coming in electrical contact e.g. through a bridging conductor, with a conducting male snap fastener inserted in the receiving hole.",
"[0005] The belt connector and belt should be configured such that a person wearing the belt under operation is insulated from current running through the belt, in order to meet existing standards for medical devices.",
"The belt connector of the present disclosure is configured accordingly, and in a preferred embodiment, the belt connector comprises a shield member which is arranged on the rear side of the frame to electrically shield the wire end from the rear side exterior of the belt connector.",
"[0006] The belt connector preferably comprises a cover enclosing the connector and wire end.",
"The cover may suitably include a pre-perforated hole overlapping the hole of the frame, or in other embodiments is made from such material that can readily be perforated by pressing the connector onto a male fastener which fits the receiving hole of the frame.",
"[0007] The belt end is fixedly engaged with the connector and the electrode wire connected to the connector such that the electrode wire is in electrical contact with the female snap fastener hole and thereby comes in electrical contact with a conducting male snap fastener inserted in the hole.",
"[0008] Preferably the belt end is engaged with the connector in a fashion allowing adjustment of the length of the belt.",
"BRIEF DESCRIPTION OF THE FIGURES [0009] FIGS. 1A, 1B, 1C, and 1D illustrate a belt connector according to a first embodiment.",
"[0010] FIG. 1A shows a prospective top view according to the first embodiment.",
"[0011] FIG. 1B shows a prospective bottom view according to the first embodiment.",
"[0012] FIG. 1C shows a top plan view according to the first embodiment.",
"[0013] FIG. 1D shows a bottom plan view according to the first embodiment.",
"[0014] FIGS. 2A, 2B, and 2C illustrate a belt connector and connected belt according to a second embodiment.",
"[0015] FIG. 2A shows a prospective top view according to the second embodiment.",
"[0016] FIG. 2B shows a prospective bottom view according to the second embodiment.",
"[0017] FIG. 2C shows a prospective top view according to the second embodiment.",
"[0018] FIG. 3A shows a top plan view according to another embodiment.",
"[0019] FIG. 3B shows a prospective top view according to the embodiment of FIG. 3A .",
"DETAILED DESCRIPTION [0020] The disclosed belt connector is suitable for various types of electrode belts, such as for cardiographic measurements, both in clinical settings or for training purposes, but also for belts such as RIP (respiratory inductive plethysmography) belts.",
"[0021] As mentioned above, the belt connector is intended for electrically connecting an electrode belt to a biometric device, the term biometric device in this context includes any devices for receiving electrical biosignals as well as extension cables, intermediate devices, connecting boxes, etc.",
"or other means for receiving and transmitting the biosignals.",
"[0022] The belt connector is preferably made from any of various suitable non-conducting plastic materials, such as but not limited to ABS (acrylonitrile butadiene styrene), PC/ABS, polyethylene, e.g. low density polyethylene (LDPE) or high density polyethylene (HDPE), or derivatives such as polyethylene terephthalate (PET) or polyfluoroethylene (PTFE), or more preferably polypropylene, polyvinyl chloride, or polyamide (nylon).",
"In other embodiments the connector is made from paper based material or other material from natural fibers.",
"[0023] The electrode belt is generally a flexible belt such as commonly used in respiratory inductance plethysmography (RIP) devices today.",
"Such electrode belt is preferably a flexible textile belt where an electrode wire is interwoven in the belt or can be laminated between two layers, typically in a zig-zag fashion to allow longitudinal elasticity.",
"[0024] The molded frame of the connector has a front side and a rear side, which are defined as follows: the front side of the frame faces the biometric device which is fastened onto the connector for operation and the rear side faces away from the device.",
"In the presently preferred embodiment the rear side of the connector faces the body of the patient when mounted, i.e. the belt connector comes between the patient and the biometric device.",
"However, the biometric device can also be configured such that the device faces the patient and the belt connectors lie on top of the device, i.e. connect to the device on the face of the device facing away from the patient, thus in such embodiment the front side of the connectors face the patient and the rear side face away from the patient.",
"[0025] The frame has a receiving hole with radial flexibility to function as a female snap button fastener for receiving and fastening on the front side of the frame a male snap protrusion.",
"A mating biometric device will thus have a corresponding mating male snap fastener which can be fastened securely onto the belt connector.",
"The hole can preferably be shaped circular or semi-circular but may in other embodiments have any other suitable shape, such as a general elongated shape shaped by two parallel members, suitably including guiding members to ensure proper positioning of the mating male snap member, a square opening, or the like.",
"[0026] The radial flexibility of the hole can in one embodiment be achieved by one or more slot extending from the hole.",
"The embodiment shown if FIGS. 1 and 2 shows two slots extending across from each other in the belt direction.",
"The one or more slot are preferably formed by at least one elongated member having flexibility transverse to its longitudinal axis (e.g. by being sufficiently thin), thus imparting flexibility to the width of the hole.",
"Preferably the hole is between two elongated members where one or both have sufficient and suitable flexibility to provide a snap fastener hole with suitable fastening strength.",
"[0027] As mentioned, the belt connector comprises a member adjacent to the snap fastener receiving hole to engage an electrode wire coming from the belt end.",
"This wire must come in electrical contact with the receiving hole, either by extending into the hole or coming in electrical contact with the hole e.g. through a bridging conductor.",
"In one embodiment, the wire end is crimped onto the member such the crimping tubing fixes the wire and conducts and connects electrically the wire to the receiving hole, such that thus the wire and the belt is in electrical contact with a conducting male snap fastener inserted in the receiving hole.",
"[0028] The slot mentioned above can also function to provide an additional opening for a mating male projection on the biometric device.",
"By this arrangement it is assured that the device cannot be incorrectly fastened, and the device will not fit any generic non-proprietary belts having connectors with female fasteners but without the correctly shaped and placed extended hole.",
"[0029] The connector frame has in another embodiment a separate further hole, not joined to the main fastener and electrical connection hole, where the further hole can mate with a corresponding male projection on the biometric device.",
"Alternatively, the biometric device can have a female hole for mating with a corresponding male projection on the belt connector.",
"[0030] The connector frame further comprises fastening means for fastening to the frame a belt end of an electrode belt.",
"The fastening means can in one embodiment comprise a slot with a row of teeth, pins or hooks, transverse to the belt direction, to engage a belt end.",
"The slot preferably allows to insert through it a loop of the belt such that the belt length is adjusted and fixed, but preferably so that a user can later re-adjust the length.",
"[0031] In another embodiment, the fastening means comprise a ridge member, which can be a flat or sharp elongated ridge or ridge or row comprising pins or hooks, which ridge lies transverse to the belt direction and to which a belt end can be fastened onto with heat melting or gluing.",
"Alternatively, the ridge member can have pins hooks that grab onto the belt fabric without need of heating.",
"[0032] Preferably, the frame has also an adjustment slot for user adjustment of the belt, which can configured with either of the two described fastening means, the adjustment slot having a row of teeth, pins or hooks transverse to the belt direction, through which adjustment slot a loop of the belt can be inserted, which hooks onto the teeth/pins when pulled on, such that the length of the belt can be readily adjusted but also secured in the desired adjusted length.",
"[0033] As shown in the embodiment of FIGS. 3A and 3B , the connector will preferably include a cover 21 substantially or essentially fully enclosing the frame 3 , which cover 21 either includes a pre-made hole 22 overlapping the receiving hole 6 of the frame, or can be readily perforated 23 by pressing the connector onto a male fastener which fits the receiving hole 6 of the frame 3 .",
"A suitable cover can be arranged by a suitably sized paper, plastic or fabric sticker (foldable sheet with glue on one side) which sticker is folded over the frame after the belt end has been fastened and the wire end electrically connected to the receiving hole, or the cover can be from but not limited to a paper envelope, a plastic envelope and a textile envelope, which envelope is suitably fastened by gluing, sewing or the like.",
"[0034] In the embodiments where the biometric device has a further male projecting member which fits within the slot of the frame or within a separate mating hole, the cover is suitably arranged with corresponding openings for such hole or slot for receiving such mating male member, and the cover may also have a suitable hole allowing the protrusion of a male protruding member being a part of the frame which fits in a mating receiving hole or slot on the mating biometric device.",
"[0035] In a preferred embodiment, the connector comprises a shield member which is arranged on the rear side of the frame to electrically shield the wire from the rear side exterior of the belt connector.",
"The shield member is in one embodiment a sheet member extending from the frame, which sheet member is configured to be folded over onto the rear side of the frame to cover the hole and engaged wire.",
"Such shield member molded in one piece with the frame with enough 30 strength but suitably flexible to allow folding at least once without braking allows the use of a cover enclosing the frame, which cover need not be electrically insulating, as the shield insulates the only part of the connector which could conduct electrical current of the connector, except through the hole.",
"[0036] In another aspect, the present disclosure sets forth a process for making an electrode belt with biometric belt connectors, comprising: placing an end of a flexible electrode belt with an incorporated wire onto a belt connector as defined above, in the suitable direction in which it is to be fastened onto the connector, such that a portion of the belt end extends beyond the ridge member or row of pins, pressing a heat element ultrasonic hot body or other means of heat transfer onto the belt and ridge member, and through the action of the heat, shearing an end piece of the belt but leaving intact the incorporated wire, thus revealing an end of the wire, through the action of heat from the heat element, fastening by heat melting the belt to the ridge, and fastening the wire end to a member adjacent to the hole of the connector frame, such that the end is in electrical contact with the hole and comes in electrical contact with a conducting male snap fastener inserted in the hole.",
"[0041] The process further preferably comprises enclosing the connector frame with the fastened belt end and connected wire with a cover such as suitably a cover as described above.",
"[0042] FIGS. 1A, 1B, 1C, and 1D illustrate a belt connector according to a first embodiment.",
"FIG. 1A shows a prospective top view according to the first embodiment.",
"[0043] FIG. 1B shows a prospective bottom view according to the first embodiment.",
"FIG. 1C shows a top plan view according to the first embodiment.",
"FIG. 1D shows a bottom plan view according to the first embodiment.",
"[0044] FIGS. 2A, 2B, and 2C illustrate a belt connector and connected belt according to a second embodiment.",
"[0045] FIG. 2A shows a prospective top view according to the second embodiment.",
"[0046] FIG. 2B shows a prospective bottom view according to the second embodiment.",
"[0047] FIG. 2C shows a prospective top view according to the second embodiment.",
"[0048] As seen in the first and second embodiments of FIGS. 1A, 1B, 1C, and 1D and FIGS. 2A, 2B , and 2 C, respectively, a biometric belt connector ( 1 ) is electrically connected to an electrode belt ( 2 ).",
"The connector ( 1 ) may comprise a molded plastic frame ( 3 ) having a front side ( 4 ) and a rear side ( 5 ), a shaped circular or semi-circular hole ( 6 ) with radial flexibility to function as a female snap button fastener, fastening means ( 7 ) which comprise a ridge member ( 12 ).",
"According to the first embodiment, the ridge member ( 12 ) may include a series of buts which are provided transverse to the belt direction and to which the belt end can be fastened onto with heat melting or gluing.",
"The frame ( 3 ) may include two members ( 8 , 13 ) adjacent to the hole ( 6 ), the two members ( 8 , 13 ) forming a slot ( 11 ) extending from the hole and a second slot ( 15 ) across from the first slot ( 11 ).",
"[0049] The elongated members and slots provide the hole with sufficient flexibility (i.e. elasticity in the width of the hole) to function as a female snap fastener.",
"The member ( 13 ) also functions to engage an electrode wire end ( 9 ) from the belt end electrically connecting the belt with the hole and which comes in electrical contact with a conducting male snap fastener inserted in the hole.",
"The connector further comprises a belt slot ( 14 ) with teeth members or pins ( 17 ), through which slot a loop of the belt ( 2 ) can be inserted such that it is held by the teeth/pins when pulled back, to adjust the length of the belt.",
"[0050] The connector further comprises a shield member ( 10 ) which may be molded in one piece with the frame ( 3 ) and joined to the frame with foldable hinges ( 16 ) such that the shield member can be folded over to cover the rear side of the hole and wire end."
] |
BACKGROUND OF THE INVENTION
[0001] The present invention relates in general to Internet-based project information management and customer request management (CRM) systems and in particular to a software system for providing interactive and cost-effective project management and customer request resolution service for project participants.
[0002] Traditional Internet-based CRM systems use a point-to-point model in which a single customer communicates with only one service representative to resolve an issue. Issues raised by customers are resolved one at a time and in complete isolation from any other issue that has been or is being resolved for the same customer. These characteristics of the point-to-point model make traditional customer service a slow process since information about related issues cannot be shared. Specifically, under the point-to-point model, one service representative may only have limited knowledge or access to the environment in which the issue arises. Moreover, the isolation of issues means that experiences obtained through solving one issue cannot be utilized to help solve other issues. Further more, little collaboration between representatives exist since different representatives usually work on isolated issues. It is quite possible that an issue is not worked on by the representative with the most relevant experience and that representative cannot share his knowledge with others, thereby reducing the cost-effectiveness of the point-to-point model.
[0003] A typical way to solve the above problem is to provide an account manager to coordinate the resolution of customer requests. This approach is of limited help since the account manager may not have full knowledge about the scope of an issue and may not be able to assign the most competent representative to resolve the issue.
[0004] Another problem associated with traditional CRM systems is that it is difficult for customers to gather needed product information related to their requests. Traditional CRM tools organize service requests and related content by agreement, company, site and contact. This is not very useful for customers since they typically organize their use of products through some form of a project structure. It is therefore nearly impossible for these customers to obtain a complete picture of all the needed product information at a project level.
[0005] Yet another problem associated with the point-to-point model is accessibility. The point-to-point models are limited to phone conversations and emails with the occasional online tracking service for customer requests. New technologies that we now use all the time (e.g. PDAs, Instant Messaging services) have not been integrated into these models. Moreover, information related to a request is usually kept in different formats such as word documents, powerpoint slides, emails, source code, etc. This makes it very difficult to access this information from different devices such as cell phones and PDAs.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention comprises an Internet-based customer request management software system for assisting customers to resolve service requests raised in projects. This software system comprises software interfaces for sharing and manipulating project-related information and documents and software interfaces for receiving and resolving project-related service requests (SRs) from customers.
[0007] Another aspect of the present invention comprises an Internet-based customer request management software system that further comprises software interfaces to a discussion forum for members involved in a common project to share project-related information and discuss problems that have arisen in the project.
[0008] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from customers further comprises a first interface for creating and submitting SRs and a second interface for linking SRs to projects. SRs may be created and submitted by customers and resolved by project members. Project members can be either customer or staff providing technical support. Project members can also include anyone authorized under the project agreement, e.g. consultants, etc. To become a project member, a user's membership must be approved by the project administrator.
[0009] Yet another aspect of the present invention comprises an SR pool comprising data representing a plurality of SRs. Subject to restrictions which may be imposed by an administrator, an SR pool can contain SRs linking to any project within the same agreement, and a project member can draw from an SR pool to append to or create the project's SR collection linking together SR's from any project under their agreement. An SR collection can be created by either the submission of SRs from that project or by selecting SRs from the SR pool. An SR may be represented (typically by a pointer, index or object reference) in multiple SR pools.
[0010] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from project members further comprise an interface for modifying the content of SRs.
[0011] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from project members further comprise an interface for requesting service callback regarding SRs.
[0012] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from project members further comprise an interface for displaying all the action items associated with an SR.
[0013] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise a first interface for removing project documents and loading documents from a user's local computer to project documents, a second interface for sorting project documents, and a third interface for filtering project documents.
[0014] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise interfaces for viewing and updating products and product documentation used by a project.
[0015] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for viewing and updating products used by a project further comprise a first interface for viewing the list of products, a second interface for viewing the details of a product, and a third interface for updating the information of a product. The product information being updated preferably includes product deployment information comprising information regarding product installation and configuration.
[0016] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for viewing and updating products used by a project further comprise an interface for configuring test cases for a product.
[0017] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise interfaces for creating and viewing tasks related to a project.
[0018] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the interfaces for creating and viewing tasks related a project further comprise a first interface for viewing, sorting, filtering or deleting tasks from the project's task list; a second interface for creating new tasks; and a third interface for modifying task contents.
[0019] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise interfaces for viewing project member information.
[0020] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise an interface for locating project-related information within the project hierarchy. Project-related information may be accessed using any suitable communications medium, such as the Internet, corporate intra-net or LAN.
[0021] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise an interface for managing bookmarks related to the project.
[0022] Yet another aspect of the present invention comprises a method for providing project-related customer support. The method comprises the steps of providing an interface for customers to create and submit project-related SRs; parsing the SR to obtain project information and sender's identity; linking the SR to its related projects.
[0023] Yet another aspect of the present invention comprises a method for creating a discussion forum within the project for project members to share project-related information.
[0024] Yet another aspect of the present invention comprises a method for providing project-related customer support further comprising the step of providing callbacks in response to customer's request to discuss details on an existing SR.
[0025] Yet another aspect of the present invention comprises a database containing project-related information. Information in the database is preferably categorized by association with a plurality of hierarchically-ordered projects. Information in the database preferably comprises profiles of each project; profiles of each customer involved in a project; lists of products used in each project; lists of SR's created by clients; and lists of action items associated with each SR.
[0026] Yet another aspect of the present invention comprises a document database wherein each service request further comprises the name of the company who owns the project, the contact of the client who creates the SR, the severity of the SR, the SR Type, and lists of product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 schematically depicts the relationship between various components in the preferred embodiment.
[0028] [0028]FIG. 2 schematically depicts an interface for SR management used by the preferred embodiment.
[0029] [0029]FIG. 3 schematically depicts an interface for creating links between SRs and projects.
[0030] [0030]FIG. 4 schematically depicts an interface for updating products associated with the project.
[0031] [0031]FIG. 5 schematically depicts an interface for sharing project-related documents.
[0032] [0032]FIG. 6 schematically depicts an interface for tracking actions related to the project from a task list.
[0033] [0033]FIG. 7 schematically depicts a schema for a project area member data model.
[0034] [0034]FIG. 8 schematically depicts the relationship between SR collections, projects and SR pools.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] In one aspect, the present invention comprises a customer request management software system for customers and service representatives to solve project-related SRs in a collaborative fashion. The system permits customers to communicate with customer services and each other in a virtual project environment. The software system also assists in the exchange, organization and management of information within a project environment. In a preferred embodiment, a project may be created based on an agreement between the customer and the customer service provider. Multiple projects may be created under the same agreement, in accordance with the terms of the agreement. An agreement may place restrictions on the sharing of information within the software system. Preferably, project members cannot share information or service requests (SRs) with projects created under different agreements. The relationship between various component within a preferred embodiment of the software system is shown in FIG. 1.
[0036] One embodiment of the present invention comprises an Internet-based customer request management software system for assisting project members to resolve service requests raised in projects. The software system may comprise project manager software that allows project members to share and manipulate project-related information and documents and service request manager software that receives and tracks resolution of project-related service requests (SRs) from project members. The embodiment may also comprise a discussion forum for project members involved in the same project to share project-related information and discuss problems that have arisen in the project.
[0037] One preferred embodiment of the present invention comprises an SR management software system, a project management software system, and a discussion forum. In the SR management software system, project members are associated with the projects they participate in. Any customer can submit an SR, and SRs associated with a project are viewable by all the project members within the same project. An SR can be submitted by a customer, or it can be added to the project by the software system. A project may have more than one SR linked to it. An SR can be linked to more than one project. An SR has a single owner. The default owner of the SR is the customer who creates it. A project member can draw from an SR pool to append to or create the project's SR collection linking together SR's from any project under their agreement. An SR collection is created by either the submission of SRs from that project or by selecting SRs from the SR pool. An SR pool can contain SRs linking to projects within the same agreement. An SR may be contained in multiple SR pools. FIG. 8 schematically depicts the relationship between SR pools, SR collections and Projects.
[0038] The definitions below indicate the meaning of terms used in this document.
[0039] “Project administrator” means a person, typically a project member, responsible for the administration of a project. Typical duties of a project administrator include creating and setting up new projects, maintaining existing projects, assigning/removing members for a project, registering new users and assigning them to a project, removing documents from a project, and adding members who are not covered by the agreement to the discussion forum.
[0040] “Project member” means a person who is an agent of a customer or customer services and who can use the system in connection with a project. Typical duties and activities include adding documents to the project, creating/updating SRs, taking part in project discussions, adding SRs to project, updating product deployment information, adding/removing tasks, adding/removing bookmarks, and updating project details.
[0041] “Customer services provider” means an entity, typically an organization or individual, that provides support services for a customer pursuant to an agreement. Typical duties and activities include.
[0042] “Customer” means an entity, typically an organization or individual, that receives support services pursuant to an agreement.
[0043] “Agreement administrator” means a person responsible for the administration of an agreement.
[0044] “Agreement” means a contract between a customer and customer services provider which defines a level of service which will be provided by the customer services provider to the customer.
[0045] “Service request” means a request for service from a customer to the customer services provider. Examples include a request for technical information on a product, a request for feature information, or a bug or defect report.
[0046] [0046]FIG. 2 shows an SR management scheme used by the preferred embodiment. A customer can create an SR through an interface. A example interface is the window labeled “New SR” 110 as shown in FIG. 2. The four buttons labeled “Company, “Support Level”, “Product”, “Cust. Type” correspond to system data files populated by the software system upon submission of company information, support level information product information, and customer type information, respectively.
[0047] The customer is required to provide data concerning the SR using the dialog box labeled “Data fields for the iPM” 120 . The data preferably include the severity of the SR, the SR type and the list of products affected by the SR. Typical SR type may include “User Misunderstanding”, “Possible Product Bug”, “Documentation Question”, “Technical Question”, “General Request”, “Subject”, “Description”, and “Attachments”. The products affected by the SR may be selected from a product list. The product list may further comprise a primary product list and a secondary product list, wherein the secondary product list contains products that are being used by a product in the primary product list. The product list may be independent from the project, or specific to a project, depending on user preference.
[0048] The customer will be notified after the successful submission of an SR via email and a window served to the customer's web browser. The email notification will be send to the customer's email address with instructions on how to reply. The success window will preferably provide a summary of the SR submitted and an SR ID number, as shown in the window labeled “Successful Process Notification” 130 in FIG. 2. Before the notification is sent, the SR is parsed and project and customer information obtained for the SR. An SR link is created for every project affected by the SR. At the same time the notification is sent, an action item list for recording all the performed actions associated with the SR will be created and a “SR submitted” action is added to the list. An service engineer will be assigned to the SR and a correspondence list for the SR will be created to record the communications between the customer and the assigned engineer.
[0049] The process of resolving an SR preferably involves collaboration between the customer and project members as well as the sharing of information in the project or information from other projects or resources. A customer belonging to a project can access any SR that is associated with the project using an interface like the window labeled “SR Links” 140 in FIG. 2. By selection of an SR listed in the window, the customer is directed to another interface where information related to the selected SR is listed, like the window labeled “SRI” in FIG. 2 150 .
[0050] In the preferred embodiment, if the customer is also the owner of the selected SR, he/she can also modify the content of the SR. Modifiable fields of the SR preferably include: Severity, SR Type, SR Status, Subject and Description. After the submission of the modified SR, both the SR Owner and the assigned engineer will be notified of the change. A notification of change will also appear in the action item list associated with the SR.
[0051] A customer preferably can also request a callback from a service engineer to discuss details on an existing SR. The callback request will be automatically added to the action item list and a callback notification is sent to the assigned engineer.
[0052] Every project generally has its own discussion forum typically accessible only by the project's members. The forum allows the project team to discuss issues of interest to the team in a common community area. Optionally, more accessible forums can also be created that are open to persons who are not project members.
[0053] In the preferred embodiment, an SR is normally linked to a project automatically upon its submission. An SR can also be manually linked to other projects by a project administrator through an interface like the one shown in FIG. 3. (Note that an SR may not be linked to a project created based on a different agreement.) To link an SR to a project, the administrator can either select from a list of available SRs 210 , or just type the SR ID in the text box labeled “Enter an SR number” 220 . The list of SRs can be sorted and filtered using Sort button 230 an f filter button 240 and associated field selection check boxes 250 , 260 . Fields for sorting and filtering SRs preferably include “Date”, “Status”, “Product” and “Owner” (iPM). An SR can also be removed from a project using the same interface.
[0054] The preferred embodiment also comprises interfaces and systems to update products associated with the project. Product updates can be accomplished through the interface shown in FIG. 4. Using this interface, project members can download and install any release, service package, or patch of any product available to the customer. The customer chooses the product for update from the product list 310 and submit the request to the system. The system will provide a window like the one labeled “Update” 320 in FIG. 4 detailing the available releases, service packages and patches for download. The customer selects the desired release service package, or patch then clicks the download button 330 to download it.
[0055] After a successful download the update is appended to the product list as product available for use in the project. All the downloads, installations and configurations can be archived to provide a map of the customer's working environment. This map can be accessed by customer services to automatically configure a testing environment to build test cases from. All the test cases can also be archived and shared using a document sharing service.
[0056] The preferred embodiment of the present invention also comprises a document sharing service that enables project members to share documents related to the project. Project members can add, remove and download the documents. Examples of documents may include: operations guides, status reports, or project/architecture overviews.
[0057] A typical interface for document sharing is shown in FIG. 5. A project member can select any document provided in the document list in the window labeled “Document Sharing” 410 . These documents can be sorted and filtered based on certain fields described in the “sort” window 420 and the “filter” window 430 in FIG. 5.
[0058] A project member can also post a document to the project from the local filing system or download a selected document to the local file system using the window labeled “Post/Download Document” 440 shown in FIG. 5. Document can also be removed from the project. Document protection is preferably available on a per document basis. Document encryption may be available on a document-to-document basis.
[0059] Every time a document is added, downloaded or removed, the system preferably logs these details. Information to be logged preferably include name of the project member, date, document name, action (add, remove, download) and security information. Project members may opt to be notified when documents are added, downloaded or removed.
[0060] The present invention also comprises an interface for tracking actions related to the project from a task list. FIG. 6 shows a preferred embodiment of such an interface. The task list may be sorted and filtered using any task fields. Any project member is able to select a task to view and create a new task using the “Task View” window 510 and the “New Task” window 520 , respectively.
[0061] When a new task is created, the project member who creates the task is the default owner of that task. Tasks are distinguished by availability, either being assigned or unassigned. A new task is unassigned by default.
[0062] In both the “New Task” 520 and the “Task View” 510 windows, the field “Assigned to” is used to indicate the ownership of the task; other descriptive fields for a task may include: subject, due date, start date, status, priority, percentage of completion, and description of the task. The task details may be modified by the task owner only. A task may be removed by the owner, or by the creator if it is unassigned.
[0063] The present invention also comprises an interface for project members to view information about other project members. FIG. 7 shows such an interface. A project member can access contact information about another by selecting a project member from the list of members in the window labeled “Project Area Members” 610 . The contact information may include: user name, project roles, job title, mailing address, email address, and company information.
[0064] The preferred embodiment may also include an interface of a document locator for customers or project members to search for documents within the project hierarchy on the Internet. The keyword entered by the project member may be automatically populated with project information in order to narrow the scope of the search. For example, if the project member enters key word “IDL” in the search field and OrbixWeb was the only product being used by the project, then the locator will only search OrbixWeb IDL articles.
[0065] The preferred embodiment also comprises an interface that allows project members to manage bookmarks relevant to the project itself.
[0066] The present invention also comprises an interface for project members to customize certain elements of their project environment and speeding up the process of SR resolution. Throughout the life-cycle of the project, project details will change. The existence of this interface facilitates the need for being able to change project details as work on the project progresses.
[0067] The interface for changing project details may comprise an interface to view and edit project details such as name, description and status. Any change in project status may be recorded. Typical values for project status include: Development, Archived, testing, or Deployment. Other local project status attributes can also be created by project administrators.
[0068] In one embodiment, projects are arranged in a hierarchical structure. A project member must register himself into the system and after completing a registration process the project member is given access to a root project. The root project is created based on an agreement between the customer and the customer service provider, as indicated before. The first root project is created by the system using default settings established when the agreement is created. It is ready to run without any immediate need to setup.
[0069] New projects may also be created from within root projects. This new project will also link back to the same agreement. A root project is unrelated to any other projects except those contained within it. A sub-project may be created from within another project based on the same agreement. A project hierarchy is created by creating sub-projects.
[0070] The content of project details may also comprise information about the products used by the project. In the preferred embodiment, an interface is provided for project members to view a list of installed products for the project. The interface also allows project members to indicate whether a product in the list is in use. This then allows the system to filter the product listings so that only products that are in use are presented to the project member in the SR management and product update interfaces. When a project is created all products in the product list are assumed to be in use.
[0071] The interface also allows view and edit product details. A product detail window is available for viewing the details of a product. The project member can access details by drilling down into the product from any of the three product interfaces: Installed Product, Agreement Product, or 3 rd Party Product. Information about a product preferably includes: Serial Number, Ship RequestID, Product Release, Version, Part Number, Date Shipped, OS product is installed on, URL's to product pages, and a free text note field to comment in. Information in the text note field preferably includes: an identifier of the machine the product is installed on, and URL's for product information pages. Information entered into the note field is seen only from the project into which it was entered. The interface may also allow the project administrator to add and remove project members belonging to a project.
[0072] The interfaces and software within the project member request management software system can be realized using a variety of programming tools such as the J2EE suite. | An Internet-based customer request management software system for assisting customers to resolve service requests raised in projects is disclosed. In a preferred embodiment, the system comprises a server computer operatively connected to a network; at least one server program executing on the server computer comprising at least one software interface for sharing and manipulating project-related information and documents, and at least one software interface for receiving project-related service requests (SRs) from customers and linking at least a portion of the SRs to at least a portion of the project-related information. | Condense the core contents of the given document. | [
"BACKGROUND OF THE INVENTION [0001] The present invention relates in general to Internet-based project information management and customer request management (CRM) systems and in particular to a software system for providing interactive and cost-effective project management and customer request resolution service for project participants.",
"[0002] Traditional Internet-based CRM systems use a point-to-point model in which a single customer communicates with only one service representative to resolve an issue.",
"Issues raised by customers are resolved one at a time and in complete isolation from any other issue that has been or is being resolved for the same customer.",
"These characteristics of the point-to-point model make traditional customer service a slow process since information about related issues cannot be shared.",
"Specifically, under the point-to-point model, one service representative may only have limited knowledge or access to the environment in which the issue arises.",
"Moreover, the isolation of issues means that experiences obtained through solving one issue cannot be utilized to help solve other issues.",
"Further more, little collaboration between representatives exist since different representatives usually work on isolated issues.",
"It is quite possible that an issue is not worked on by the representative with the most relevant experience and that representative cannot share his knowledge with others, thereby reducing the cost-effectiveness of the point-to-point model.",
"[0003] A typical way to solve the above problem is to provide an account manager to coordinate the resolution of customer requests.",
"This approach is of limited help since the account manager may not have full knowledge about the scope of an issue and may not be able to assign the most competent representative to resolve the issue.",
"[0004] Another problem associated with traditional CRM systems is that it is difficult for customers to gather needed product information related to their requests.",
"Traditional CRM tools organize service requests and related content by agreement, company, site and contact.",
"This is not very useful for customers since they typically organize their use of products through some form of a project structure.",
"It is therefore nearly impossible for these customers to obtain a complete picture of all the needed product information at a project level.",
"[0005] Yet another problem associated with the point-to-point model is accessibility.",
"The point-to-point models are limited to phone conversations and emails with the occasional online tracking service for customer requests.",
"New technologies that we now use all the time (e.g. PDAs, Instant Messaging services) have not been integrated into these models.",
"Moreover, information related to a request is usually kept in different formats such as word documents, powerpoint slides, emails, source code, etc.",
"This makes it very difficult to access this information from different devices such as cell phones and PDAs.",
"SUMMARY OF THE INVENTION [0006] One aspect of the present invention comprises an Internet-based customer request management software system for assisting customers to resolve service requests raised in projects.",
"This software system comprises software interfaces for sharing and manipulating project-related information and documents and software interfaces for receiving and resolving project-related service requests (SRs) from customers.",
"[0007] Another aspect of the present invention comprises an Internet-based customer request management software system that further comprises software interfaces to a discussion forum for members involved in a common project to share project-related information and discuss problems that have arisen in the project.",
"[0008] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from customers further comprises a first interface for creating and submitting SRs and a second interface for linking SRs to projects.",
"SRs may be created and submitted by customers and resolved by project members.",
"Project members can be either customer or staff providing technical support.",
"Project members can also include anyone authorized under the project agreement, e.g. consultants, etc.",
"To become a project member, a user's membership must be approved by the project administrator.",
"[0009] Yet another aspect of the present invention comprises an SR pool comprising data representing a plurality of SRs.",
"Subject to restrictions which may be imposed by an administrator, an SR pool can contain SRs linking to any project within the same agreement, and a project member can draw from an SR pool to append to or create the project's SR collection linking together SR's from any project under their agreement.",
"An SR collection can be created by either the submission of SRs from that project or by selecting SRs from the SR pool.",
"An SR may be represented (typically by a pointer, index or object reference) in multiple SR pools.",
"[0010] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from project members further comprise an interface for modifying the content of SRs.",
"[0011] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from project members further comprise an interface for requesting service callback regarding SRs.",
"[0012] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for receiving and resolving project-related service requests (SRs) from project members further comprise an interface for displaying all the action items associated with an SR.",
"[0013] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise a first interface for removing project documents and loading documents from a user's local computer to project documents, a second interface for sorting project documents, and a third interface for filtering project documents.",
"[0014] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise interfaces for viewing and updating products and product documentation used by a project.",
"[0015] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for viewing and updating products used by a project further comprise a first interface for viewing the list of products, a second interface for viewing the details of a product, and a third interface for updating the information of a product.",
"The product information being updated preferably includes product deployment information comprising information regarding product installation and configuration.",
"[0016] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for viewing and updating products used by a project further comprise an interface for configuring test cases for a product.",
"[0017] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise interfaces for creating and viewing tasks related to a project.",
"[0018] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the interfaces for creating and viewing tasks related a project further comprise a first interface for viewing, sorting, filtering or deleting tasks from the project's task list;",
"a second interface for creating new tasks;",
"and a third interface for modifying task contents.",
"[0019] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise interfaces for viewing project member information.",
"[0020] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise an interface for locating project-related information within the project hierarchy.",
"Project-related information may be accessed using any suitable communications medium, such as the Internet, corporate intra-net or LAN.",
"[0021] Yet another aspect of the present invention comprises an Internet-based customer request management software system wherein the software interfaces for sharing and manipulating project-related information and documents further comprise an interface for managing bookmarks related to the project.",
"[0022] Yet another aspect of the present invention comprises a method for providing project-related customer support.",
"The method comprises the steps of providing an interface for customers to create and submit project-related SRs;",
"parsing the SR to obtain project information and sender's identity;",
"linking the SR to its related projects.",
"[0023] Yet another aspect of the present invention comprises a method for creating a discussion forum within the project for project members to share project-related information.",
"[0024] Yet another aspect of the present invention comprises a method for providing project-related customer support further comprising the step of providing callbacks in response to customer's request to discuss details on an existing SR.",
"[0025] Yet another aspect of the present invention comprises a database containing project-related information.",
"Information in the database is preferably categorized by association with a plurality of hierarchically-ordered projects.",
"Information in the database preferably comprises profiles of each project;",
"profiles of each customer involved in a project;",
"lists of products used in each project;",
"lists of SR's created by clients;",
"and lists of action items associated with each SR.",
"[0026] Yet another aspect of the present invention comprises a document database wherein each service request further comprises the name of the company who owns the project, the contact of the client who creates the SR, the severity of the SR, the SR Type, and lists of product.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0027] [0027 ]FIG. 1 schematically depicts the relationship between various components in the preferred embodiment.",
"[0028] [0028 ]FIG. 2 schematically depicts an interface for SR management used by the preferred embodiment.",
"[0029] [0029 ]FIG. 3 schematically depicts an interface for creating links between SRs and projects.",
"[0030] [0030 ]FIG. 4 schematically depicts an interface for updating products associated with the project.",
"[0031] [0031 ]FIG. 5 schematically depicts an interface for sharing project-related documents.",
"[0032] [0032 ]FIG. 6 schematically depicts an interface for tracking actions related to the project from a task list.",
"[0033] [0033 ]FIG. 7 schematically depicts a schema for a project area member data model.",
"[0034] [0034 ]FIG. 8 schematically depicts the relationship between SR collections, projects and SR pools.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS [0035] In one aspect, the present invention comprises a customer request management software system for customers and service representatives to solve project-related SRs in a collaborative fashion.",
"The system permits customers to communicate with customer services and each other in a virtual project environment.",
"The software system also assists in the exchange, organization and management of information within a project environment.",
"In a preferred embodiment, a project may be created based on an agreement between the customer and the customer service provider.",
"Multiple projects may be created under the same agreement, in accordance with the terms of the agreement.",
"An agreement may place restrictions on the sharing of information within the software system.",
"Preferably, project members cannot share information or service requests (SRs) with projects created under different agreements.",
"The relationship between various component within a preferred embodiment of the software system is shown in FIG. 1. [0036] One embodiment of the present invention comprises an Internet-based customer request management software system for assisting project members to resolve service requests raised in projects.",
"The software system may comprise project manager software that allows project members to share and manipulate project-related information and documents and service request manager software that receives and tracks resolution of project-related service requests (SRs) from project members.",
"The embodiment may also comprise a discussion forum for project members involved in the same project to share project-related information and discuss problems that have arisen in the project.",
"[0037] One preferred embodiment of the present invention comprises an SR management software system, a project management software system, and a discussion forum.",
"In the SR management software system, project members are associated with the projects they participate in.",
"Any customer can submit an SR, and SRs associated with a project are viewable by all the project members within the same project.",
"An SR can be submitted by a customer, or it can be added to the project by the software system.",
"A project may have more than one SR linked to it.",
"An SR can be linked to more than one project.",
"An SR has a single owner.",
"The default owner of the SR is the customer who creates it.",
"A project member can draw from an SR pool to append to or create the project's SR collection linking together SR's from any project under their agreement.",
"An SR collection is created by either the submission of SRs from that project or by selecting SRs from the SR pool.",
"An SR pool can contain SRs linking to projects within the same agreement.",
"An SR may be contained in multiple SR pools.",
"FIG. 8 schematically depicts the relationship between SR pools, SR collections and Projects.",
"[0038] The definitions below indicate the meaning of terms used in this document.",
"[0039] “Project administrator”",
"means a person, typically a project member, responsible for the administration of a project.",
"Typical duties of a project administrator include creating and setting up new projects, maintaining existing projects, assigning/removing members for a project, registering new users and assigning them to a project, removing documents from a project, and adding members who are not covered by the agreement to the discussion forum.",
"[0040] “Project member”",
"means a person who is an agent of a customer or customer services and who can use the system in connection with a project.",
"Typical duties and activities include adding documents to the project, creating/updating SRs, taking part in project discussions, adding SRs to project, updating product deployment information, adding/removing tasks, adding/removing bookmarks, and updating project details.",
"[0041] “Customer services provider”",
"means an entity, typically an organization or individual, that provides support services for a customer pursuant to an agreement.",
"Typical duties and activities include.",
"[0042] “Customer”",
"means an entity, typically an organization or individual, that receives support services pursuant to an agreement.",
"[0043] “Agreement administrator”",
"means a person responsible for the administration of an agreement.",
"[0044] “Agreement”",
"means a contract between a customer and customer services provider which defines a level of service which will be provided by the customer services provider to the customer.",
"[0045] “Service request”",
"means a request for service from a customer to the customer services provider.",
"Examples include a request for technical information on a product, a request for feature information, or a bug or defect report.",
"[0046] [0046 ]FIG. 2 shows an SR management scheme used by the preferred embodiment.",
"A customer can create an SR through an interface.",
"A example interface is the window labeled “New SR”",
"110 as shown in FIG. 2. The four buttons labeled “Company, “Support Level”, “Product”, “Cust. Type”",
"correspond to system data files populated by the software system upon submission of company information, support level information product information, and customer type information, respectively.",
"[0047] The customer is required to provide data concerning the SR using the dialog box labeled “Data fields for the iPM”",
"120 .",
"The data preferably include the severity of the SR, the SR type and the list of products affected by the SR.",
"Typical SR type may include “User Misunderstanding”, “Possible Product Bug”, “Documentation Question”, “Technical Question”, “General Request”, “Subject”, “Description”, and “Attachments.”",
"The products affected by the SR may be selected from a product list.",
"The product list may further comprise a primary product list and a secondary product list, wherein the secondary product list contains products that are being used by a product in the primary product list.",
"The product list may be independent from the project, or specific to a project, depending on user preference.",
"[0048] The customer will be notified after the successful submission of an SR via email and a window served to the customer's web browser.",
"The email notification will be send to the customer's email address with instructions on how to reply.",
"The success window will preferably provide a summary of the SR submitted and an SR ID number, as shown in the window labeled “Successful Process Notification”",
"130 in FIG. 2. Before the notification is sent, the SR is parsed and project and customer information obtained for the SR.",
"An SR link is created for every project affected by the SR.",
"At the same time the notification is sent, an action item list for recording all the performed actions associated with the SR will be created and a “SR submitted”",
"action is added to the list.",
"An service engineer will be assigned to the SR and a correspondence list for the SR will be created to record the communications between the customer and the assigned engineer.",
"[0049] The process of resolving an SR preferably involves collaboration between the customer and project members as well as the sharing of information in the project or information from other projects or resources.",
"A customer belonging to a project can access any SR that is associated with the project using an interface like the window labeled “SR Links”",
"140 in FIG. 2. By selection of an SR listed in the window, the customer is directed to another interface where information related to the selected SR is listed, like the window labeled “SRI”",
"in FIG. 2 150 .",
"[0050] In the preferred embodiment, if the customer is also the owner of the selected SR, he/she can also modify the content of the SR.",
"Modifiable fields of the SR preferably include: Severity, SR Type, SR Status, Subject and Description.",
"After the submission of the modified SR, both the SR Owner and the assigned engineer will be notified of the change.",
"A notification of change will also appear in the action item list associated with the SR.",
"[0051] A customer preferably can also request a callback from a service engineer to discuss details on an existing SR.",
"The callback request will be automatically added to the action item list and a callback notification is sent to the assigned engineer.",
"[0052] Every project generally has its own discussion forum typically accessible only by the project's members.",
"The forum allows the project team to discuss issues of interest to the team in a common community area.",
"Optionally, more accessible forums can also be created that are open to persons who are not project members.",
"[0053] In the preferred embodiment, an SR is normally linked to a project automatically upon its submission.",
"An SR can also be manually linked to other projects by a project administrator through an interface like the one shown in FIG. 3. (Note that an SR may not be linked to a project created based on a different agreement.) To link an SR to a project, the administrator can either select from a list of available SRs 210 , or just type the SR ID in the text box labeled “Enter an SR number”",
"220 .",
"The list of SRs can be sorted and filtered using Sort button 230 an f filter button 240 and associated field selection check boxes 250 , 260 .",
"Fields for sorting and filtering SRs preferably include “Date”, “Status”, “Product”",
"and “Owner”",
"(iPM).",
"An SR can also be removed from a project using the same interface.",
"[0054] The preferred embodiment also comprises interfaces and systems to update products associated with the project.",
"Product updates can be accomplished through the interface shown in FIG. 4. Using this interface, project members can download and install any release, service package, or patch of any product available to the customer.",
"The customer chooses the product for update from the product list 310 and submit the request to the system.",
"The system will provide a window like the one labeled “Update”",
"320 in FIG. 4 detailing the available releases, service packages and patches for download.",
"The customer selects the desired release service package, or patch then clicks the download button 330 to download it.",
"[0055] After a successful download the update is appended to the product list as product available for use in the project.",
"All the downloads, installations and configurations can be archived to provide a map of the customer's working environment.",
"This map can be accessed by customer services to automatically configure a testing environment to build test cases from.",
"All the test cases can also be archived and shared using a document sharing service.",
"[0056] The preferred embodiment of the present invention also comprises a document sharing service that enables project members to share documents related to the project.",
"Project members can add, remove and download the documents.",
"Examples of documents may include: operations guides, status reports, or project/architecture overviews.",
"[0057] A typical interface for document sharing is shown in FIG. 5. A project member can select any document provided in the document list in the window labeled “Document Sharing”",
"410 .",
"These documents can be sorted and filtered based on certain fields described in the “sort”",
"window 420 and the “filter”",
"window 430 in FIG. 5. [0058] A project member can also post a document to the project from the local filing system or download a selected document to the local file system using the window labeled “Post/Download Document”",
"440 shown in FIG. 5. Document can also be removed from the project.",
"Document protection is preferably available on a per document basis.",
"Document encryption may be available on a document-to-document basis.",
"[0059] Every time a document is added, downloaded or removed, the system preferably logs these details.",
"Information to be logged preferably include name of the project member, date, document name, action (add, remove, download) and security information.",
"Project members may opt to be notified when documents are added, downloaded or removed.",
"[0060] The present invention also comprises an interface for tracking actions related to the project from a task list.",
"FIG. 6 shows a preferred embodiment of such an interface.",
"The task list may be sorted and filtered using any task fields.",
"Any project member is able to select a task to view and create a new task using the “Task View”",
"window 510 and the “New Task”",
"window 520 , respectively.",
"[0061] When a new task is created, the project member who creates the task is the default owner of that task.",
"Tasks are distinguished by availability, either being assigned or unassigned.",
"A new task is unassigned by default.",
"[0062] In both the “New Task”",
"520 and the “Task View”",
"510 windows, the field “Assigned to”",
"is used to indicate the ownership of the task;",
"other descriptive fields for a task may include: subject, due date, start date, status, priority, percentage of completion, and description of the task.",
"The task details may be modified by the task owner only.",
"A task may be removed by the owner, or by the creator if it is unassigned.",
"[0063] The present invention also comprises an interface for project members to view information about other project members.",
"FIG. 7 shows such an interface.",
"A project member can access contact information about another by selecting a project member from the list of members in the window labeled “Project Area Members”",
"610 .",
"The contact information may include: user name, project roles, job title, mailing address, email address, and company information.",
"[0064] The preferred embodiment may also include an interface of a document locator for customers or project members to search for documents within the project hierarchy on the Internet.",
"The keyword entered by the project member may be automatically populated with project information in order to narrow the scope of the search.",
"For example, if the project member enters key word “IDL”",
"in the search field and OrbixWeb was the only product being used by the project, then the locator will only search OrbixWeb IDL articles.",
"[0065] The preferred embodiment also comprises an interface that allows project members to manage bookmarks relevant to the project itself.",
"[0066] The present invention also comprises an interface for project members to customize certain elements of their project environment and speeding up the process of SR resolution.",
"Throughout the life-cycle of the project, project details will change.",
"The existence of this interface facilitates the need for being able to change project details as work on the project progresses.",
"[0067] The interface for changing project details may comprise an interface to view and edit project details such as name, description and status.",
"Any change in project status may be recorded.",
"Typical values for project status include: Development, Archived, testing, or Deployment.",
"Other local project status attributes can also be created by project administrators.",
"[0068] In one embodiment, projects are arranged in a hierarchical structure.",
"A project member must register himself into the system and after completing a registration process the project member is given access to a root project.",
"The root project is created based on an agreement between the customer and the customer service provider, as indicated before.",
"The first root project is created by the system using default settings established when the agreement is created.",
"It is ready to run without any immediate need to setup.",
"[0069] New projects may also be created from within root projects.",
"This new project will also link back to the same agreement.",
"A root project is unrelated to any other projects except those contained within it.",
"A sub-project may be created from within another project based on the same agreement.",
"A project hierarchy is created by creating sub-projects.",
"[0070] The content of project details may also comprise information about the products used by the project.",
"In the preferred embodiment, an interface is provided for project members to view a list of installed products for the project.",
"The interface also allows project members to indicate whether a product in the list is in use.",
"This then allows the system to filter the product listings so that only products that are in use are presented to the project member in the SR management and product update interfaces.",
"When a project is created all products in the product list are assumed to be in use.",
"[0071] The interface also allows view and edit product details.",
"A product detail window is available for viewing the details of a product.",
"The project member can access details by drilling down into the product from any of the three product interfaces: Installed Product, Agreement Product, or 3 rd Party Product.",
"Information about a product preferably includes: Serial Number, Ship RequestID, Product Release, Version, Part Number, Date Shipped, OS product is installed on, URL's to product pages, and a free text note field to comment in.",
"Information in the text note field preferably includes: an identifier of the machine the product is installed on, and URL's for product information pages.",
"Information entered into the note field is seen only from the project into which it was entered.",
"The interface may also allow the project administrator to add and remove project members belonging to a project.",
"[0072] The interfaces and software within the project member request management software system can be realized using a variety of programming tools such as the J2EE suite."
] |
BACKGROUND OF THE INVENTION
The present invention relates to guides to assist connection of a pipe, e.g. a conductor pipe, lowered from a platform over the surface of the sea, to a wellhead positioned on the sea bed and to processes of connection employing such guides.
Offshore oil and gas fields have been developed using large platforms, which were constructed and installed offshore before drilling began. This meant that production rate would increase gradually as each well was drilled and completed.
In order to reduce the time taken to produce hydrcarbons at a significant rate, it is possible to drill wells using mobile drilling rig during the period required to construct the production platform. When the platform has been accurately installed over the "pre-drilled" wells, conductor pipes are lowered through guides to connect to the seabed wellheads. These pipes effectively lengthen the well bores above water level, so that the wellheads can be positioned at platform deck level. This permits tubing to be installed from the deck, and wellhead valves which form the "Christmas tree" can be manually actuated by an operator on the platform. These pipes are known as "tie-back" conductor pipes.
As offshore fields progress to deeper water, mobile rigs have been developed from being bottom supported, or "jack-up" type, to floating rigs which are either shipshape or semi-submersible. Floating rigs are less easily maintained directly over a point on the sea bed than jack-up rigs, as they tend to drift laterally against their anchor chains or their dynamic positioning reference beacon.
Drilling from a jack-up rig involves the use of a conductor pipe extending from the sea bed to the deck level where a safety system or "blow-out-preventor (BOP) is mounted on top of the conductor. The BOP is used to control the well in the event that the drill bit pierces a formation containing pressurised oil or gas which is at a higher pressure than that exerted by the head of drilling mud in the hole. With a floating rig the lateral motion of the vessel is accommodated by a flexing "riser" incorporating an articulated joint at the lower end.
Because the articulated joint is relatively poor at retaining high pressure oil and gas, the BOP is mounted on a sea bed wellhead.
This difference in drilling method means that the vertical misalignment tolerance of the wellbore immediately below the seabed is wider for wells drilled from a floating rig than those drilled from a jack-up rig. Also in deeper water, the fixed platform structure tends to an increasing height to base-width ratio, and therefore vertically becomes less controllable. If "pre-drilling" is to be successfully applied in deeper water, the connection system between the conductor pipes and the sub sea wellheads must be able to accept a wider angular misalignment tolerance between guide funnels in the platform structure and the sub sea wellbores.
DESCRIPTION OF THE PRIOR ART
The present Applicant has previously proposed (Offshore Services--May 1979) an apparatus for forming an underwater connection which comprised a guide post having at one end an expandable mandrel. In use, the mandrel was to be locked into a wellhead and a pipe was to be slid down a cable tensioned between the surface and the free end of the guide post so that the pipe would pass over the post and be aligned for engagement with the wellhead. It has now however been appreciated that the misalignment between the pipe and the wellhead corrected by the post would result in many cases in so much frictional engagement between the post and the pipe that it would not be possible to turn the pipe to effect a connection to the wellhead in the case where the connecting means is such as to require rotation e.g. a screw thread.
BRIEF DESCRIPTION OF THE INVENTION
It is desired therefore to provide means first to guide the end of the conductor pipe to a position directly above the sub sea wellhead, then to apply a bending moment to the lower end of the conductor pipe if needed, to bring its axis into coincidence with the wellhead axis, and finally to permit free rotation of the conductor pipe, if necessary, while in the bent configuration, to effect a connection, e.g. a threaded or other rigid connection to the wellhead.
Accordingly, the present invention provides a guide for use in connecting a pipe 6 to a sub sea wellhead 3, which guide comprises a guide post 1 having a reversibly radially expandable portion 2 to locate in and rigidly attach the guide post to the sub sea wellhead, and an elongate portion 1A to be received in the end of the pipe, characterised in that the elongate portion comprises means 12 rotatable about the axis of the post for supporting the pipe for rotation to connect to the wellhead.
In use, the guide post will normally be suspended on suitable means for lowering it from the sea surface, e.g. a cable or hollow pipe, usually attached on the axis of the guide post and preferably providing a hydraulic connection to the guide post when the expandable portion is hydraulically actuated.
The expandable portion may be an expanding mandrel and the expanding mandrel will preferably be wholly or partially segmented and co-operate with wedging surfaces so that as the segments move over the wedging surfaces, the outside diameter either increases or decreases, depending on the direction of motion.
To enable the expanding mandrel to be actuated in a remote location, the actuating means will preferably be hydraulic, and able to cause expansion or contraction of the mandrel.
The elongate portion of the guide post preferably comprises a rotatable sleeve which may be supported on the post on low-friction bearings to provide the said means for supporting the pipe for rotation.
The invention includes a process for connecting a pipe 6 to a sub sea wellhead 3 to which it is connectable which process comprises suspending the pipe 6 above the wellhead 3, lowering through the bore of the pipe a guide comprising guide post 1 and means 4 for lowering the guide post 1, the guide post 1 having a reversibly radially expandable portion 2 and an elongate portion 1A.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention may be more readily understood, the following description of a specific example is given for illustration, reference being made to the accompanying drawings wherein:
FIG. 1 is a view showing a guide post being positioned over the wellhead, and
FIG. 2 is a view showing the guide post of FIG. 1. latched into the wellhead prior to lowering the conductor.
FIG. 3 is a half-sectional view showing the guide post of FIG. 1 latched into the wellhead, with the conductor pipe lowered over the post.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 the guide according to the invention includes a guide post 1 having toward one end an expanding mandrel 2, each end of the post 1 being frusto conical to aid location in the wellhead and pipe as described hereafter. As shown in FIG. 3, the post 1 bears, above the expanding mandrel 2 a sleeve 12 having an exterior surface 12A. Sleeve 12 is rotatable on bearings 13. The body of the post 1 under the sleeve 12 is recessed so that the outer surface 12A of the sleeve lies flush with or slightly raised above the adjacent parts of the post. A bearing 13 is provided at each end of the sleeve and may be a plain bearing or a roller, e.g. a tapered roller, bearing. A shaped nut 14 maintains the sleeve 12 in position on the post.
The post 1 is hollow allowing a pair of hydraulic lines 19 (one shown in ghost lines) connecting a hydraulic line containing cable 4 on which the guide post is suspended to a distribution block 20 which provides connection to two hydraulic lines 8 and 15 serving the expanding mandrel 12.
Cable 4 is attached by a gland 17 to the top of post 1. The internal gland nut 18 acts to grip reinforcing armour wires around the cable 4. Sealing between the block 20 and the bore of post 1 is effected typically by resilient seal 21.
In place of cable 4 it would also be possible to employ a pipe as the means for lowering the guide post. Such a pipe would normally be composed of many threaded sections assembled onto one another as the guide is lowered.
Expanding mandrel 2 includes a set of segments 2A movable radially outward and inward in response to the motion of a hydraulic piston 9 located in a cylinder on the axis of the post and bearing pins 10, which each engage a segment 2A and drive their segment 2A up and down over a set of wedge surfaces 11 so that downward motion of the piston 9 upon introduction of fluid into the cylinder above the piston via line 8 expands the mandrel. The segments are held against the wedge surfaces by sprung bands 16. Line 15 communicates between the distribution block 20 and the cylinder below piston 9. The mandrel is shown in FIG. 3 in the expanded position.
The ratio length of the rotatable portion of the guide post to its diameter is generally preferably about 3:1 but may be less e.g. 2:1. The length necessary to enable a sufficient moment to be applied to the pipe to bend it into alignment will depend on the operating circumstances and the material of which the pipe is constructed.
The tolerance in angular alignment of the tie back conductor to wellhead to which conventional drilling equipment operates is about 1.5°. The present invention as specifically described enables an angular misalignment of 1.5° to be corrected and may allow greater misalignments, e.g. of up to 2.5°, to be corrected.
The operation of the apparatus shown in the drawings is as follows:
As shown in FIG. 1, the guide post 1 is lowered on its own cable 4 through the inside of the conductor pipe until it is about 2 ft. above the wellhead. A diver or Remotely Controlled Vehicle (RCV) 5 with television and manipulator then positions the post directly over the wellhead, and it is lowered the remaining few feet into a latching position inside the wellhead 3 with the major portion of the post protruding about 6 ft. The expanding mandrel 2 at the lower end of the guide post can be actuated hydraulically to rigidly clamp the post to the wellhead bore.
By pressurising the hydraulic line 8 which extends from cable 4, the piston 9 is driven downwards and pins 10 push the mandrel segments 2 to expand against the inside bore of the wellhead 3 by moving along wedge surfaces 11.
When the lower end of the post is fixed into the wellhead as shown in FIG. 2, the cable is tensioned by pulling at the platform deck. The conductor 6 is lowered the remaining distance to the wellhead, and is guided laterally by the cable to the top of the post which has a conical shape to assist the lower end of the conductor on its way down over the major portion of the post. As the conductor closely approaches the wellhead, the conductor bore has a close sliding fit over the sleeve 12 which extends over the outside of the major portion of the post. The combination of the weight of the conductor and two spaced points of contacts between the conductor and the sleeve is able to supply a bending moment to the conductor to eliminate most of any initial angular misalignment.
The pipe and wellhead have co-operating connecting means which are connectable by rotation of the pipe. On the right hand side of FIGS. 1 and 2 the connecting means are shown as scree threaded portions. On the left hand side of FIGS. 1 and 2 an alternative possibility is schematically shown, namely a latch mechanism actuated by rotation.
On the right hand side of FIG. 3, the lower threaded end of conductor pipe 6 is shown about to enter the mating threaded portion of the wellhead 3.
Rotation of the conductor pipe 6 in the correct sense causes the threaded end of pipe 6 to enter the mating thread at the top of wellhead 3. As this rotation proceeds, the two spaced locations along the sleeve 12 support lateral loads to maintain close axial alignment between the conductor 6 and the wellhead 3. If the post had no sleeve 12 with low-friction bearings 13, there would be a scuffing or galling action between the inside surface of pipe 6 and the outside surface of post 2. With the sleeve 12 and bearings 13 in place, the conductor pipe 6 can rotate freely round the post even though there may be a lateral force and a considerable bending moment action between the conductor pipe 6 and the post 1. The position then reached is shown on the left side of FIG. 3.
When the conductor pipe 6 is fully screwed into the wellhead 3, the post 1 can be released. This is done by pressurising the second hydraulic line 15 which pushes the piston 9 upwards to raise the mandrel segments 2A.
The wellhead may have an extension piece rigidly attached above it, which piece may have a threaded or other type of profile for effecting a connection to the tie-back conductor. The guide post may be adapted to locate into the wellbore extension piece, rather than into the wellhead itself.
The apparatus is useful in a situation where sub sea wells have been drilled through a seabed template and a platform structure has been positioned over them. A conductor usually consisting of 40 ft. long lengths of pipe which are joined in the vertical position and progressively lowered through guide funnels in the structure, is supported 30 to 50 ft. above the mating wellhead.
The connector between the conductor and wellhead will generally require conductor rotation to permit makeup. It may be a direct threaded type connection; or may require rotation to clamp a lock ring, e.g. the Koomey Triple--S System. In the illustrated embodiment the sleeve over the major portion of the post is mounted on low-friction bearings, so that when torque is applied to the conductor at platform deck level, the two parts of the connector are held in axial alignment and the bending moment is supported by the bearings. This eliminates the possibilities of
(a) cross threading the connector, and
(b) scuffing or galling the mating surfaces of the two parts of the connector.
After connection has been made, the expanding mandrel can be released and the post can be recovered by pulling it up through the conductor.
Although the invention has been described with reference to forming a connection to a sub sea wellhead, it will be appreciated that the invention is also applicable to other situations where a pipe is to be connected to an open hollow structure, particularly where angular misalignment may be encountered. Accordingly, the invention includes a guide for use in connecting a pipe to an open hollow structure by a joint formed upon rotation of the pipe or the structure and comprising a guide post having a radially expandable portion to locate in and rigidly attach the guide post to the hollow structure, and an elongate portion providing means rotatable about the axis of the post and to be received in the end of the pipe to support the pipe for rotation relative to the hollow structure. | A guide is provided for forming a pipe connection from a sub sea wellhead back to a surface platform which may not be in perfect alignment. The guide comprises a guide post and a cable on which it may be lowered through a pipe to the wellhead. The guide post has a radially expandable mandrel for temporary rigid attachment in the wellhead and an elongate portion having a rotatable sleeve over which the pipe may be lowered into engagement with the wellhead and rotation to form the connection desired. The rotation of the pipe to form the connection is possible because of the sleeve. | Identify and summarize the most critical features from the given passage. | [
"BACKGROUND OF THE INVENTION The present invention relates to guides to assist connection of a pipe, e.g. a conductor pipe, lowered from a platform over the surface of the sea, to a wellhead positioned on the sea bed and to processes of connection employing such guides.",
"Offshore oil and gas fields have been developed using large platforms, which were constructed and installed offshore before drilling began.",
"This meant that production rate would increase gradually as each well was drilled and completed.",
"In order to reduce the time taken to produce hydrcarbons at a significant rate, it is possible to drill wells using mobile drilling rig during the period required to construct the production platform.",
"When the platform has been accurately installed over the "pre-drilled"",
"wells, conductor pipes are lowered through guides to connect to the seabed wellheads.",
"These pipes effectively lengthen the well bores above water level, so that the wellheads can be positioned at platform deck level.",
"This permits tubing to be installed from the deck, and wellhead valves which form the "Christmas tree"",
"can be manually actuated by an operator on the platform.",
"These pipes are known as "tie-back"",
"conductor pipes.",
"As offshore fields progress to deeper water, mobile rigs have been developed from being bottom supported, or "jack-up"",
"type, to floating rigs which are either shipshape or semi-submersible.",
"Floating rigs are less easily maintained directly over a point on the sea bed than jack-up rigs, as they tend to drift laterally against their anchor chains or their dynamic positioning reference beacon.",
"Drilling from a jack-up rig involves the use of a conductor pipe extending from the sea bed to the deck level where a safety system or "blow-out-preventor (BOP) is mounted on top of the conductor.",
"The BOP is used to control the well in the event that the drill bit pierces a formation containing pressurised oil or gas which is at a higher pressure than that exerted by the head of drilling mud in the hole.",
"With a floating rig the lateral motion of the vessel is accommodated by a flexing "riser"",
"incorporating an articulated joint at the lower end.",
"Because the articulated joint is relatively poor at retaining high pressure oil and gas, the BOP is mounted on a sea bed wellhead.",
"This difference in drilling method means that the vertical misalignment tolerance of the wellbore immediately below the seabed is wider for wells drilled from a floating rig than those drilled from a jack-up rig.",
"Also in deeper water, the fixed platform structure tends to an increasing height to base-width ratio, and therefore vertically becomes less controllable.",
"If "pre-drilling"",
"is to be successfully applied in deeper water, the connection system between the conductor pipes and the sub sea wellheads must be able to accept a wider angular misalignment tolerance between guide funnels in the platform structure and the sub sea wellbores.",
"DESCRIPTION OF THE PRIOR ART The present Applicant has previously proposed (Offshore Services--May 1979) an apparatus for forming an underwater connection which comprised a guide post having at one end an expandable mandrel.",
"In use, the mandrel was to be locked into a wellhead and a pipe was to be slid down a cable tensioned between the surface and the free end of the guide post so that the pipe would pass over the post and be aligned for engagement with the wellhead.",
"It has now however been appreciated that the misalignment between the pipe and the wellhead corrected by the post would result in many cases in so much frictional engagement between the post and the pipe that it would not be possible to turn the pipe to effect a connection to the wellhead in the case where the connecting means is such as to require rotation e.g. a screw thread.",
"BRIEF DESCRIPTION OF THE INVENTION It is desired therefore to provide means first to guide the end of the conductor pipe to a position directly above the sub sea wellhead, then to apply a bending moment to the lower end of the conductor pipe if needed, to bring its axis into coincidence with the wellhead axis, and finally to permit free rotation of the conductor pipe, if necessary, while in the bent configuration, to effect a connection, e.g. a threaded or other rigid connection to the wellhead.",
"Accordingly, the present invention provides a guide for use in connecting a pipe 6 to a sub sea wellhead 3, which guide comprises a guide post 1 having a reversibly radially expandable portion 2 to locate in and rigidly attach the guide post to the sub sea wellhead, and an elongate portion 1A to be received in the end of the pipe, characterised in that the elongate portion comprises means 12 rotatable about the axis of the post for supporting the pipe for rotation to connect to the wellhead.",
"In use, the guide post will normally be suspended on suitable means for lowering it from the sea surface, e.g. a cable or hollow pipe, usually attached on the axis of the guide post and preferably providing a hydraulic connection to the guide post when the expandable portion is hydraulically actuated.",
"The expandable portion may be an expanding mandrel and the expanding mandrel will preferably be wholly or partially segmented and co-operate with wedging surfaces so that as the segments move over the wedging surfaces, the outside diameter either increases or decreases, depending on the direction of motion.",
"To enable the expanding mandrel to be actuated in a remote location, the actuating means will preferably be hydraulic, and able to cause expansion or contraction of the mandrel.",
"The elongate portion of the guide post preferably comprises a rotatable sleeve which may be supported on the post on low-friction bearings to provide the said means for supporting the pipe for rotation.",
"The invention includes a process for connecting a pipe 6 to a sub sea wellhead 3 to which it is connectable which process comprises suspending the pipe 6 above the wellhead 3, lowering through the bore of the pipe a guide comprising guide post 1 and means 4 for lowering the guide post 1, the guide post 1 having a reversibly radially expandable portion 2 and an elongate portion 1A.",
"BRIEF DESCRIPTION OF THE DRAWINGS In order that the present invention may be more readily understood, the following description of a specific example is given for illustration, reference being made to the accompanying drawings wherein: FIG. 1 is a view showing a guide post being positioned over the wellhead, and FIG. 2 is a view showing the guide post of FIG. 1. latched into the wellhead prior to lowering the conductor.",
"FIG. 3 is a half-sectional view showing the guide post of FIG. 1 latched into the wellhead, with the conductor pipe lowered over the post.",
"DETAILED DESCRIPTION OF THE INVENTION As shown in FIG. 1 the guide according to the invention includes a guide post 1 having toward one end an expanding mandrel 2, each end of the post 1 being frusto conical to aid location in the wellhead and pipe as described hereafter.",
"As shown in FIG. 3, the post 1 bears, above the expanding mandrel 2 a sleeve 12 having an exterior surface 12A.",
"Sleeve 12 is rotatable on bearings 13.",
"The body of the post 1 under the sleeve 12 is recessed so that the outer surface 12A of the sleeve lies flush with or slightly raised above the adjacent parts of the post.",
"A bearing 13 is provided at each end of the sleeve and may be a plain bearing or a roller, e.g. a tapered roller, bearing.",
"A shaped nut 14 maintains the sleeve 12 in position on the post.",
"The post 1 is hollow allowing a pair of hydraulic lines 19 (one shown in ghost lines) connecting a hydraulic line containing cable 4 on which the guide post is suspended to a distribution block 20 which provides connection to two hydraulic lines 8 and 15 serving the expanding mandrel 12.",
"Cable 4 is attached by a gland 17 to the top of post 1.",
"The internal gland nut 18 acts to grip reinforcing armour wires around the cable 4.",
"Sealing between the block 20 and the bore of post 1 is effected typically by resilient seal 21.",
"In place of cable 4 it would also be possible to employ a pipe as the means for lowering the guide post.",
"Such a pipe would normally be composed of many threaded sections assembled onto one another as the guide is lowered.",
"Expanding mandrel 2 includes a set of segments 2A movable radially outward and inward in response to the motion of a hydraulic piston 9 located in a cylinder on the axis of the post and bearing pins 10, which each engage a segment 2A and drive their segment 2A up and down over a set of wedge surfaces 11 so that downward motion of the piston 9 upon introduction of fluid into the cylinder above the piston via line 8 expands the mandrel.",
"The segments are held against the wedge surfaces by sprung bands 16.",
"Line 15 communicates between the distribution block 20 and the cylinder below piston 9.",
"The mandrel is shown in FIG. 3 in the expanded position.",
"The ratio length of the rotatable portion of the guide post to its diameter is generally preferably about 3:1 but may be less e.g. 2:1.",
"The length necessary to enable a sufficient moment to be applied to the pipe to bend it into alignment will depend on the operating circumstances and the material of which the pipe is constructed.",
"The tolerance in angular alignment of the tie back conductor to wellhead to which conventional drilling equipment operates is about 1.5°.",
"The present invention as specifically described enables an angular misalignment of 1.5° to be corrected and may allow greater misalignments, e.g. of up to 2.5°, to be corrected.",
"The operation of the apparatus shown in the drawings is as follows: As shown in FIG. 1, the guide post 1 is lowered on its own cable 4 through the inside of the conductor pipe until it is about 2 ft.",
"above the wellhead.",
"A diver or Remotely Controlled Vehicle (RCV) 5 with television and manipulator then positions the post directly over the wellhead, and it is lowered the remaining few feet into a latching position inside the wellhead 3 with the major portion of the post protruding about 6 ft.",
"The expanding mandrel 2 at the lower end of the guide post can be actuated hydraulically to rigidly clamp the post to the wellhead bore.",
"By pressurising the hydraulic line 8 which extends from cable 4, the piston 9 is driven downwards and pins 10 push the mandrel segments 2 to expand against the inside bore of the wellhead 3 by moving along wedge surfaces 11.",
"When the lower end of the post is fixed into the wellhead as shown in FIG. 2, the cable is tensioned by pulling at the platform deck.",
"The conductor 6 is lowered the remaining distance to the wellhead, and is guided laterally by the cable to the top of the post which has a conical shape to assist the lower end of the conductor on its way down over the major portion of the post.",
"As the conductor closely approaches the wellhead, the conductor bore has a close sliding fit over the sleeve 12 which extends over the outside of the major portion of the post.",
"The combination of the weight of the conductor and two spaced points of contacts between the conductor and the sleeve is able to supply a bending moment to the conductor to eliminate most of any initial angular misalignment.",
"The pipe and wellhead have co-operating connecting means which are connectable by rotation of the pipe.",
"On the right hand side of FIGS. 1 and 2 the connecting means are shown as scree threaded portions.",
"On the left hand side of FIGS. 1 and 2 an alternative possibility is schematically shown, namely a latch mechanism actuated by rotation.",
"On the right hand side of FIG. 3, the lower threaded end of conductor pipe 6 is shown about to enter the mating threaded portion of the wellhead 3.",
"Rotation of the conductor pipe 6 in the correct sense causes the threaded end of pipe 6 to enter the mating thread at the top of wellhead 3.",
"As this rotation proceeds, the two spaced locations along the sleeve 12 support lateral loads to maintain close axial alignment between the conductor 6 and the wellhead 3.",
"If the post had no sleeve 12 with low-friction bearings 13, there would be a scuffing or galling action between the inside surface of pipe 6 and the outside surface of post 2.",
"With the sleeve 12 and bearings 13 in place, the conductor pipe 6 can rotate freely round the post even though there may be a lateral force and a considerable bending moment action between the conductor pipe 6 and the post 1.",
"The position then reached is shown on the left side of FIG. 3. When the conductor pipe 6 is fully screwed into the wellhead 3, the post 1 can be released.",
"This is done by pressurising the second hydraulic line 15 which pushes the piston 9 upwards to raise the mandrel segments 2A.",
"The wellhead may have an extension piece rigidly attached above it, which piece may have a threaded or other type of profile for effecting a connection to the tie-back conductor.",
"The guide post may be adapted to locate into the wellbore extension piece, rather than into the wellhead itself.",
"The apparatus is useful in a situation where sub sea wells have been drilled through a seabed template and a platform structure has been positioned over them.",
"A conductor usually consisting of 40 ft.",
"long lengths of pipe which are joined in the vertical position and progressively lowered through guide funnels in the structure, is supported 30 to 50 ft.",
"above the mating wellhead.",
"The connector between the conductor and wellhead will generally require conductor rotation to permit makeup.",
"It may be a direct threaded type connection;",
"or may require rotation to clamp a lock ring, e.g. the Koomey Triple--S System.",
"In the illustrated embodiment the sleeve over the major portion of the post is mounted on low-friction bearings, so that when torque is applied to the conductor at platform deck level, the two parts of the connector are held in axial alignment and the bending moment is supported by the bearings.",
"This eliminates the possibilities of (a) cross threading the connector, and (b) scuffing or galling the mating surfaces of the two parts of the connector.",
"After connection has been made, the expanding mandrel can be released and the post can be recovered by pulling it up through the conductor.",
"Although the invention has been described with reference to forming a connection to a sub sea wellhead, it will be appreciated that the invention is also applicable to other situations where a pipe is to be connected to an open hollow structure, particularly where angular misalignment may be encountered.",
"Accordingly, the invention includes a guide for use in connecting a pipe to an open hollow structure by a joint formed upon rotation of the pipe or the structure and comprising a guide post having a radially expandable portion to locate in and rigidly attach the guide post to the hollow structure, and an elongate portion providing means rotatable about the axis of the post and to be received in the end of the pipe to support the pipe for rotation relative to the hollow structure."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a shelving system and, more particularly, to an easily assembled and installed modular shelving system that may be customized by the user to suit the user's particular needs.
2. Description of the Prior Art
It is often desirable or even necessary to provide shelving for storage of items in various places such as a closet, a storage room, a workroom, a utility room, an office or a garage. Many different types of shelving systems are known in the art, including various metal, wood or plastic systems that may be shipped and/or sold to the user in an unassembled state and subsequently assembled and installed by the user in a desired location.
For example, one prior art metal shelving unit consists of a number of metal shelves and four elongated, vertical corner pieces. Such units are sold in pieces, and require the user to attach the corners of the metal shelves to the corner pieces by a nut and bolt assembly or the like. This type of shelving system requires a large number of individual pieces and various tools for assembly. Also, assembly configurations are limited in this type of a system, and thus there is limited opportunity for the user to customize the system to meet his or her needs.
Other prior art shelving systems include modular shelving systems constructed in a number of pieces from a material such as wood and/or metal. The separate pieces of the system are designed to be mounted together using hardware such as screws, latches and/or nut and bolt assemblies. Again, this type of shelving system requires a large number of pieces and various tools for assembly. In addition, such systems are often difficult, time consuming and confusing to assemble, leading to frustration and wasted time on the part of the user. Further, once assembled, such systems are difficult and time consuming to disassemble and modify, which may be required as the needs of the user change.
Still another type of prior art shelving system often utilized in closets consists of a number of shelves made of a plurality of welded, coated wires. The shelves are typically mounted to a wall by the user using screws and the like, often making installation difficult and time consuming, particularly to a user who may not be particularly handy. Such systems, while lightweight, do not present a sturdy appearance due to the gaps that exist between the wire supports. In addition, items that are smaller than the gaps between the small, one-eighth inch diameter wire supports may not be stored with this type of system as those items will fall through the gaps.
There is therefore a need for a modular shelving system that is quick and easy to assemble and disassemble with very limited or no use of separate tools. There is further a need for such a modular shelving system that may be customized by a user to meet certain needs, and that may be easily and readily reconfigured and adjusted as needs change.
SUMMARY OF THE INVENTION
The present invention relates to a customizable modular shelving system including a number of separate pieces that is easy to assemble and disassemble with very limited or no use of separate tools. As a result, the shelving system may be easily and readily reconfigured and adjusted as the needs of the user change.
One aspect of the present invention relates to a shelving system, and a method of assembling same, including a vertical support column having one or more slots provided in the upper portion thereof, and a shelf having one or more connectors protruding from a first end thereof. The slots in the vertical support column have a first shape and the connectors each have an enlarged portion having a second shape, wherein the first shape and the second shape are generally complementary to one another. The enlarged portion of each of the connectors is disposed in a respective one of the slots. The shelving system may further include a second vertical support column having slots having the same first shape provided in the upper portion thereof, wherein the shelf has connectors having an enlarged portion having the same second shape protruding from a second end thereof. The connectors on the second end of the shelf are, in this embodiment, disposed in the slots provided in the second vertical support column. The slots and connectors may be generally T-shaped.
The upper portion of the vertical support column may also have one or more detents, and the first end of the shelf may have one or more protruding tabs, wherein the one or more protruding tabs are received and held in place by the one or more detents. In addition, the upper portion of the vertical support column may also have a recess, and the first end of the shelf may have a protruding member, wherein the protruding member is received by and supported on a bottom edge of the recess. Further, the upper portion of the vertical support column may have a horizontal support ledge extending therefrom, and the bottom edge of the first end of the shelf may rest on and be supported by the support ledge.
The shelf in this aspect of the invention may have a generally planar top surface and one or more valances extending downwardly from and generally perpendicular to the top surface. In addition, the lower portion of the vertical support column may have a plurality of feet extending therefrom. Preferably, the plurality of feet may include a front foot and a back foot, with the front foot being slightly longer than the back foot to cause the vertical support column to be angled backwardly against a wall in the location where the shelving system is placed.
In another embodiment, the shelving system further includes a second vertical support column having one or more tabs extending from the upper portion thereof, and the upper portion of the first vertical support column has one or more recesses provided therein. The first vertical support column is a bottom vertical support column and the second vertical support column is a top vertical support column. In this embodiment, each of the tabs is disposed in a respective one of the recesses to hold the second vertical support column in place. The lower portion of the vertical support column may also include a recessed portion that provides clearance for a baseboard affixed to a wall in a location where the shelving system is placed. Similarly, the vertical support column may include a recessed portion located between the upper portion and the lower portion thereof that provides clearance for a chair rail affixed to a wall in a location where the shelving system is placed. In addition, the lower portion of the vertical support column may have one or more recessed portions adapted to receive a fastening element for fastening the vertical support column in place.
Another aspect of the present invention relates to a shelving system including a vertical support column having a slot provided in the first side thereof and an elongated rod having an enlarged end that is disposed in the slot. Preferably, the enlarged end of the rod is flared, and the rod is elongated and tubular. Also, the slot is preferably angled rearwardly and downwardly. In one particular embodiment, the slot is angled downwardly at an angle of between approximately 15 degrees and approximately 45 degrees from the horizontal axis of the vertical support column. The shelving system according to this aspect of the invention may further include a second vertical support column having a second slot provided therein, wherein the rod has a second enlarged end opposite the first enlarged end that is disposed in the second slot. In addition, a wall plate having another slot may be mounted on a wall adjacent to the shelving system, and an enlarged end of the rod may be received in the slot provided on the wall plate.
Yet another aspect of the present invention relates to a shelving system including a vertical support column having a plurality of mounting openings, and a support element removeably attached to the vertical support column through one of the mounting openings. The support element includes a receiving portion that fits over and receives a portion of the vertical support column that defines a bottom outer edge of the mounting opening. The support element preferably includes either one or two elongated tongues adjacent to the receiving portion. Also, the receiving portion may have one or more barbs extending from an inner surface thereof that are adapted to be disposed in an indentation provided in the vertical support column below the mounting opening. In one particular embodiment, the shelving system further includes a shelf having an elongated groove along a first side thereof, wherein the elongated tongue is disposed in the elongated groove such that the shelf is supported by the support element. In another particular embodiment, the shelving system further includes a drawer having an elongated groove along a first side thereof, wherein the elongated tongue is disposed in the elongated groove such that the drawer is slideably supported by the support element.
The shelving system according to this aspect of the invention may further include a second vertical support column having a plurality of second mounting openings and a second support element removeably attached to the second vertical support column through one of the second mounting openings that is generally aligned with the mounting opening of the first vertical support column to which the first support element is attached. The second support element includes a second receiving portion that fits over and receives a portion of the second vertical support column that defines a bottom outer edge of the second mounting opening. The second support element preferably includes a second elongated tongue adjacent to the second receiving portion for supporting a shelf or a drawer.
Yet another aspect of the present invention relates to a shelving system including a first vertical support column having an upper portion having a first configuration, a lower portion, and a plurality of first openings therethrough, and a second vertical support column attached to the first vertical support column having an upper portion having a second configuration, a lower portion, and a plurality of second openings therethrough. The first configuration and said second configuration are generally complementary to one another such that the upper portion of the first vertical support column mates with the lower portion of the second vertical support column. The first configuration may comprise one or more recesses provided in the upper portion of the first vertical support column and the second configuration may comprise one or more tabs extending from the lower portion of the second vertical support column, wherein each of the tabs is disposed in a respective one of the recesses.
It is an object of this invention to provide a shelving system that is easily and quickly assembled and disassembled, offering time saving advantages not found in similar products.
It is a further object of this invention to provide a shelving system that may be assembled with limited or no use of separate tools.
It is a further object of this invention to provide a shelving system that is made of an attractive material such as molded plastic.
It is a further object of this invention to provide a shelving system that is economical.
It is a further object of this invention to provide a method of assembling a shelving system that enables the pieces of the shelving system to be packed and shipped in simple and compact manner.
It is a further object of this invention to provide a shelving system that may be easily and readily reconfigured and adjusted as the needs of the user change.
It is a further object of this invention to provide a shelving system that is usable in a wide variety of residential, commercial and industrial locations.
DESCRIPTION OF THE DRAWINGS
These and other advantages of the present invention will become readily apparent upon consideration of the following detailed description and attached drawings, wherein:
FIG. 1 is an isometric view of an exemplary configuration of a shelving system according to the present invention;
FIG. 2A is a left side view of a lower column forming a part of a shelving system according to the present invention;
FIG. 2B is a cross-sectional view of the lower column shown in FIG. 2A taken along lines 2 B- 2 B in FIG. 2A ;
FIG. 2C is a top plan view of the lower column shown in FIG. 2A ;
FIG. 3A is a left side view of an upper column forming a part of a shelving system according to the present invention;
FIG. 3B is a top plan view of the upper column shown in FIG. 3A ;
FIG. 3C is a bottom plan view of the upper column shown in FIG. 3A ;
FIG. 4 is an isometric view of a cap shelf forming a part of a shelving system according to the present invention;
FIGS. 5 and 6 are top plan and front elevational views, respectively, of the cap shelf shown in FIG. 4 in the state in which it is packaged and shipped to a user;
FIG. 7 is a partial isometric view showing the cap shelf shown in FIG. 4 being attached to the lower column shown in FIG. 2A ;
FIG. 8 is a partial isometric view showing the upper column shown in FIG. 3A being mounted on top of the lower column shown in FIG. 2A ;
FIG. 9 is an isometric view of a corner cap shelf forming a part of a shelving system according to the present invention;
FIGS. 10A , 10 B and 10 C are isometric, end and side views, respectively, of a rod forming a part of a shelving system according to the present invention;
FIG. 11A is a partial isometric view showing the rod shown in FIGS. 10A-10C inserted into the rod pocket of the upper column shown in FIG. 3A ;
FIG. 11B is a cross-sectional view taken along lines 11 B- 11 B shown in FIG. 11A ;
FIG. 12 is an isometric view of an adjustable shelf forming a part of a shelving system according to the present invention;
FIG. 13 is an isometric view of a corner adjustable shelf forming a part of a shelving system according to the present invention;
FIG. 14 is an isometric view of a drawer forming a part of a shelving system according to the present invention;
FIGS. 15 and 16 are isometric views of double and single adjustable supports, respectively, forming a part of a shelving system according to the present invention;
FIG. 17 is a partial isometric view showing the double and single adjustable supports shown in FIGS. 15 and 16 mounted on the lower column shown in FIG. 2A ;
FIG. 18A is a cross sectional view of a portion of a shelving system according to the present invention showing a lower column of FIG. 2A or an upper column of FIG. 3A having a drawer and an adjustable shelf mounted thereon;
FIG. 18B is an enlarged view of a portion of the cross-section shown in FIG. 18A ; and
FIG. 19 is a front elevational view of a wall plate forming a part of a shelving system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a modular shelving system consisting of a number of separate pieces that may be selectively assembled together in a number of different configurations depending on the particular wants and needs of the user. FIG. 1 is an isometric view of one possible configuration of a shelving system 10 according to the present invention which includes a number of shelves, drawers and rods for holding and storing items such as clothing and the like in an area such as a closet. It should be appreciated that the configuration shown in FIG. 1 is exemplary only, and, as will be understood from the following description, many other configurations of shelving system 10 may be created depending on the particular wants and needs of the user.
As can be seen in FIG. 1 , shelving system 10 consists of a number of different modular pieces that may be quickly and easily fit together by a user. Each of the pieces of shelving system 10 is described in detail herein, as is the manner in which the pieces may be selectively fit together in a customizable fashion by the user.
FIGS. 2A and 2C are left side and top plan views, respectively, of a lower column 12 that forms one piece of shelving system 10 . FIG. 2B is a cross-sectional view of lower column 12 taken along lines 2 B- 2 B shown in FIG. 2A . Each lower column 12 used in shelving system 10 is an elongated piece that is intended to act as a base for shelving system 10 . The length of lower column 12 is preferably in the range of about 36 inches to 48 inches (to allow the shelving system to fit with standard eight inch ceilings), and most preferably in the range of about 40 inches to 46 inches. In one particular embodiment, lower column 12 is approximately 42 inches long. Lower column 12 includes a plurality of mounting openings 14 disposed along the length thereof. As seen in FIG. 1 , mounting openings 14 extend entirely through the body of lower column 12 . Indentations 16 , the purpose of which will be described herein, are provided beneath each mounting hole 14 . Lower column 12 includes feet 18 A and 18 B at its lower portion for contacting the floor in the location where shelving system 10 is to be placed. Preferably, foot 18 B is made slightly longer than foot 18 A so that lower column 12 will angle slightly backward against a wall in the location where shelving system 10 is assembled. In addition, the lower portion of lower column 12 has a recessed portion 20 that is offset from the remainder of lower column 12 . Recessed portion 20 provides a clearance for a baseboard or the like that may be in place at the location where shelving system 10 is placed. As seen in FIG. 1 , a spacer 23 may be used when a baseboard is not present. Also, one particular embodiment of lower column 12 , shown as lower column 12 A in FIG. 1 , includes recessed portion 21 which provides clearance for a chair rail or the like that may be present in the location where shelving system 10 is placed. An elongated vertical recess 22 A is defined within the lower portion of lower column 12 adjacent to recessed portion 20 . Recess 22 A is adapted to receive a screw or the like to facilitate the anchoring of lower column 12 to a wall or baseboard. Similarly, an elongated horizontal recess 22 B is provided within the lower portion of lower column 12 between feet 18 A and 18 B. Recess 22 B is adapted to receive a screw or the like to facilitate mounting of lower column 12 to, for example, wood floors. Recess 22 A and 22 B can be seen in cross-section in FIG. 2B .
As seen in FIGS. 2A and 2C , the upper portion of lower column 12 includes four generally T-shaped slots 24 , 25 , 27 and 29 , two of which are provided on the left side of lower column 12 and two of which are provided on the right side of lower column 12 . Also provided at the upper portion of lower column 12 on each side thereof are recesses 26 and 31 , recesses 28 and 33 , detents 30 and 35 , and support ledges 32 A and 32 B, all of which are used in the assembly of shelving system 10 . The specific purpose of each of these elements will be described in more detail herein.
A rod pocket 34 A is provided on the left (shown in FIG. 2A ) side of lower column 12 near the upper portion thereof. A corresponding rod pocket 34 B (see FIG. 1 ) is provided on the right (not shown in FIG. 2A ) side of lower column 12 . As seen more easily in FIG. 1 , each rod pocket 34 A and 34 B consists of a recess or slot provided in lower column 12 for receiving a flared end 36 of a rod 38 shown in FIGS. 10A-10C and described in greater detail herein. Preferably, the recess or slot extends generally downwardly and rearwardly at an angle of between 15 degrees and 45 degrees, most preferably at 30 degrees. As seen in FIG. 2A , inner edge 40 A surrounding recess 34 A is provided deeper inside lower column 12 than outer edge 42 A. This difference forms the pocket or slot that receives and holds in place the flared end 36 of a rod 38 .
FIGS. 3A , 3 B and 3 C show left side, top plan and bottom plan views, respectively, of an upper column 44 that forms another piece of shelving system 10 . Upper column 44 is similar to lower column 12 , and includes generally T-shaped slots 37 , 39 , 41 and 43 , recesses 45 and 47 , detents 49 , 51 , 53 and 55 , and support ledges 32 C and 32 D. Upper column 44 also includes rod pockets 34 C and 34 D (not shown in FIG. 3A ) for receiving the flared end of a rod 38 . Another view of rod pockets 34 C and 34 D (which are similar in shape to rod pockets 34 A and 34 B) is provided in FIG. 11B , which is a cross-sectional view of rod pockets 34 A and 34 B taken along lines 11 A- 11 B in FIG. 11A . One significant difference between the two is that upper column 44 includes tabs 46 and 59 extending from the lower portion thereof which are, as seen in FIG. 8 , adapted to be received in recesses 28 and 33 , respectively, of lower column 12 during the assembly of shelving system 10 . Also, as seen in FIG. 3B , unlike lower column 12 , upper column 44 does not include recesses similar to recesses 28 and 33 , and includes four detents 49 , 51 , 53 and 55 rather than two detents 30 and 35 .
FIG. 4 is an isometric view of a cap shelf 48 that forms another piece of shelving system 10 . As seen in FIG. 1 , cap shelves 48 are intended to be attached to the ends of two lower columns 12 or upper columns 44 to provide a surface on which to place and store items. Cap shelf 48 includes a base 50 having a generally planar top surface and front and back valences 52 and 73 , respectively. The base 50 is generally perpendicular to the valences 52 and 73 , and, as a result, the valences 52 and 73 strengthen cap shelf 48 for load support. Cap shelf 48 may be provided with integral ribs which act as a stiffener. As seen in FIG. 4 , each end of cap shelf 48 includes a protruding member 54 and 75 , respectively, a pair of protruding generally T-shaped connectors 56 and 61 and 63 and 65 , respectively, (see FIG. 5 ), and a pair of protruding tabs 58 and 67 and 69 and 71 , respectively (see FIG. 5 ).
During assembly of shelving system 10 , each end of cap shelf 48 is adapted to be attached to a respective lower column 12 or upper column 44 in the manner shown in FIG. 7 . In particular, each T-shaped connector 56 , 61 , 63 , 65 is adapted to be received and disposed in a corresponding T-shaped slot 24 , 25 , 27 , 29 (lower column 12 ) or 37 , 39 , 41 , 43 (upper column 44 ), as the case may be. In addition, each protruding member 54 , 75 is adapted to be received in a corresponding recess 26 , 31 (lower column 12 ) or 45 , 47 (upper column 44 ) and supported on a bottom edge thereof, and two or more of tabs 58 , 67 , 69 , 71 are adapted to be received and held by corresponding detents 30 , 35 (lower column 12 ), or 49 , 51 , 53 , 55 (upper column 44 ), preferably producing an audible snapping sound when located in place. Further, a bottom edge 60 of each end of cap shelf 48 is adapted to rest on and be supported by a corresponding support ledge 32 A, 32 B, 32 C, 32 D.
As will be appreciated, when a cap shelf 48 is attached at each end to a lower column 12 , the three pieces together, as can bee seen in FIG. 1 , will be able to stand on their own. Preferably, cap shelf 48 is provided in two or more sizes, ranging from 12 inches to 48 inches to provide flexibility in the manner in which shelving system 10 is assembled. In one specific embodiment of the present invention, a 21 inch long and a 42 inch long cap shelf 48 are provided.
As will also be appreciated, alternatively shaped connectors and complimentary shaped slots may be substituted for T-shaped connectors 56 , 61 , 63 and 65 and T-shaped slots 24 , 25 , 27 , 29 , 37 , 39 , 41 and 43 without departing from the scope of the present invention. For example, connectors having an enlarged portion having a generally triangular, cylindrical, spherical, or other shape may be provided on cap shelf 48 and/or corner cap shelf 64 ( FIG. 9 ), with complimentary shaped slots for receipt thereof being provided on lower column 12 and upper column 44 .
According to one aspect of the invention, cap shelves 48 are blow-molded from a plastic material such as HDPE (high density polyethylene) generally planar configuration as shown in FIGS. 5 and 6 . The wall thickness of a cap shelf 48 that is manufactured in this manner may preferably range from about one-sixteenth of an inch to one-eighth of an inch, and most preferably range from about 0.075 inches to 0.100 inches. This planar configuration, in which the top surface of base 50 and the top surfaces of valences 52 and 73 are generally parallel to one another, allows cap shelves 48 to take up less space, which makes the packing and shipping of cap shelves 48 easier and more compact. In this embodiment, each valence 52 , 73 is connected to base 50 by a living hinge 62 , 77 . As is known in the art, a “living hinge” refers to a hinge in a plastics material article formed from the plastics material itself. When it is time to assemble shelving system 10 , each cap shelf 48 is folded at living hinges 62 and 77 , causing the top surface of base 50 to be generally perpendicular to the top surface of each valence 52 , 73 . Valences 52 and 73 may be held in this folded down position when attached to a lower column 12 or an upper column 44 as shown in FIG. 7 , after which time they will be held down as a result of T-shaped connectors 56 , 61 , 63 and 65 being inserted into corresponding T-shaped slots 24 , 25 , 27 , 29 , 37 , 39 , 41 or 43 , as the case may be. Alternatively, cap shelf 48 may be provided with a known snap connection mechanism, such as a protruding member on each of valences 52 and 73 and corresponding detents on base 50 , that will hold valences 52 and 73 in the folded down position. As will be appreciated, any of the parts of shelving system 10 described herein may also be made from a plastic material as described above using a technique such as blow-molding. In addition, other parts, such as the separate pieces used to make drawer 80 described herein ( FIG. 14 ) may be manufactured in a generally planar configuration with one or more “living hinges” for subsequent assembly by a user.
Once a cap shelf 48 is attached to a lower column 12 , upper column 44 may be attached to lower column 12 in the manner shown in FIG. 8 . Specifically, tabs 46 and 59 of upper column 44 may be inserted into corresponding recesses 28 and 33 , which, in some situations, will be bounded on one end or both ends by a cap shelf 48 . As will be appreciated, this step will result in upper column 44 being stacked on top of lower column 12 , as can be seen in several places in FIG. 1 . Once a number of upper columns 44 have been so stacked on top of respective lower columns 12 in a desired configuration, cap shelves 48 may be attached to upper columns 44 as desired.
FIG. 9 shows an isometric view of corner cap shelf 64 that forms yet another piece of shelving system 10 . Corner cap shelf 64 is similar to cap shelf 48 in that it is adapted to be attached to and to be located between respective lower columns 12 or upper columns 44 . As such, it includes protruding members 89 , 91 and 93 , T-shaped connectors 81 , 83 , 85 and 87 and tabs 96 , 97 , 99 and 101 . Corner cap shelf 64 has a six-sided shape that is adapted to fit into a corner of a room or other space such that the respective lower columns 12 or upper columns 44 to which it is attached are generally perpendicular to one another, as can be seen in FIG. 1 .
FIGS. 10A , 10 B and 10 C are isometric, end and side views, respectively, of rod 38 that forms another piece of shelving system 10 . Rod 38 includes flared end 36 at each end thereof. Preferably, to reduce weight and expense, rod 38 is hollow and tubular. Rod 38 may be made of a plated or painted metal, such as CRS (cold rolled steel), a plastic material such as TPR, or any other suitable material. One or more rods 38 may be selectively inserted into rod pockets 34 A and 34 B provided in lower columns 12 or rod pockets 34 C and 34 D provided in upper columns 44 in the manner shown in FIG. 11A as desired. FIG. 11B is a cross-sectional view of upper column 44 taken along lines 11 B- 11 B in FIG. 11A which depicts rod pockets 34 C and 34 D. As seen in FIG. 11B , rod pockets 34 C and 34 D are separated by a portion 120 of upper column 44 . As will be appreciated, rod pockets 34 A and 34 B of lower column 12 have a similar configuration. As will also be appreciated, items such as clothing may be hung on rods 38 .
FIG. 12 is an isometric view of adjustable shelf 66 that forms yet another piece of shelving system 10 . Adjustable shelf 66 includes a generally flat surface 121 onto which items may be placed for storage. Preferably, adjustable shelf 66 is provided in two or more sizes, ranging from 12 inches to 48 inches to provide flexibility in the manner in which shelving system 10 is assembled. In one specific embodiment of the invention, a 21 inch and a 42 inch width adjustable shelf 66 are provided. Adjustable shelf 66 also includes an outer lip 68 , 105 and a groove 70 , 107 on each lateral end thereof, the purpose of which is described herein. Adjustable shelf 66 may be selectively placed between any two lower columns 12 or upper columns 44 as shown in FIG. 1 in a manner to be described herein.
FIG. 13 is an isometric view of corner adjustable shelf 72 that forms another piece of shelving system 10 . Corner adjustable shelf 72 is similar to adjustable shelf 66 , except that it is intended to be selectively placed between two lower columns 12 or two upper columns 44 as shown in FIG. 1 in a corner of a room or other space. As such, corner adjustable shelf 72 has a six-sided shape similar to corner cap shelf 64 . Like adjustable shelf 66 , corner adjustable shelf 72 includes generally flat surface 74 , lips 76 and 109 and grooves 78 and 111 .
FIG. 14 is an isometric view of a drawer 80 that forms still another piece of shelving system 10 . Drawer 80 may be used for receiving items for storage. Like adjustable shelf 66 , drawer 80 may be selectively placed between any two lower columns 12 or upper columns 44 . Drawer 80 is preferably provided in two or more sizes ranging from 12 inches to 48 inches wide and 5 inches to 10 inches deep (any depth may, however, be used as needed) to provide flexibility in the manner of assembly of shelving system 10 . In one specific embodiment of the present invention, 21 inch and 42 inch width drawers 80 are provided. Drawer 80 includes a lip 82 and a groove 84 (see FIG. 18A ) on each end thereof. Drawer 80 may be shipped to a user in a number of separate pieces (e.g., front, back. And bottom with attached (by a living hinge) right and left sides) for subsequent assembly by the user.
FIG. 15 is a perspective view of double adjustable support 86 , and FIG. 16 is an isometric view of single adjustable support 88 . Double adjustable support 86 and single adjustable support 88 are “adjustable” in that, as described below, they may be selectively placed between two mounting openings 14 of opposing lower columns 12 or upper columns 44 . Double adjustable support 86 and single adjustable support 88 are preferably made of metal, such as stamped or roll formed steel, and are utilized to selectively attach adjustable shelf 66 , corner adjustable shelf 72 , and drawer 80 to lower columns 12 and upper columns 44 . Specifically, double adjustable support 86 and single adjustable support 88 each include a central, generally concave receiving portion 90 , 113 and either two longitudinally extending tongues 92 and 115 in the case of double adjustable support 86 or one longitudinally extending tongue 117 in the case of single adjustable support 86 . As seen in FIG. 17 , which is a partial isometric view of lower column 12 , double adjustable support 86 and single adjustable support 88 may be selectively inserted through any of the mounting openings 14 of a lower column 12 or an upper column 44 , with receiving portion 90 or 113 fitting over and receiving therein the portion of lower column 12 or upper column 44 , as the case may be, that defines the bottom edge of the mounting opening 14 .
FIG. 18A is a cross sectional view of either a lower column 12 or an upper column 44 on which a double adjustable support 86 and a single adjustable support 88 have been attached, along with an adjustable shelf 66 and a drawer 80 . As seen in FIG. 18A , adjustable shelf 66 and drawer 80 may be removeably attached to either a double adjustable support 86 or a single adjustable support 88 by inserting the tongues 92 , 115 or 117 thereof into a respective groove 70 or 107 of adjustable shelf 66 or groove 84 of drawer 80 . In the case of a drawer 80 , once so attached, the tongues 92 , 115 or 117 are free to slide within grooves 84 such that drawer 80 may be slid in and out of place in order to place items in and remove items from drawer 80 . As seen in FIG. 18A and in an enlarged fashion in FIG. 18B , double adjustable support 86 and single adjustable support 88 each include one or more outwardly extending barbs 94 and 119 (preferably forming by stamping) that are adapted to be received in indentations 16 provided in lower columns 12 and upper columns 44 to both hold double adjustable support 86 and single adjustable support 88 in place and, preferably, to provide an audible snapping sound to the user to indicate that they have been correctly and securely attached.
Finally, FIG. 19 is a front elevational view of wall plate 96 . Wall plate 96 may be mounted on a building wall at a location that is adjacent to a last lower column 12 or upper column 44 forming a part of shelving assembly 10 . As will be appreciated, one side of such a last lower column 12 or upper column 44 will not have an opposing lower column 12 or upper column 44 , and wall plate 96 may be utilized when it is desired to have a rod 38 extend from such a side of a last lower column 12 or upper column 44 . For example, such a last lower column 12 may be lower column 12 A shown in FIG. 1 . Wall plate 96 is provided to receive and hold one end of a rod 38 with the other end being held in the rod pocket 34 A, 34 B, 34 C or 34 D of the last lower column 12 or upper column 44 . Wall plate 96 includes a plurality of apertures 98 for receiving therethrough a screw or the like for mounting wall plate 96 to a building wall, and rod slot 100 for receiving and holding the flared end 36 of a rod 38 . In addition, wall plate 96 is provided in a number of sections that may be selectively broken off and detached by a user at lines 102 in order to allow a user to customize the size of wall plate 96 .
Thus, as will be appreciated from the above description, the various pieces forming shelving system 10 may be selectively chosen and assembled in multiple configurations that may be customized to suit the particular needs of the user. In addition, shelving system 10 may be easily assembled using almost no tools (screws or the like may be used to anchor lower column 12 to a wall or baseboard and wall plate 96 to a wall, if desired) in a short time. Furthermore, shelving system 10 may be quickly and easily disassembled and reassembled in a different configuration as the needs of the user change.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof. | A modular shelving system including a number of separate, selectively inter-connectable pieces, and methods of assembling such a shelving system. The selectively inter-connectable pieces of the shelving system include vertical supports columns, cap shelves for attachment thereto, hanging rods, and adjustable shelves and drawers and selectively placeable support elements for supporting same. | Identify and summarize the most critical technical features from the given patent document. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to a shelving system and, more particularly, to an easily assembled and installed modular shelving system that may be customized by the user to suit the user's particular needs.",
"Description of the Prior Art It is often desirable or even necessary to provide shelving for storage of items in various places such as a closet, a storage room, a workroom, a utility room, an office or a garage.",
"Many different types of shelving systems are known in the art, including various metal, wood or plastic systems that may be shipped and/or sold to the user in an unassembled state and subsequently assembled and installed by the user in a desired location.",
"For example, one prior art metal shelving unit consists of a number of metal shelves and four elongated, vertical corner pieces.",
"Such units are sold in pieces, and require the user to attach the corners of the metal shelves to the corner pieces by a nut and bolt assembly or the like.",
"This type of shelving system requires a large number of individual pieces and various tools for assembly.",
"Also, assembly configurations are limited in this type of a system, and thus there is limited opportunity for the user to customize the system to meet his or her needs.",
"Other prior art shelving systems include modular shelving systems constructed in a number of pieces from a material such as wood and/or metal.",
"The separate pieces of the system are designed to be mounted together using hardware such as screws, latches and/or nut and bolt assemblies.",
"Again, this type of shelving system requires a large number of pieces and various tools for assembly.",
"In addition, such systems are often difficult, time consuming and confusing to assemble, leading to frustration and wasted time on the part of the user.",
"Further, once assembled, such systems are difficult and time consuming to disassemble and modify, which may be required as the needs of the user change.",
"Still another type of prior art shelving system often utilized in closets consists of a number of shelves made of a plurality of welded, coated wires.",
"The shelves are typically mounted to a wall by the user using screws and the like, often making installation difficult and time consuming, particularly to a user who may not be particularly handy.",
"Such systems, while lightweight, do not present a sturdy appearance due to the gaps that exist between the wire supports.",
"In addition, items that are smaller than the gaps between the small, one-eighth inch diameter wire supports may not be stored with this type of system as those items will fall through the gaps.",
"There is therefore a need for a modular shelving system that is quick and easy to assemble and disassemble with very limited or no use of separate tools.",
"There is further a need for such a modular shelving system that may be customized by a user to meet certain needs, and that may be easily and readily reconfigured and adjusted as needs change.",
"SUMMARY OF THE INVENTION The present invention relates to a customizable modular shelving system including a number of separate pieces that is easy to assemble and disassemble with very limited or no use of separate tools.",
"As a result, the shelving system may be easily and readily reconfigured and adjusted as the needs of the user change.",
"One aspect of the present invention relates to a shelving system, and a method of assembling same, including a vertical support column having one or more slots provided in the upper portion thereof, and a shelf having one or more connectors protruding from a first end thereof.",
"The slots in the vertical support column have a first shape and the connectors each have an enlarged portion having a second shape, wherein the first shape and the second shape are generally complementary to one another.",
"The enlarged portion of each of the connectors is disposed in a respective one of the slots.",
"The shelving system may further include a second vertical support column having slots having the same first shape provided in the upper portion thereof, wherein the shelf has connectors having an enlarged portion having the same second shape protruding from a second end thereof.",
"The connectors on the second end of the shelf are, in this embodiment, disposed in the slots provided in the second vertical support column.",
"The slots and connectors may be generally T-shaped.",
"The upper portion of the vertical support column may also have one or more detents, and the first end of the shelf may have one or more protruding tabs, wherein the one or more protruding tabs are received and held in place by the one or more detents.",
"In addition, the upper portion of the vertical support column may also have a recess, and the first end of the shelf may have a protruding member, wherein the protruding member is received by and supported on a bottom edge of the recess.",
"Further, the upper portion of the vertical support column may have a horizontal support ledge extending therefrom, and the bottom edge of the first end of the shelf may rest on and be supported by the support ledge.",
"The shelf in this aspect of the invention may have a generally planar top surface and one or more valances extending downwardly from and generally perpendicular to the top surface.",
"In addition, the lower portion of the vertical support column may have a plurality of feet extending therefrom.",
"Preferably, the plurality of feet may include a front foot and a back foot, with the front foot being slightly longer than the back foot to cause the vertical support column to be angled backwardly against a wall in the location where the shelving system is placed.",
"In another embodiment, the shelving system further includes a second vertical support column having one or more tabs extending from the upper portion thereof, and the upper portion of the first vertical support column has one or more recesses provided therein.",
"The first vertical support column is a bottom vertical support column and the second vertical support column is a top vertical support column.",
"In this embodiment, each of the tabs is disposed in a respective one of the recesses to hold the second vertical support column in place.",
"The lower portion of the vertical support column may also include a recessed portion that provides clearance for a baseboard affixed to a wall in a location where the shelving system is placed.",
"Similarly, the vertical support column may include a recessed portion located between the upper portion and the lower portion thereof that provides clearance for a chair rail affixed to a wall in a location where the shelving system is placed.",
"In addition, the lower portion of the vertical support column may have one or more recessed portions adapted to receive a fastening element for fastening the vertical support column in place.",
"Another aspect of the present invention relates to a shelving system including a vertical support column having a slot provided in the first side thereof and an elongated rod having an enlarged end that is disposed in the slot.",
"Preferably, the enlarged end of the rod is flared, and the rod is elongated and tubular.",
"Also, the slot is preferably angled rearwardly and downwardly.",
"In one particular embodiment, the slot is angled downwardly at an angle of between approximately 15 degrees and approximately 45 degrees from the horizontal axis of the vertical support column.",
"The shelving system according to this aspect of the invention may further include a second vertical support column having a second slot provided therein, wherein the rod has a second enlarged end opposite the first enlarged end that is disposed in the second slot.",
"In addition, a wall plate having another slot may be mounted on a wall adjacent to the shelving system, and an enlarged end of the rod may be received in the slot provided on the wall plate.",
"Yet another aspect of the present invention relates to a shelving system including a vertical support column having a plurality of mounting openings, and a support element removeably attached to the vertical support column through one of the mounting openings.",
"The support element includes a receiving portion that fits over and receives a portion of the vertical support column that defines a bottom outer edge of the mounting opening.",
"The support element preferably includes either one or two elongated tongues adjacent to the receiving portion.",
"Also, the receiving portion may have one or more barbs extending from an inner surface thereof that are adapted to be disposed in an indentation provided in the vertical support column below the mounting opening.",
"In one particular embodiment, the shelving system further includes a shelf having an elongated groove along a first side thereof, wherein the elongated tongue is disposed in the elongated groove such that the shelf is supported by the support element.",
"In another particular embodiment, the shelving system further includes a drawer having an elongated groove along a first side thereof, wherein the elongated tongue is disposed in the elongated groove such that the drawer is slideably supported by the support element.",
"The shelving system according to this aspect of the invention may further include a second vertical support column having a plurality of second mounting openings and a second support element removeably attached to the second vertical support column through one of the second mounting openings that is generally aligned with the mounting opening of the first vertical support column to which the first support element is attached.",
"The second support element includes a second receiving portion that fits over and receives a portion of the second vertical support column that defines a bottom outer edge of the second mounting opening.",
"The second support element preferably includes a second elongated tongue adjacent to the second receiving portion for supporting a shelf or a drawer.",
"Yet another aspect of the present invention relates to a shelving system including a first vertical support column having an upper portion having a first configuration, a lower portion, and a plurality of first openings therethrough, and a second vertical support column attached to the first vertical support column having an upper portion having a second configuration, a lower portion, and a plurality of second openings therethrough.",
"The first configuration and said second configuration are generally complementary to one another such that the upper portion of the first vertical support column mates with the lower portion of the second vertical support column.",
"The first configuration may comprise one or more recesses provided in the upper portion of the first vertical support column and the second configuration may comprise one or more tabs extending from the lower portion of the second vertical support column, wherein each of the tabs is disposed in a respective one of the recesses.",
"It is an object of this invention to provide a shelving system that is easily and quickly assembled and disassembled, offering time saving advantages not found in similar products.",
"It is a further object of this invention to provide a shelving system that may be assembled with limited or no use of separate tools.",
"It is a further object of this invention to provide a shelving system that is made of an attractive material such as molded plastic.",
"It is a further object of this invention to provide a shelving system that is economical.",
"It is a further object of this invention to provide a method of assembling a shelving system that enables the pieces of the shelving system to be packed and shipped in simple and compact manner.",
"It is a further object of this invention to provide a shelving system that may be easily and readily reconfigured and adjusted as the needs of the user change.",
"It is a further object of this invention to provide a shelving system that is usable in a wide variety of residential, commercial and industrial locations.",
"DESCRIPTION OF THE DRAWINGS These and other advantages of the present invention will become readily apparent upon consideration of the following detailed description and attached drawings, wherein: FIG. 1 is an isometric view of an exemplary configuration of a shelving system according to the present invention;",
"FIG. 2A is a left side view of a lower column forming a part of a shelving system according to the present invention;",
"FIG. 2B is a cross-sectional view of the lower column shown in FIG. 2A taken along lines 2 B- 2 B in FIG. 2A ;",
"FIG. 2C is a top plan view of the lower column shown in FIG. 2A ;",
"FIG. 3A is a left side view of an upper column forming a part of a shelving system according to the present invention;",
"FIG. 3B is a top plan view of the upper column shown in FIG. 3A ;",
"FIG. 3C is a bottom plan view of the upper column shown in FIG. 3A ;",
"FIG. 4 is an isometric view of a cap shelf forming a part of a shelving system according to the present invention;",
"FIGS. 5 and 6 are top plan and front elevational views, respectively, of the cap shelf shown in FIG. 4 in the state in which it is packaged and shipped to a user;",
"FIG. 7 is a partial isometric view showing the cap shelf shown in FIG. 4 being attached to the lower column shown in FIG. 2A ;",
"FIG. 8 is a partial isometric view showing the upper column shown in FIG. 3A being mounted on top of the lower column shown in FIG. 2A ;",
"FIG. 9 is an isometric view of a corner cap shelf forming a part of a shelving system according to the present invention;",
"FIGS. 10A , 10 B and 10 C are isometric, end and side views, respectively, of a rod forming a part of a shelving system according to the present invention;",
"FIG. 11A is a partial isometric view showing the rod shown in FIGS. 10A-10C inserted into the rod pocket of the upper column shown in FIG. 3A ;",
"FIG. 11B is a cross-sectional view taken along lines 11 B- 11 B shown in FIG. 11A ;",
"FIG. 12 is an isometric view of an adjustable shelf forming a part of a shelving system according to the present invention;",
"FIG. 13 is an isometric view of a corner adjustable shelf forming a part of a shelving system according to the present invention;",
"FIG. 14 is an isometric view of a drawer forming a part of a shelving system according to the present invention;",
"FIGS. 15 and 16 are isometric views of double and single adjustable supports, respectively, forming a part of a shelving system according to the present invention;",
"FIG. 17 is a partial isometric view showing the double and single adjustable supports shown in FIGS. 15 and 16 mounted on the lower column shown in FIG. 2A ;",
"FIG. 18A is a cross sectional view of a portion of a shelving system according to the present invention showing a lower column of FIG. 2A or an upper column of FIG. 3A having a drawer and an adjustable shelf mounted thereon;",
"FIG. 18B is an enlarged view of a portion of the cross-section shown in FIG. 18A ;",
"and FIG. 19 is a front elevational view of a wall plate forming a part of a shelving system according to the present invention.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to a modular shelving system consisting of a number of separate pieces that may be selectively assembled together in a number of different configurations depending on the particular wants and needs of the user.",
"FIG. 1 is an isometric view of one possible configuration of a shelving system 10 according to the present invention which includes a number of shelves, drawers and rods for holding and storing items such as clothing and the like in an area such as a closet.",
"It should be appreciated that the configuration shown in FIG. 1 is exemplary only, and, as will be understood from the following description, many other configurations of shelving system 10 may be created depending on the particular wants and needs of the user.",
"As can be seen in FIG. 1 , shelving system 10 consists of a number of different modular pieces that may be quickly and easily fit together by a user.",
"Each of the pieces of shelving system 10 is described in detail herein, as is the manner in which the pieces may be selectively fit together in a customizable fashion by the user.",
"FIGS. 2A and 2C are left side and top plan views, respectively, of a lower column 12 that forms one piece of shelving system 10 .",
"FIG. 2B is a cross-sectional view of lower column 12 taken along lines 2 B- 2 B shown in FIG. 2A .",
"Each lower column 12 used in shelving system 10 is an elongated piece that is intended to act as a base for shelving system 10 .",
"The length of lower column 12 is preferably in the range of about 36 inches to 48 inches (to allow the shelving system to fit with standard eight inch ceilings), and most preferably in the range of about 40 inches to 46 inches.",
"In one particular embodiment, lower column 12 is approximately 42 inches long.",
"Lower column 12 includes a plurality of mounting openings 14 disposed along the length thereof.",
"As seen in FIG. 1 , mounting openings 14 extend entirely through the body of lower column 12 .",
"Indentations 16 , the purpose of which will be described herein, are provided beneath each mounting hole 14 .",
"Lower column 12 includes feet 18 A and 18 B at its lower portion for contacting the floor in the location where shelving system 10 is to be placed.",
"Preferably, foot 18 B is made slightly longer than foot 18 A so that lower column 12 will angle slightly backward against a wall in the location where shelving system 10 is assembled.",
"In addition, the lower portion of lower column 12 has a recessed portion 20 that is offset from the remainder of lower column 12 .",
"Recessed portion 20 provides a clearance for a baseboard or the like that may be in place at the location where shelving system 10 is placed.",
"As seen in FIG. 1 , a spacer 23 may be used when a baseboard is not present.",
"Also, one particular embodiment of lower column 12 , shown as lower column 12 A in FIG. 1 , includes recessed portion 21 which provides clearance for a chair rail or the like that may be present in the location where shelving system 10 is placed.",
"An elongated vertical recess 22 A is defined within the lower portion of lower column 12 adjacent to recessed portion 20 .",
"Recess 22 A is adapted to receive a screw or the like to facilitate the anchoring of lower column 12 to a wall or baseboard.",
"Similarly, an elongated horizontal recess 22 B is provided within the lower portion of lower column 12 between feet 18 A and 18 B. Recess 22 B is adapted to receive a screw or the like to facilitate mounting of lower column 12 to, for example, wood floors.",
"Recess 22 A and 22 B can be seen in cross-section in FIG. 2B .",
"As seen in FIGS. 2A and 2C , the upper portion of lower column 12 includes four generally T-shaped slots 24 , 25 , 27 and 29 , two of which are provided on the left side of lower column 12 and two of which are provided on the right side of lower column 12 .",
"Also provided at the upper portion of lower column 12 on each side thereof are recesses 26 and 31 , recesses 28 and 33 , detents 30 and 35 , and support ledges 32 A and 32 B, all of which are used in the assembly of shelving system 10 .",
"The specific purpose of each of these elements will be described in more detail herein.",
"A rod pocket 34 A is provided on the left (shown in FIG. 2A ) side of lower column 12 near the upper portion thereof.",
"A corresponding rod pocket 34 B (see FIG. 1 ) is provided on the right (not shown in FIG. 2A ) side of lower column 12 .",
"As seen more easily in FIG. 1 , each rod pocket 34 A and 34 B consists of a recess or slot provided in lower column 12 for receiving a flared end 36 of a rod 38 shown in FIGS. 10A-10C and described in greater detail herein.",
"Preferably, the recess or slot extends generally downwardly and rearwardly at an angle of between 15 degrees and 45 degrees, most preferably at 30 degrees.",
"As seen in FIG. 2A , inner edge 40 A surrounding recess 34 A is provided deeper inside lower column 12 than outer edge 42 A. This difference forms the pocket or slot that receives and holds in place the flared end 36 of a rod 38 .",
"FIGS. 3A , 3 B and 3 C show left side, top plan and bottom plan views, respectively, of an upper column 44 that forms another piece of shelving system 10 .",
"Upper column 44 is similar to lower column 12 , and includes generally T-shaped slots 37 , 39 , 41 and 43 , recesses 45 and 47 , detents 49 , 51 , 53 and 55 , and support ledges 32 C and 32 D. Upper column 44 also includes rod pockets 34 C and 34 D (not shown in FIG. 3A ) for receiving the flared end of a rod 38 .",
"Another view of rod pockets 34 C and 34 D (which are similar in shape to rod pockets 34 A and 34 B) is provided in FIG. 11B , which is a cross-sectional view of rod pockets 34 A and 34 B taken along lines 11 A- 11 B in FIG. 11A .",
"One significant difference between the two is that upper column 44 includes tabs 46 and 59 extending from the lower portion thereof which are, as seen in FIG. 8 , adapted to be received in recesses 28 and 33 , respectively, of lower column 12 during the assembly of shelving system 10 .",
"Also, as seen in FIG. 3B , unlike lower column 12 , upper column 44 does not include recesses similar to recesses 28 and 33 , and includes four detents 49 , 51 , 53 and 55 rather than two detents 30 and 35 .",
"FIG. 4 is an isometric view of a cap shelf 48 that forms another piece of shelving system 10 .",
"As seen in FIG. 1 , cap shelves 48 are intended to be attached to the ends of two lower columns 12 or upper columns 44 to provide a surface on which to place and store items.",
"Cap shelf 48 includes a base 50 having a generally planar top surface and front and back valences 52 and 73 , respectively.",
"The base 50 is generally perpendicular to the valences 52 and 73 , and, as a result, the valences 52 and 73 strengthen cap shelf 48 for load support.",
"Cap shelf 48 may be provided with integral ribs which act as a stiffener.",
"As seen in FIG. 4 , each end of cap shelf 48 includes a protruding member 54 and 75 , respectively, a pair of protruding generally T-shaped connectors 56 and 61 and 63 and 65 , respectively, (see FIG. 5 ), and a pair of protruding tabs 58 and 67 and 69 and 71 , respectively (see FIG. 5 ).",
"During assembly of shelving system 10 , each end of cap shelf 48 is adapted to be attached to a respective lower column 12 or upper column 44 in the manner shown in FIG. 7 .",
"In particular, each T-shaped connector 56 , 61 , 63 , 65 is adapted to be received and disposed in a corresponding T-shaped slot 24 , 25 , 27 , 29 (lower column 12 ) or 37 , 39 , 41 , 43 (upper column 44 ), as the case may be.",
"In addition, each protruding member 54 , 75 is adapted to be received in a corresponding recess 26 , 31 (lower column 12 ) or 45 , 47 (upper column 44 ) and supported on a bottom edge thereof, and two or more of tabs 58 , 67 , 69 , 71 are adapted to be received and held by corresponding detents 30 , 35 (lower column 12 ), or 49 , 51 , 53 , 55 (upper column 44 ), preferably producing an audible snapping sound when located in place.",
"Further, a bottom edge 60 of each end of cap shelf 48 is adapted to rest on and be supported by a corresponding support ledge 32 A, 32 B, 32 C, 32 D. As will be appreciated, when a cap shelf 48 is attached at each end to a lower column 12 , the three pieces together, as can bee seen in FIG. 1 , will be able to stand on their own.",
"Preferably, cap shelf 48 is provided in two or more sizes, ranging from 12 inches to 48 inches to provide flexibility in the manner in which shelving system 10 is assembled.",
"In one specific embodiment of the present invention, a 21 inch long and a 42 inch long cap shelf 48 are provided.",
"As will also be appreciated, alternatively shaped connectors and complimentary shaped slots may be substituted for T-shaped connectors 56 , 61 , 63 and 65 and T-shaped slots 24 , 25 , 27 , 29 , 37 , 39 , 41 and 43 without departing from the scope of the present invention.",
"For example, connectors having an enlarged portion having a generally triangular, cylindrical, spherical, or other shape may be provided on cap shelf 48 and/or corner cap shelf 64 ( FIG. 9 ), with complimentary shaped slots for receipt thereof being provided on lower column 12 and upper column 44 .",
"According to one aspect of the invention, cap shelves 48 are blow-molded from a plastic material such as HDPE (high density polyethylene) generally planar configuration as shown in FIGS. 5 and 6 .",
"The wall thickness of a cap shelf 48 that is manufactured in this manner may preferably range from about one-sixteenth of an inch to one-eighth of an inch, and most preferably range from about 0.075 inches to 0.100 inches.",
"This planar configuration, in which the top surface of base 50 and the top surfaces of valences 52 and 73 are generally parallel to one another, allows cap shelves 48 to take up less space, which makes the packing and shipping of cap shelves 48 easier and more compact.",
"In this embodiment, each valence 52 , 73 is connected to base 50 by a living hinge 62 , 77 .",
"As is known in the art, a “living hinge”",
"refers to a hinge in a plastics material article formed from the plastics material itself.",
"When it is time to assemble shelving system 10 , each cap shelf 48 is folded at living hinges 62 and 77 , causing the top surface of base 50 to be generally perpendicular to the top surface of each valence 52 , 73 .",
"Valences 52 and 73 may be held in this folded down position when attached to a lower column 12 or an upper column 44 as shown in FIG. 7 , after which time they will be held down as a result of T-shaped connectors 56 , 61 , 63 and 65 being inserted into corresponding T-shaped slots 24 , 25 , 27 , 29 , 37 , 39 , 41 or 43 , as the case may be.",
"Alternatively, cap shelf 48 may be provided with a known snap connection mechanism, such as a protruding member on each of valences 52 and 73 and corresponding detents on base 50 , that will hold valences 52 and 73 in the folded down position.",
"As will be appreciated, any of the parts of shelving system 10 described herein may also be made from a plastic material as described above using a technique such as blow-molding.",
"In addition, other parts, such as the separate pieces used to make drawer 80 described herein ( FIG. 14 ) may be manufactured in a generally planar configuration with one or more “living hinges”",
"for subsequent assembly by a user.",
"Once a cap shelf 48 is attached to a lower column 12 , upper column 44 may be attached to lower column 12 in the manner shown in FIG. 8 .",
"Specifically, tabs 46 and 59 of upper column 44 may be inserted into corresponding recesses 28 and 33 , which, in some situations, will be bounded on one end or both ends by a cap shelf 48 .",
"As will be appreciated, this step will result in upper column 44 being stacked on top of lower column 12 , as can be seen in several places in FIG. 1 .",
"Once a number of upper columns 44 have been so stacked on top of respective lower columns 12 in a desired configuration, cap shelves 48 may be attached to upper columns 44 as desired.",
"FIG. 9 shows an isometric view of corner cap shelf 64 that forms yet another piece of shelving system 10 .",
"Corner cap shelf 64 is similar to cap shelf 48 in that it is adapted to be attached to and to be located between respective lower columns 12 or upper columns 44 .",
"As such, it includes protruding members 89 , 91 and 93 , T-shaped connectors 81 , 83 , 85 and 87 and tabs 96 , 97 , 99 and 101 .",
"Corner cap shelf 64 has a six-sided shape that is adapted to fit into a corner of a room or other space such that the respective lower columns 12 or upper columns 44 to which it is attached are generally perpendicular to one another, as can be seen in FIG. 1 .",
"FIGS. 10A , 10 B and 10 C are isometric, end and side views, respectively, of rod 38 that forms another piece of shelving system 10 .",
"Rod 38 includes flared end 36 at each end thereof.",
"Preferably, to reduce weight and expense, rod 38 is hollow and tubular.",
"Rod 38 may be made of a plated or painted metal, such as CRS (cold rolled steel), a plastic material such as TPR, or any other suitable material.",
"One or more rods 38 may be selectively inserted into rod pockets 34 A and 34 B provided in lower columns 12 or rod pockets 34 C and 34 D provided in upper columns 44 in the manner shown in FIG. 11A as desired.",
"FIG. 11B is a cross-sectional view of upper column 44 taken along lines 11 B- 11 B in FIG. 11A which depicts rod pockets 34 C and 34 D. As seen in FIG. 11B , rod pockets 34 C and 34 D are separated by a portion 120 of upper column 44 .",
"As will be appreciated, rod pockets 34 A and 34 B of lower column 12 have a similar configuration.",
"As will also be appreciated, items such as clothing may be hung on rods 38 .",
"FIG. 12 is an isometric view of adjustable shelf 66 that forms yet another piece of shelving system 10 .",
"Adjustable shelf 66 includes a generally flat surface 121 onto which items may be placed for storage.",
"Preferably, adjustable shelf 66 is provided in two or more sizes, ranging from 12 inches to 48 inches to provide flexibility in the manner in which shelving system 10 is assembled.",
"In one specific embodiment of the invention, a 21 inch and a 42 inch width adjustable shelf 66 are provided.",
"Adjustable shelf 66 also includes an outer lip 68 , 105 and a groove 70 , 107 on each lateral end thereof, the purpose of which is described herein.",
"Adjustable shelf 66 may be selectively placed between any two lower columns 12 or upper columns 44 as shown in FIG. 1 in a manner to be described herein.",
"FIG. 13 is an isometric view of corner adjustable shelf 72 that forms another piece of shelving system 10 .",
"Corner adjustable shelf 72 is similar to adjustable shelf 66 , except that it is intended to be selectively placed between two lower columns 12 or two upper columns 44 as shown in FIG. 1 in a corner of a room or other space.",
"As such, corner adjustable shelf 72 has a six-sided shape similar to corner cap shelf 64 .",
"Like adjustable shelf 66 , corner adjustable shelf 72 includes generally flat surface 74 , lips 76 and 109 and grooves 78 and 111 .",
"FIG. 14 is an isometric view of a drawer 80 that forms still another piece of shelving system 10 .",
"Drawer 80 may be used for receiving items for storage.",
"Like adjustable shelf 66 , drawer 80 may be selectively placed between any two lower columns 12 or upper columns 44 .",
"Drawer 80 is preferably provided in two or more sizes ranging from 12 inches to 48 inches wide and 5 inches to 10 inches deep (any depth may, however, be used as needed) to provide flexibility in the manner of assembly of shelving system 10 .",
"In one specific embodiment of the present invention, 21 inch and 42 inch width drawers 80 are provided.",
"Drawer 80 includes a lip 82 and a groove 84 (see FIG. 18A ) on each end thereof.",
"Drawer 80 may be shipped to a user in a number of separate pieces (e.g., front, back.",
"And bottom with attached (by a living hinge) right and left sides) for subsequent assembly by the user.",
"FIG. 15 is a perspective view of double adjustable support 86 , and FIG. 16 is an isometric view of single adjustable support 88 .",
"Double adjustable support 86 and single adjustable support 88 are “adjustable”",
"in that, as described below, they may be selectively placed between two mounting openings 14 of opposing lower columns 12 or upper columns 44 .",
"Double adjustable support 86 and single adjustable support 88 are preferably made of metal, such as stamped or roll formed steel, and are utilized to selectively attach adjustable shelf 66 , corner adjustable shelf 72 , and drawer 80 to lower columns 12 and upper columns 44 .",
"Specifically, double adjustable support 86 and single adjustable support 88 each include a central, generally concave receiving portion 90 , 113 and either two longitudinally extending tongues 92 and 115 in the case of double adjustable support 86 or one longitudinally extending tongue 117 in the case of single adjustable support 86 .",
"As seen in FIG. 17 , which is a partial isometric view of lower column 12 , double adjustable support 86 and single adjustable support 88 may be selectively inserted through any of the mounting openings 14 of a lower column 12 or an upper column 44 , with receiving portion 90 or 113 fitting over and receiving therein the portion of lower column 12 or upper column 44 , as the case may be, that defines the bottom edge of the mounting opening 14 .",
"FIG. 18A is a cross sectional view of either a lower column 12 or an upper column 44 on which a double adjustable support 86 and a single adjustable support 88 have been attached, along with an adjustable shelf 66 and a drawer 80 .",
"As seen in FIG. 18A , adjustable shelf 66 and drawer 80 may be removeably attached to either a double adjustable support 86 or a single adjustable support 88 by inserting the tongues 92 , 115 or 117 thereof into a respective groove 70 or 107 of adjustable shelf 66 or groove 84 of drawer 80 .",
"In the case of a drawer 80 , once so attached, the tongues 92 , 115 or 117 are free to slide within grooves 84 such that drawer 80 may be slid in and out of place in order to place items in and remove items from drawer 80 .",
"As seen in FIG. 18A and in an enlarged fashion in FIG. 18B , double adjustable support 86 and single adjustable support 88 each include one or more outwardly extending barbs 94 and 119 (preferably forming by stamping) that are adapted to be received in indentations 16 provided in lower columns 12 and upper columns 44 to both hold double adjustable support 86 and single adjustable support 88 in place and, preferably, to provide an audible snapping sound to the user to indicate that they have been correctly and securely attached.",
"Finally, FIG. 19 is a front elevational view of wall plate 96 .",
"Wall plate 96 may be mounted on a building wall at a location that is adjacent to a last lower column 12 or upper column 44 forming a part of shelving assembly 10 .",
"As will be appreciated, one side of such a last lower column 12 or upper column 44 will not have an opposing lower column 12 or upper column 44 , and wall plate 96 may be utilized when it is desired to have a rod 38 extend from such a side of a last lower column 12 or upper column 44 .",
"For example, such a last lower column 12 may be lower column 12 A shown in FIG. 1 .",
"Wall plate 96 is provided to receive and hold one end of a rod 38 with the other end being held in the rod pocket 34 A, 34 B, 34 C or 34 D of the last lower column 12 or upper column 44 .",
"Wall plate 96 includes a plurality of apertures 98 for receiving therethrough a screw or the like for mounting wall plate 96 to a building wall, and rod slot 100 for receiving and holding the flared end 36 of a rod 38 .",
"In addition, wall plate 96 is provided in a number of sections that may be selectively broken off and detached by a user at lines 102 in order to allow a user to customize the size of wall plate 96 .",
"Thus, as will be appreciated from the above description, the various pieces forming shelving system 10 may be selectively chosen and assembled in multiple configurations that may be customized to suit the particular needs of the user.",
"In addition, shelving system 10 may be easily assembled using almost no tools (screws or the like may be used to anchor lower column 12 to a wall or baseboard and wall plate 96 to a wall, if desired) in a short time.",
"Furthermore, shelving system 10 may be quickly and easily disassembled and reassembled in a different configuration as the needs of the user change.",
"While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure.",
"Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof."
] |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to managing device features and more specifically keeping device features locked during normal use while having the capability of securely unlocking device features.
[0003] 2. Description of the Related Art
[0004] As demand for a genuinely open source community where the next generation of networked application platforms may evolve, the marketplace is being overwhelmed with consumer electronics ranging from smart phones, hand held PDA's, and even digital book readers. Along with burgeoning consumer electronics market, application developers help to bridge the gap between the end consumer and their wants.
[0005] One conventional approach for protecting and controlling the use of software is done through licensing the use of software on a particular central processing unit residing on a computing device. After a code is generated at a central service, the code is provided to a third party publisher, who then provides the code to the end user, who then provides it to the computing device, thereby unlocking the appropriate software or features residing on the computing device. However, this approach is undesirable for an application developer who may need more extensive access to a computing device than a simple licensing code would provide. The networked application platform, on the other hand, may require additional protections when allowing the application access to normally locked features of the computing device.
[0006] Another mechanism for managing and providing services to a third party application developer involves allowing the application developer to use a scaled-down version of a registered application on a specific electronic device, creating a specialized version of the registered application. After which, a central facility can substitute the specific version of the registered application appropriate to the needs of the application developer and the specific electronic device. Once again, however, the third party application developer in need of unlocking key features and tools of a computing device, may require the full version of the registered development application vis-à-vis the electronic device.
[0007] Though other approaches have tried to protect the rights of application developer while protecting the digital content of the networked application platform, the current state of technology has not adequately accounted for targeting the requirements of specific users with specific devices. Requirements such as access to developer documentations, tools and SDK's.
[0008] It would be desirable to provide a secure, efficient and scaleable resource for third party application developers to ensure that only registered developers and registered devices gain access to developmental applications.
SUMMARY OF THE INVENTION
[0009] A mechanism is provided for keeping device features locked or reduced while the device is being used as a normal customer computer electronic device, but adds the capability of securely unlocking features for registered application developers and registered application development device only.
[0010] According to an embodiment of the invention, there is provided a mechanism for managing device features though a network connection for receiving a request to download a development application from an application developer via a computing device, wherein the development application being configured to unlock device features stored on the computing device, verifying the status of said application developer before the development application is sent to the computing device, verifying the status of said computing device on which the application is to be run before the development application is sent to the computing device, and facilitating access to retrieve said development application in order to allow the application developer access to the unlocked features stored on the computing device.
[0011] This mechanism can be embodied in various forms, including business processes, computer implemented methods, computer program products, computer systems and networks, user interfaces, application programming interfaces, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and other more detailed and specific features of the present invention are more fully disclosed in the following specification, reference being had to the accompanying drawings, in which:
[0013] FIG. 1 is a schematic diagram illustrating a conventional approach for managing software applications via a network connection.
[0014] FIG. 2 is a schematic diagram illustrating an example of one aspect of managing software applications via a network connection for applications development.
[0015] FIG. 3 is a schematic diagram illustrating an example of another aspect of managing software applications via a network connection for applications development.
[0016] FIG. 4 is a block schematic illustrating an example of managing software applications via a network connection.
[0017] FIG. 5 is flow diagram showing one example of the registration process of managing software applications via a network connection.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the following description, for purposes of explanation, numerous details are set forth, such as flowcharts and system configurations, in order to provide an understanding of one or more embodiments of the present invention. However, it is and will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention.
[0019] Opening normally locked down features on computer electronic devices can harm electronic devices and prompt unnecessary warranty claims. When a third party application developer signs up to become a registered application developer, the developer can gain access to developer documentation, tools and application development kits. Hence, by having the application developer register a device as an application development device, a development application (“Development App”) may become available for download to the registered application development device.
[0020] Downloading and running this Development App may unlock features on the device which are otherwise locked for normal users. Since downloading and installing the Development App should void the warranty of the application development device, it becomes possible for the application developer to use the application development device for executing programs not normally tested or approved. This mechanism ensures only registered application developers and registered application development devices gain access to the unlocked features.
[0021] FIG. 1 is a conventional system for managing software applications via a network connection and illustrates the functional components for managing software applications. The system may be, for example, a mechanism for downloading software applications from an Application Store 10 to a computing device 20 by a customer 5 over a network connection 220 .
[0022] The system may revolve around a central database 200 where the Application Store 10 is housed. Application Store 10 may facilitate access to software applications App 1 , App 2 , etc. Central database 200 is configured to have a network interface 210 that may communicate to computing device 20 over network connection 220 .
[0023] Network interface 210 allows access to Application Store 10 over network connection 220 such that the computing device 20 may be configured to create an application login account 230 . Application store 10 may be configured to output a list of public applications App 1 , App 2 , etc. over network connection 220 to computing device 20 .
[0024] Computing device 20 is configured to have a customer interface 25 that may receive customer login information 26 from customer 5 such that Application Store 10 is accessible over network connection 220 where software applications App 1 , App 2 , etc. may be downloaded to computing device 20 over network connection 220 .
[0025] To accommodate a download of software applications App 1 , App 2 , etc., computing device 20 is configured to receive customer login information 26 from customer 5 at customer interface 25 . After this, the computing device 20 logs into App Store 10 over network connection 220 via network interface 210 . After receiving App Store Account login information 230 , network interface 210 outputs software applications App 1 , App 2 , etc., over network connection 220 such that the data base presents a list of public software applications 240 consisting of software applications App 1 , App 2 , etc. to the computer device 20 to be manipulated by customer 5 .
[0026] FIG. 2 is a schematic diagram illustrating an example of one aspect of managing software applications via a network connection for applications development. The system facilitates downloading software applications from an Application Store 40 to a computing device 30 by a registered developer 15 over a network connection 420 .
[0027] The system includes a central database 400 configured to house Application Store 40 . Application Store 40 facilitates access to public software applications App 1 , App 2 , etc. and to private software applications AppX, AppY, etc. Central database 400 is configured to have a network interface 410 that communicates to computing device 30 over network connection 420 .
[0028] Network interface 410 allows access to Application Store 40 over network connection 420 such that the computing device 30 is configured to create an application login account 430 . Application store 40 is configured to output a list of public software applications App 1 , App 2 , etc. and private software applications AppX, AppY, etc. over network connection 420 to computing device 30 . It may be appreciated that Central database 400 and network interface 410 that allows access to Application Store 40 over network connection 420 may reside in a server which can perform the functionality described below.
[0029] Computing device 30 is configured to have a developer interface 35 that receives developer login information 36 from developer 15 such that Application Store 40 is accessible over network connection 420 where public software applications App 1 , App 2 , etc. and private software applications AppX, AppY, etc. are downloaded to computing device 30 over network connection 420 .
[0030] Developer 15 registers as an application developer through computer 50 via application developer account login 55 such that the developer 15 is listed on registration server 60 as a registered application developer. Upon recording the registration of developer 15 , registration server 60 outputs SDK 65 to computer 50 . The SDK 65 provides the PC environment in which the developer 15 can create applications.
[0031] In response to a request for verification of developer registration, the registration server 60 exchanges registered application developer account information with the Application Store 40 . This ensures that only registered application developers are allowed access to private software applications AppX, AppY, etc.
[0032] To accommodate a secure download of private software applications AppX, AppY, etc., computing device 30 is configured to receive developer login information 36 from developer 15 at developer interface 35 . Computing device 30 logs into App Store 40 over network connection 420 via network interface 410 . After receiving App Store Account login information 430 , central database 400 exchanges developer login information 36 with registration server 60 . Registration server 60 verifies that developer login information 36 is associated with developer 15 such that developer 15 is a registered application developer, where the developer 15 has performed application developer account login 55 .
[0033] After the verification process is complete, registration server 60 exchanges verification information with central database 400 indicating developer 15 is a registered application developer. At this point, network interface 410 securely outputs private software applications AppX, AppY, etc. as well as public software applications App 1 , App 2 , etc. over network connection 420 such that central database 400 presents a list of public and private software applications 440 to computer device 30 to be manipulated by developer 15 .
[0034] FIG. 3 is a schematic diagram illustrating an example of another aspect of managing software applications via a network connection for applications development. The system facilitates downloading software applications from an Application Store 40 to a registered computing device 40 by a registered developer 15 over a network connection 420 .
[0035] The system may include a central database 400 configured to house Application Store 40 . Application Store 40 may facilitate secure access to public software applications App 1 , App 2 , etc., private software applications AppX, AppY, etc., an all purpose developmental application DEV 1 , and other levels of developmental applications DEV 2 , DEV 3 , etc. The development applications DEV 2 , DEV 3 , etc. change the behavior of the computing device such that various USB and debug ports are unlocked and accessible by registered developer 15 . Central database 400 is configured to have a network interface 410 that communicates to computing device 30 over network connection 420 .
[0036] Network interface 410 allows access to Application Store 40 over network connection 420 such that the computing device 30 is configured to create an application login account 430 . Application store 40 is configured to output a list of public software applications App 1 , App 2 , etc., private software applications AppX, AppY, etc., an all purpose developmental application DEV 1 , and other levels of developmental applications DEV 2 , DEV 3 , etc. over network connection 420 to computing device 30 . It may be appreciated that Central database 400 and network interface 410 that allows access to Application Store 40 over network connection 420 may reside in a server which can perform the functionality described below.
[0037] Computing device 30 is configured to have a developer interface 35 that receives developer login information 36 from developer 15 such that Application Store 40 is accessible over network connection 420 where public software applications App 1 , App 2 , etc., private software applications AppX, AppY, etc., an all purpose developmental application DEV 1 , and other levels of developmental applications DEV 2 , DEV 3 , etc., are downloaded to computing device 30 over network connection 420 .
[0038] Developer 15 registers as an application developer through computer 50 via application developer account login 55 . Upon recording the registration of developer 15 , registration server 60 outputs SDK 65 to computer 50 . The SDK 65 provides the PC environment in which the developer 15 can create applications.
[0039] In response to a request for verification of developer registration, the registration server 60 exchanges registered application developer account information with the Application Store 40 . This similarly ensures that only registered application developers are allowed access to private software applications AppX, AppY, etc.
[0040] Developer 15 registers computing device 30 through computer 50 via device registration account login 56 such that computing device 30 is listed on registration server 60 as a registered developmental computing device. The registration server 60 records a list of registered developmental computing device with the matching registered application developer as an all purpose registration type REG type 1 or other registration types Reg type 2 , Reg type 3 , etc. such that warranty claims is handled properly. The registration server 60 also exchanges registered application developer account information with the Application Store 40 in response to a request for verification of developer registration.
[0041] It should be appreciated that this system is an assurance that only registered application developers associated with the appropriate registered developmental computing device are allowed access to an all purpose developmental application DEV 1 or other levels of developmental applications DEV 2 , DEV 3 , etc. As an aside, all purpose registration type REG type 1 is associated with all purpose developmental application DEV 1 , while registration types Reg type 2 , Reg type 3 , etc. is associated with developmental applications DEV 2 , DEV 3 , etc.
[0042] To accommodate a secure download of developmental applications DEV 1 , DEV 2 , etc., computing device 30 is configured to receive developer login information 36 from developer 15 at developer interface 35 . Computing device 30 logs into App Store 40 over network connection 420 via network interface 410 . After receiving App Store Account login information 430 , central database 400 exchanges developer login information 36 and information about computing device 30 with registration server 60 . Registration server 60 verifies that developer login information 36 is associated with developer 15 such that developer 15 is a registered application developer. Registration server 60 also verifies that computing device 30 is associated with developer 15 such that developer 15 has performed computing device registration and performed application developer registration.
[0043] After the verification process is complete, registration server 60 exchanges verification information and registration type Reg type 1 , Reg type 2 , etc. information with central database 400 indicating developer 15 is a registered application developer and device 30 is a registered developmental computing device. At this point, network interface 410 securely outputs developmental applications DEV 1 , DEV 2 , etc., that correlate to registration types Reg type 1 , Reg type 2 , etc. over network connection 420 such that central database 400 presents a list of developmental software applications 450 to computer device 30 , to be manipulated by developer 15 . Private software applications AppX, AppY, etc. as well as public software applications App 1 , App 2 , etc. are also securely outputted over network connection 420 such that that data base presents a list of public and private software applications 440 to computer device 30 , to be manipulated by developer 15 .
[0044] Downloading and running an all purpose developmental application DEV 1 or other levels of developmental applications DEV 2 , DEV 3 , etc., unlocks features on computing device 30 which are otherwise locked for normal users. By assuring that only registered application developers and registered developmental computing devices have access to the unlocked features an application developer uses the computing device 30 for executing programs not previously tested or approved for the computing device 30 . As an aside, an all purpose developmental application DEV 1 or other levels of developmental applications DEV 2 , DEV 3 , etc., unlocks different types of content features on computing device 30 that are dependant upon the registered developmental computing device that is associated with the registered application developer.
[0045] FIG. 4 is a block schematic illustrating an example of control system for managing software applications via a network connection. For illustrative purposes, the control system is considered to comprise a Central database 400 , Application Store 40 , public software applications App 1 , App 2 , etc., private software applications AppX, AppY, etc., developmental applications DEV 1 , DEV 2 , etc., application retrieval unit 100 , transmit/receive unit 110 , and exchange unit 120 . A computing device 30 to be manipulated by a developer and a registration server 60 employing a verification unit 130 and verification exchange unit 140 is external to the control system.
[0046] Upon receiving a request for downloading public software applications App 1 , App 2 , etc., private software applications AppX, AppY, etc., and developmental applications DEV 1 , DEV 2 , etc., from computing device 30 , Central database 400 exchanges computing device 30 information and developer 15 information with registration server 60 via exchange unit 120 . Verification unit 130 is configured to verify that developer 15 is registered as an registered application developer and computing device 30 is registered as a registered developmental computing device. Verification exchange unit 140 exchanges registration information about developer 15 and computing device 30 with Central database 400 .
[0047] Depending on the verification information received from verification exchange unit 140 , application retrieval unit 100 is configured to retrieve either public software applications App 1 , App 2 , etc., private software applications AppX, AppY, etc., or developmental applications DEV 1 , DEV 2 , etc. from Application Store 40 . Transmit/receive unit 110 is configured to transmit the appropriate software application to be downloaded onto computing device 30 .
[0048] FIG. 5 is flow diagram showing one example of the registration process of managing software applications via a network connection. At S 500 , the developer initiates a request for downloading certain software applications from an Application Store. At S 505 , the control system for managing software applications asks if the developer is a registered application developer. If the answer is no, the control system provides only the public software applications to the developer at S 510 .
[0049] If the answer to S 505 is yes, developer information is exchanged at S 520 and sent to registration server at S 525 . The registration server verifies at 530 the registration status of the developer given the information provided by exchange step 520 and outputs the registration status of developer back to exchange step 520 . In the alternative, S 520 , S 525 , and S 530 may occur before S 505 .
[0050] If the exchange step 520 receives status verification that the developer is a registered application developer, the control system provides both public software application and private software applications at S 540 .
[0051] After S 540 , the control system determines whether the computing device is a registered developmental device at S 545 . If so, the control system provides the public software applications and private software applications to the developer at S 550 .
[0052] If the computing device is a registered developmental computing device, computing device information is exchanged at S 560 and sent to registration server at S 565 . The registration server verifies at 570 the registration status of the computing device given the information provided by exchange step 560 and outputs the registration status of computing device back to exchange step 560 . In one alternative, S 560 , S 565 , and S 570 may occur before S 545 .
[0053] If the exchange step 560 receives status verification that the computing device is a registered developmental computing device, the control system provides public software applications, private software applications, and DEV applications at S 565 .
[0054] The Central database 400 and the registration server 60 may be resident on any computing hardware and run on a conventional operating system to carry out the described functionality by execution of computer instructions. Operating systems may include but are not limited to Windows, Unix, Linux and Macintosh. The computer system may further implement applications that facilitate calculation including but not limited to MATLAB. The artisan will readily recognize the various alternative programming languages and execution platforms that are and will become available, and the present invention is not limited to any specific execution environment.
[0055] Although Central database 400 and the registration server 60 is preferably provided as software, it may alternatively be hardware, firmware, or any combination of software, hardware and firmware.
[0056] An article of manufacture wherein the program instructions that are executed to carry out the functionality described are stored on a computer readable storage medium. The medium may be of any type, including but not limited to magnetic storage media (e.g., floppy disks, hard disks), optical storage media (e.g., CD, DVD), and others.
[0057] Although the present invention has been described in considerable detail with reference to certain embodiments thereof, the invention may be variously embodied without departing from the spirit or scope of the invention. Therefore, the following claims should not be limited to the description of the embodiments contained herein in any way. | An apparatus and method for managing device features though a network connection for receiving a request to download a development application from an application developer via a computing device, verifying the status of said application developer before the development application is sent to the computing device, verifying the status of said computing device on which the application is to be run before the development application is sent to the computing device, and for facilitating access to retrieve said development application in order to allow the application developer access to the unlocked features stored on the computing device. | Summarize the information, clearly outlining the challenges and proposed solutions. | [
"BACKGROUND OF THE INVENTION [0001] 1.",
"Field of the Invention [0002] This invention relates generally to managing device features and more specifically keeping device features locked during normal use while having the capability of securely unlocking device features.",
"[0003] 2.",
"Description of the Related Art [0004] As demand for a genuinely open source community where the next generation of networked application platforms may evolve, the marketplace is being overwhelmed with consumer electronics ranging from smart phones, hand held PDA's, and even digital book readers.",
"Along with burgeoning consumer electronics market, application developers help to bridge the gap between the end consumer and their wants.",
"[0005] One conventional approach for protecting and controlling the use of software is done through licensing the use of software on a particular central processing unit residing on a computing device.",
"After a code is generated at a central service, the code is provided to a third party publisher, who then provides the code to the end user, who then provides it to the computing device, thereby unlocking the appropriate software or features residing on the computing device.",
"However, this approach is undesirable for an application developer who may need more extensive access to a computing device than a simple licensing code would provide.",
"The networked application platform, on the other hand, may require additional protections when allowing the application access to normally locked features of the computing device.",
"[0006] Another mechanism for managing and providing services to a third party application developer involves allowing the application developer to use a scaled-down version of a registered application on a specific electronic device, creating a specialized version of the registered application.",
"After which, a central facility can substitute the specific version of the registered application appropriate to the needs of the application developer and the specific electronic device.",
"Once again, however, the third party application developer in need of unlocking key features and tools of a computing device, may require the full version of the registered development application vis-à-vis the electronic device.",
"[0007] Though other approaches have tried to protect the rights of application developer while protecting the digital content of the networked application platform, the current state of technology has not adequately accounted for targeting the requirements of specific users with specific devices.",
"Requirements such as access to developer documentations, tools and SDK's.",
"[0008] It would be desirable to provide a secure, efficient and scaleable resource for third party application developers to ensure that only registered developers and registered devices gain access to developmental applications.",
"SUMMARY OF THE INVENTION [0009] A mechanism is provided for keeping device features locked or reduced while the device is being used as a normal customer computer electronic device, but adds the capability of securely unlocking features for registered application developers and registered application development device only.",
"[0010] According to an embodiment of the invention, there is provided a mechanism for managing device features though a network connection for receiving a request to download a development application from an application developer via a computing device, wherein the development application being configured to unlock device features stored on the computing device, verifying the status of said application developer before the development application is sent to the computing device, verifying the status of said computing device on which the application is to be run before the development application is sent to the computing device, and facilitating access to retrieve said development application in order to allow the application developer access to the unlocked features stored on the computing device.",
"[0011] This mechanism can be embodied in various forms, including business processes, computer implemented methods, computer program products, computer systems and networks, user interfaces, application programming interfaces, and the like.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0012] These and other more detailed and specific features of the present invention are more fully disclosed in the following specification, reference being had to the accompanying drawings, in which: [0013] FIG. 1 is a schematic diagram illustrating a conventional approach for managing software applications via a network connection.",
"[0014] FIG. 2 is a schematic diagram illustrating an example of one aspect of managing software applications via a network connection for applications development.",
"[0015] FIG. 3 is a schematic diagram illustrating an example of another aspect of managing software applications via a network connection for applications development.",
"[0016] FIG. 4 is a block schematic illustrating an example of managing software applications via a network connection.",
"[0017] FIG. 5 is flow diagram showing one example of the registration process of managing software applications via a network connection.",
"DETAILED DESCRIPTION OF THE INVENTION [0018] In the following description, for purposes of explanation, numerous details are set forth, such as flowcharts and system configurations, in order to provide an understanding of one or more embodiments of the present invention.",
"However, it is and will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention.",
"[0019] Opening normally locked down features on computer electronic devices can harm electronic devices and prompt unnecessary warranty claims.",
"When a third party application developer signs up to become a registered application developer, the developer can gain access to developer documentation, tools and application development kits.",
"Hence, by having the application developer register a device as an application development device, a development application (“Development App”) may become available for download to the registered application development device.",
"[0020] Downloading and running this Development App may unlock features on the device which are otherwise locked for normal users.",
"Since downloading and installing the Development App should void the warranty of the application development device, it becomes possible for the application developer to use the application development device for executing programs not normally tested or approved.",
"This mechanism ensures only registered application developers and registered application development devices gain access to the unlocked features.",
"[0021] FIG. 1 is a conventional system for managing software applications via a network connection and illustrates the functional components for managing software applications.",
"The system may be, for example, a mechanism for downloading software applications from an Application Store 10 to a computing device 20 by a customer 5 over a network connection 220 .",
"[0022] The system may revolve around a central database 200 where the Application Store 10 is housed.",
"Application Store 10 may facilitate access to software applications App 1 , App 2 , etc.",
"Central database 200 is configured to have a network interface 210 that may communicate to computing device 20 over network connection 220 .",
"[0023] Network interface 210 allows access to Application Store 10 over network connection 220 such that the computing device 20 may be configured to create an application login account 230 .",
"Application store 10 may be configured to output a list of public applications App 1 , App 2 , etc.",
"over network connection 220 to computing device 20 .",
"[0024] Computing device 20 is configured to have a customer interface 25 that may receive customer login information 26 from customer 5 such that Application Store 10 is accessible over network connection 220 where software applications App 1 , App 2 , etc.",
"may be downloaded to computing device 20 over network connection 220 .",
"[0025] To accommodate a download of software applications App 1 , App 2 , etc.",
", computing device 20 is configured to receive customer login information 26 from customer 5 at customer interface 25 .",
"After this, the computing device 20 logs into App Store 10 over network connection 220 via network interface 210 .",
"After receiving App Store Account login information 230 , network interface 210 outputs software applications App 1 , App 2 , etc.",
", over network connection 220 such that the data base presents a list of public software applications 240 consisting of software applications App 1 , App 2 , etc.",
"to the computer device 20 to be manipulated by customer 5 .",
"[0026] FIG. 2 is a schematic diagram illustrating an example of one aspect of managing software applications via a network connection for applications development.",
"The system facilitates downloading software applications from an Application Store 40 to a computing device 30 by a registered developer 15 over a network connection 420 .",
"[0027] The system includes a central database 400 configured to house Application Store 40 .",
"Application Store 40 facilitates access to public software applications App 1 , App 2 , etc.",
"and to private software applications AppX, AppY, etc.",
"Central database 400 is configured to have a network interface 410 that communicates to computing device 30 over network connection 420 .",
"[0028] Network interface 410 allows access to Application Store 40 over network connection 420 such that the computing device 30 is configured to create an application login account 430 .",
"Application store 40 is configured to output a list of public software applications App 1 , App 2 , etc.",
"and private software applications AppX, AppY, etc.",
"over network connection 420 to computing device 30 .",
"It may be appreciated that Central database 400 and network interface 410 that allows access to Application Store 40 over network connection 420 may reside in a server which can perform the functionality described below.",
"[0029] Computing device 30 is configured to have a developer interface 35 that receives developer login information 36 from developer 15 such that Application Store 40 is accessible over network connection 420 where public software applications App 1 , App 2 , etc.",
"and private software applications AppX, AppY, etc.",
"are downloaded to computing device 30 over network connection 420 .",
"[0030] Developer 15 registers as an application developer through computer 50 via application developer account login 55 such that the developer 15 is listed on registration server 60 as a registered application developer.",
"Upon recording the registration of developer 15 , registration server 60 outputs SDK 65 to computer 50 .",
"The SDK 65 provides the PC environment in which the developer 15 can create applications.",
"[0031] In response to a request for verification of developer registration, the registration server 60 exchanges registered application developer account information with the Application Store 40 .",
"This ensures that only registered application developers are allowed access to private software applications AppX, AppY, etc.",
"[0032] To accommodate a secure download of private software applications AppX, AppY, etc.",
", computing device 30 is configured to receive developer login information 36 from developer 15 at developer interface 35 .",
"Computing device 30 logs into App Store 40 over network connection 420 via network interface 410 .",
"After receiving App Store Account login information 430 , central database 400 exchanges developer login information 36 with registration server 60 .",
"Registration server 60 verifies that developer login information 36 is associated with developer 15 such that developer 15 is a registered application developer, where the developer 15 has performed application developer account login 55 .",
"[0033] After the verification process is complete, registration server 60 exchanges verification information with central database 400 indicating developer 15 is a registered application developer.",
"At this point, network interface 410 securely outputs private software applications AppX, AppY, etc.",
"as well as public software applications App 1 , App 2 , etc.",
"over network connection 420 such that central database 400 presents a list of public and private software applications 440 to computer device 30 to be manipulated by developer 15 .",
"[0034] FIG. 3 is a schematic diagram illustrating an example of another aspect of managing software applications via a network connection for applications development.",
"The system facilitates downloading software applications from an Application Store 40 to a registered computing device 40 by a registered developer 15 over a network connection 420 .",
"[0035] The system may include a central database 400 configured to house Application Store 40 .",
"Application Store 40 may facilitate secure access to public software applications App 1 , App 2 , etc.",
", private software applications AppX, AppY, etc.",
", an all purpose developmental application DEV 1 , and other levels of developmental applications DEV 2 , DEV 3 , etc.",
"The development applications DEV 2 , DEV 3 , etc.",
"change the behavior of the computing device such that various USB and debug ports are unlocked and accessible by registered developer 15 .",
"Central database 400 is configured to have a network interface 410 that communicates to computing device 30 over network connection 420 .",
"[0036] Network interface 410 allows access to Application Store 40 over network connection 420 such that the computing device 30 is configured to create an application login account 430 .",
"Application store 40 is configured to output a list of public software applications App 1 , App 2 , etc.",
", private software applications AppX, AppY, etc.",
", an all purpose developmental application DEV 1 , and other levels of developmental applications DEV 2 , DEV 3 , etc.",
"over network connection 420 to computing device 30 .",
"It may be appreciated that Central database 400 and network interface 410 that allows access to Application Store 40 over network connection 420 may reside in a server which can perform the functionality described below.",
"[0037] Computing device 30 is configured to have a developer interface 35 that receives developer login information 36 from developer 15 such that Application Store 40 is accessible over network connection 420 where public software applications App 1 , App 2 , etc.",
", private software applications AppX, AppY, etc.",
", an all purpose developmental application DEV 1 , and other levels of developmental applications DEV 2 , DEV 3 , etc.",
", are downloaded to computing device 30 over network connection 420 .",
"[0038] Developer 15 registers as an application developer through computer 50 via application developer account login 55 .",
"Upon recording the registration of developer 15 , registration server 60 outputs SDK 65 to computer 50 .",
"The SDK 65 provides the PC environment in which the developer 15 can create applications.",
"[0039] In response to a request for verification of developer registration, the registration server 60 exchanges registered application developer account information with the Application Store 40 .",
"This similarly ensures that only registered application developers are allowed access to private software applications AppX, AppY, etc.",
"[0040] Developer 15 registers computing device 30 through computer 50 via device registration account login 56 such that computing device 30 is listed on registration server 60 as a registered developmental computing device.",
"The registration server 60 records a list of registered developmental computing device with the matching registered application developer as an all purpose registration type REG type 1 or other registration types Reg type 2 , Reg type 3 , etc.",
"such that warranty claims is handled properly.",
"The registration server 60 also exchanges registered application developer account information with the Application Store 40 in response to a request for verification of developer registration.",
"[0041] It should be appreciated that this system is an assurance that only registered application developers associated with the appropriate registered developmental computing device are allowed access to an all purpose developmental application DEV 1 or other levels of developmental applications DEV 2 , DEV 3 , etc.",
"As an aside, all purpose registration type REG type 1 is associated with all purpose developmental application DEV 1 , while registration types Reg type 2 , Reg type 3 , etc.",
"is associated with developmental applications DEV 2 , DEV 3 , etc.",
"[0042] To accommodate a secure download of developmental applications DEV 1 , DEV 2 , etc.",
", computing device 30 is configured to receive developer login information 36 from developer 15 at developer interface 35 .",
"Computing device 30 logs into App Store 40 over network connection 420 via network interface 410 .",
"After receiving App Store Account login information 430 , central database 400 exchanges developer login information 36 and information about computing device 30 with registration server 60 .",
"Registration server 60 verifies that developer login information 36 is associated with developer 15 such that developer 15 is a registered application developer.",
"Registration server 60 also verifies that computing device 30 is associated with developer 15 such that developer 15 has performed computing device registration and performed application developer registration.",
"[0043] After the verification process is complete, registration server 60 exchanges verification information and registration type Reg type 1 , Reg type 2 , etc.",
"information with central database 400 indicating developer 15 is a registered application developer and device 30 is a registered developmental computing device.",
"At this point, network interface 410 securely outputs developmental applications DEV 1 , DEV 2 , etc.",
", that correlate to registration types Reg type 1 , Reg type 2 , etc.",
"over network connection 420 such that central database 400 presents a list of developmental software applications 450 to computer device 30 , to be manipulated by developer 15 .",
"Private software applications AppX, AppY, etc.",
"as well as public software applications App 1 , App 2 , etc.",
"are also securely outputted over network connection 420 such that that data base presents a list of public and private software applications 440 to computer device 30 , to be manipulated by developer 15 .",
"[0044] Downloading and running an all purpose developmental application DEV 1 or other levels of developmental applications DEV 2 , DEV 3 , etc.",
", unlocks features on computing device 30 which are otherwise locked for normal users.",
"By assuring that only registered application developers and registered developmental computing devices have access to the unlocked features an application developer uses the computing device 30 for executing programs not previously tested or approved for the computing device 30 .",
"As an aside, an all purpose developmental application DEV 1 or other levels of developmental applications DEV 2 , DEV 3 , etc.",
", unlocks different types of content features on computing device 30 that are dependant upon the registered developmental computing device that is associated with the registered application developer.",
"[0045] FIG. 4 is a block schematic illustrating an example of control system for managing software applications via a network connection.",
"For illustrative purposes, the control system is considered to comprise a Central database 400 , Application Store 40 , public software applications App 1 , App 2 , etc.",
", private software applications AppX, AppY, etc.",
", developmental applications DEV 1 , DEV 2 , etc.",
", application retrieval unit 100 , transmit/receive unit 110 , and exchange unit 120 .",
"A computing device 30 to be manipulated by a developer and a registration server 60 employing a verification unit 130 and verification exchange unit 140 is external to the control system.",
"[0046] Upon receiving a request for downloading public software applications App 1 , App 2 , etc.",
", private software applications AppX, AppY, etc.",
", and developmental applications DEV 1 , DEV 2 , etc.",
", from computing device 30 , Central database 400 exchanges computing device 30 information and developer 15 information with registration server 60 via exchange unit 120 .",
"Verification unit 130 is configured to verify that developer 15 is registered as an registered application developer and computing device 30 is registered as a registered developmental computing device.",
"Verification exchange unit 140 exchanges registration information about developer 15 and computing device 30 with Central database 400 .",
"[0047] Depending on the verification information received from verification exchange unit 140 , application retrieval unit 100 is configured to retrieve either public software applications App 1 , App 2 , etc.",
", private software applications AppX, AppY, etc.",
", or developmental applications DEV 1 , DEV 2 , etc.",
"from Application Store 40 .",
"Transmit/receive unit 110 is configured to transmit the appropriate software application to be downloaded onto computing device 30 .",
"[0048] FIG. 5 is flow diagram showing one example of the registration process of managing software applications via a network connection.",
"At S 500 , the developer initiates a request for downloading certain software applications from an Application Store.",
"At S 505 , the control system for managing software applications asks if the developer is a registered application developer.",
"If the answer is no, the control system provides only the public software applications to the developer at S 510 .",
"[0049] If the answer to S 505 is yes, developer information is exchanged at S 520 and sent to registration server at S 525 .",
"The registration server verifies at 530 the registration status of the developer given the information provided by exchange step 520 and outputs the registration status of developer back to exchange step 520 .",
"In the alternative, S 520 , S 525 , and S 530 may occur before S 505 .",
"[0050] If the exchange step 520 receives status verification that the developer is a registered application developer, the control system provides both public software application and private software applications at S 540 .",
"[0051] After S 540 , the control system determines whether the computing device is a registered developmental device at S 545 .",
"If so, the control system provides the public software applications and private software applications to the developer at S 550 .",
"[0052] If the computing device is a registered developmental computing device, computing device information is exchanged at S 560 and sent to registration server at S 565 .",
"The registration server verifies at 570 the registration status of the computing device given the information provided by exchange step 560 and outputs the registration status of computing device back to exchange step 560 .",
"In one alternative, S 560 , S 565 , and S 570 may occur before S 545 .",
"[0053] If the exchange step 560 receives status verification that the computing device is a registered developmental computing device, the control system provides public software applications, private software applications, and DEV applications at S 565 .",
"[0054] The Central database 400 and the registration server 60 may be resident on any computing hardware and run on a conventional operating system to carry out the described functionality by execution of computer instructions.",
"Operating systems may include but are not limited to Windows, Unix, Linux and Macintosh.",
"The computer system may further implement applications that facilitate calculation including but not limited to MATLAB.",
"The artisan will readily recognize the various alternative programming languages and execution platforms that are and will become available, and the present invention is not limited to any specific execution environment.",
"[0055] Although Central database 400 and the registration server 60 is preferably provided as software, it may alternatively be hardware, firmware, or any combination of software, hardware and firmware.",
"[0056] An article of manufacture wherein the program instructions that are executed to carry out the functionality described are stored on a computer readable storage medium.",
"The medium may be of any type, including but not limited to magnetic storage media (e.g., floppy disks, hard disks), optical storage media (e.g., CD, DVD), and others.",
"[0057] Although the present invention has been described in considerable detail with reference to certain embodiments thereof, the invention may be variously embodied without departing from the spirit or scope of the invention.",
"Therefore, the following claims should not be limited to the description of the embodiments contained herein in any way."
] |
BACKGROUND OF THE INVENTION
This invention relates to an improvement in corona charging units for electrophotocopy machines and more particularly to a damage control resistor for dissipating excess corona power supply energy when an arc occurs and for quickly extinguishing the arc in order to prevent a corona wire from becoming damaged due to ion bombardment.
Corona charging units can perform a number of essential functions in the electrophotocopying process. That process includes the steps of charging a photosensitive member, exposing the charged member to an original to form a latent electrostatic image of the original on the photosensitive member, and developing the latent image. In plain paper copiers, the latent image is usually developed on the photosensitive member and the developed image is transferred to a plain paper copy sheet after which the photosensitive member is cleaned before another copy is made. Corona charging units are commonly used to initially charge the photosensitive member, to transfer the developed image to a copy sheet, and to discharge any residual charge on the photosensitive member so that it can be cleaned of untransferred developer before another copy cycle is begun.
Such corona charging units comprise an elongated fine wire that is maintained at a high electrical potential. The wire is supported on insulating blocks and is positioned between a grounded backing plate (shield) and the photosensitive member. A power supply with an output capacitance and capable of generating a high electrical (corona) potential is electrically connected to the corona wire. The power supply raises the potential of the corona wire to several thousand volts in order to generate an effective electric field in the vicinity of that portion of the photosensitive member that passes by the corona wire.
An unresolved and recurring problem for copy machine users is the breaking of corona wires. Broken corona wires must be replaced before the copy machine can resume production. Although replacement or repair of the corona wire can be easily made, temporary loss of the use of the copy machine and the repair thereof cost the user both time and money.
Until now it has been assumed that the cause of corona wire breakage was due to one or more of a number of factors that were beyond control. Such factors were believed to include arcing between the corona wire and the shield (or the photosensitive member which has a grounded, conductive backing), corrosion, vibration, and high mechanical stress in the corona wire which is tautly mounted between the insulating blocks. Regarding corona arcing, in general, it has been suggested that an external series resistor can prevent arcing. See, Leonard D. Loeb, Electrical Coronas, page 513 (1965). Moreover, there are a number of patents that describe corona charging units and show a resistor connected in series with the corona wire; see, e.g. U.S. Pat. Nos. 2,777,957 (Walkup), 2,868,989 (Haacke), 2,856,533 (Rosenthal), 3,604,925 (Snelling), 3,557,367 (Roth), 3,675,011 and 3,760,229 (both Silverberg). Furthermore, some types of commercially available power supplies have a resistor at the output terminal that is connectable in series with the corona wire of the corona charging device while other types have no such resistor. Nevertheless, experience with either type of supply has shown that corona wires will arc and break. Hence, if arcing is a cause of corona wire damage, a series resistor did not appear to be a solution to the problem.
INTRODUCTION AND SUMMARY
It has been discovered that corona wires can be damaged and broken as a result of at least one of two distinct arcing phenomena. One phenomenon is resistive heating of the corona wire and the other phenomenon is bombardment of the corona wire by ions. The invention described herein provides for a damage control resistor that is large enough to dissipate a significant portion of the resistive heat and still small enough to quickly extinguish the arc and thereby terminate ion bombardment of the corona wire.
When the problem of corona wire breakage was first investigated, only the first of the two phenomena were believed to be a cause of the breakage. Accordingly, it was originally believed that arcing heated the corona wire and softened it. The corona wire is always under a high mechanical stress since it is tautly mounted between its insulating blocks. During an arc, a larger than normal current heats the wire, the wire softens and ultimately breaks under the mechanical stress. It has also been observed that some arcs will melt or vaporize the corona wire, depending upon the position of the arc, the energy stored in the power supply capacitor and the electrical properties and mechanical dimensions (especially the diameter) of the wire itself. In theory, the corona wire could be prevented from breaking by reducing the corona wire current and one means for reducing the current would be a resistance inserted in series between the corona wire power supply and the corona wire.
The energy stored in the output capacitance of the power supply will be dissipated in the series resistance and the corona wire resistance which is relatively small in comparison with the series resistance. Thus, there should be little energy dissipated in the corona wire for very high series resistances and corona wire breakage should be eliminated or minimized by placing a large resistance in series with the corona wire.
The foregoing theory was tested by inserting increasingly larger resistances in series with a corona wire. The results were surprisingly contrary to those that were expected. Corona wires not only continued to break, but as the series resistance was increased, the corona wires broke sooner; for very large resistances (e.g., 75KΩ and up), the corona broke almost instantaneously.
Hence, based on the foregoing, one might conclude that arcing and subsequent corona wire breaking would occur with or without a series resistor, and would occur sooner for increasingly larger values of series resistances. However, it was also observed that the time it took for a corona wire to break became shorter as the series resistance became larger. That observation led to another hypothesis that a second, unrelated phenomenon was occurring when the series resistance was very large. It was subsequently discovered that the large resistance combined with the output capacitance of the power supply to yield a relatively long RC discharge time constant. So, during an arc, it took a long time for the output voltage of the power supply to decay. Such relatively long-lived arcs are believed to be a cause of ion bombardment that erodes the corona wire until it breaks.
It is now believed that ion bombardment occurs in the following manner A charged corona wire emits electrons that move toward the grounded shield. In their passage toward the shield, the electrons ionize some of the molecules of air that are in the path of the electrons. A portion of the ions migrate toward and impact the corona wire. Upon impact, the ions liberate a large number of electrons which in turn produce more ions, some of which likewise impact the corona wire to liberate still more electrons. It is believed that perhaps one hundred times as many electrons are liberated by ion impact than are liberated by normal corona wire emission. Under normal conditions most of the ions diffuse into the air and the few ions that impact upon the corona wire cause little damage. However, when an arc occurs, a large number of air molecules are ionized. Unless the arc is extinguished in a short period of time, an ion bombardment will start eroding the corona wire until it breaks.
Arcs are extinguished by dropping the voltage across the corona wire below the corona generating potential. The voltage to the corona is supplied by a high voltage dc power supply. The output voltage of the supply is delivered across a capacitor. When an arc occurs, the capacitor is effectively shorted out and begins to discharge. The time it takes for the capacitor to discharge its voltage to below the corona generating potential is critical. If the discharge time is too long, the arc will persist and runaway ion bombardment will occur. That discharge time is lengthened whenever a series resistance is introduced between the power supply and the corona wire.
Hence, the solution to the problems caused by lack of any series resistance and too large a series resistance lies in choosing a series resistance small enough to result in a relatively short discharge time constant but still large enough to limit the temperature rise of the corona wire.
Accordingly, it is an object of this invention to provide a means and method for preventing corona wires from breaking when either of the aforementioned arcing phenomena occur.
It is another object of this invention to provide a resistance in series between a corona wire power supply and a corona wire, said resistance having an impedance large enough to dissipate excess power supply energy and small enough to terminate an arc before ion bombardment can damage the wire.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a broken perspective view of a corona charging unit that is shown coupled to a schematic representation of a corona power supply and a series damage control resistor.
FIG. 2 is an elevation view of the corona charging unit of FIG. 1.
FIG. 3 is a schematic representation of the corona power supply, the series damage control resistor, and the corona wire resistance at an arcing point.
FIG. 4 is a schematic representation of an another embodiment of this invention.
DETAILED DESCRIPTION
With reference to FIG. 1, a series damage control resistor Rs is shown electrically connected between a high voltage corona power supply 1 and a corona charging unit 10. The corona charging unit 10 comprises an electrically grounded backing plate or shield 3 that partially encloses a corona wire 4. The corona wire 4 is mounted inside the shield 3 between insulating blocks (not shown) that are located one at each end of the shield 3. A photosensitive member 12 is disposed in front of the opening in the shield 3 and spaced from the corona wire 4.
The output voltage of the power supply 1 is a constant, high dc potential Vo. The output voltage Vo may be either positive or negative depending upon the nature of the photosensitive member 12 and upon the function of the corona charger. An initial charging corona and a transfer corona will usually have the same polarity and a cleaning or discharge corona will usually have a polarity opposite to the initial charging corona. The power supply output voltage Vo is coupled to the corona wire 4 through series damage control resistor Rs. When Vo is high enough, the air around the corona wire is ionized. The ions move toward the electrically neutral grounded shield 3, under the influence of an electric field that surrounds the corona wire. Portions of a photosensitive member 12 are sequentially exposed to that field as the photosensitive member moves past the corona wire 4. The photosensitive member 12 comprises an upper photosensitive surface and a lower conductive grounded surface. The photosensitive member 12 moves past the corona charging unit 10 in the direction indicated by the arrow 14 with the upper photosensitive surface juxaposed to the corona wire 4.
The movement of ions from the proximity of the corona wire 4 to the corona shield 3 is known as corona current. Under normal conditions, this current is small and of the order of several hundred microamperes so that the electrical connection between the corona wire 4 and the shield 3 normally functions like an open circuit. However, when a spark or arc appears between the corona wire and the backing plate, the arc acts like a short circuit between the highly charged corona wire 4 and the grounded backing plate 3. Such a short circuit causes a substantial increase in corona current that in turn causes a high current to flow in the corona wire 4. In a corona charging device without a resistor Rs, the current carried in the corona wire during arcing is dissipated as heat and for very high corona wire currents the amount of heat that is generated is damaging to the corona wire. In the invention, the resistor Rs dissipates enough of the damaging energy to keep the corona wire from melting or vaporizing or from softening and slacking. When a corona wire slackens a portion of the wire may move closer, toward the shield 3 which can increase the corona wire current.
The invention is best explained with reference to FIGS. 2 and 3. In FIG. 2 there is shown a representation of the corona wire 4 that is disposed between a grounded backing plate 3 on one side and a photosensitive member 12 on the other side. There is also shown an arc 7 between the corona wire 4 and the shield 3 occurring at a length L along the corona wire 4 whose total length is Lmax.
An arc may also occur between the corona wire 4 and the grounded backing of the photosensitive member 12. When the latter occurs, the photosensitive member is usually punctured and its usefulness impaired.
A schematic representation of the elements of FIG. 2 is shown in FIG. 3. High voltage dc supplies typically have an output capacitor across the output terminals of the supply and the high voltage dc power supply 1 has a capacitor Co at its output and the voltage Vo appears across output capacitor Co. One end of capacitor Co is grounded. A damage control resistance Rs electrically connected in series between the other end of output capacitor Co and the corona wire 4. The resistance of the corona wire up to the arc is represented by the potentiometer 8 comprising a resistance Rcw and a wiper arm 7. The wiper arm 7 represents the arc and Rcw represents the resistance of the corona wire 4 up to the position of the arc at the distance L. Rcmax is the total resistance of the corona wires for its full length, Lmax.
For practical purposes, the arc has no resistance and the resistances of the conductors that interconnect the capacitor Co, resistor Rs and the corona wire 4 are so small in comparison to Rs and Rcw that such conductor resistance can be ignored. Accordingly, the total resistance in circuit of FIG. 3 is the sum of Rs and Rcw, i.e.,
Rt=Rs+Rcw Eq. 1
When an arc occurs, the energy stored in the capacitor Co will be dissipated in the total resistance Rt and the amount of energy dissipated by any one element (Rs or Rcw) is proportional to the resistance of that element, i.e.,
Et=CoVo.sup.2 /2=Es+Ecw Eq. 2
where Et is the total energy stored in capacitor Co charged to the voltage Vo, Es is the portion of Et dissipated by Rs and EEcw is the portion of Et dissipated by Rcw.
Since the portion of energy dissipated by a resistive element is proportional to the resistance of the element, then
(Rcw/Rt)=(Ecw/Et) Eq. 3
The foregoing equation can be rewritten to show that
Ecw=(Rcw Et/Rt) Eq. 4
Recalling from Eq. 1 that Rt=Rcw+Rs, then ##EQU1##
Since the output voltage Vo is a constant, from equation 6 it is apparent that the only variables influencing the amount of energy dissipated by the corona wire are Rcw and Rs, i.e. the length of the corona wire 3 up to the arc and the series resistor, respectively.
The temperature rise in an arcing corona wire is dependent upon the location of the arc along the length of the wire. For arcs that occur close to the connection to the power supply, only a relatively small length of the whole corona wire is available to dissipate the energy discharge from the power supply capacitor. It follows that, for all other conditions being constant, when an arc occurs at or near the end of the corona wire closest to the power supply, the energy dissipated over such a short segment of wire will cause the largest temperature rise in the wire. Likewise, as an arc occurs further along the length of the wire, the corresponding temperature rise will lessen as the length increases until a minimal temperature rise occurs at the end of the wire farthest from the power supply.
Hence, the temperature rise ΔT is inversely proportional to Rcw and so ΔT will be a maximum when Rcw is a minimum, i.e., ΔT will approach its maximum value when an arc occurs at the end of the corona wire that is closest to the series resistor Rs, i.e., when Rs→0. Accordingly, by choosing a large enough value of Rs, the maximum energy dissipated by corona wire 4 can be held to an amount small enough to prevent the corona wire 4 from being damaged.
The amount of energy supplied to the corona wire in the form of heat can be computed from the following formula.
E heat=SWLΔT/0.2389 Eq. 7
where S is the specific heat in calories/gram-C, W is the weight per unit length in centimeters, L is the length of the wire in centimeters, ΔT is the rise in temperature of the wire above the ambiant wire temperature (a predetermined, damage preventing value, such as 10° C.) and 0.2389 is a conversion factor from Joules to calories.
In order to prevent the wire from damage, the amount of energy dissipated in the corona wire 4, Ecw, should be equal to or less than the energy that would cause the predetermined temperature rise. Hence,
Ecw≦E heat Eq. 8
and substituting the value for Ecw from Eq. 5 into Eq. 8 yields
Rcw Et/Rcw+Rs≦E heat Eq. 9
and by solving the foregoing for Rs, then ##EQU2## Recalling from Eq. 7 that E heat=SWLΔT/0.2389 then ##EQU3## Since Et=CoVo/2, then ##EQU4##
For a given corona wire, the value of Rcw is the product of its length (L) and its resistance per unit length, a constant Kr, i.e.
Rcw=KrL Eq. 13
Substituting Eq. 13 into the fractional expression of Eq. 11 yields ##EQU5##
Since L appears in both the numerator and denominator of the fraction, the L's cancel out. By considering the most potentially damaging case, i.e., where an arc occurs near the power supply and Rcw→0, then the value for Rs is given as follows: ##EQU6##
For example, a typical corona unit consists of a 60 cm tungsten wire having a specific heat (S) of 0.034 cal/g-° C. The diameter of the wire is 0.005 cm, its mass per unit length is 0.0003885 gram/cm and its resistance per unit length (Kr) is 0.02853Ω/cm. A typical power supply has an output voltage Vo of 8,300 volts across an output capacitor Co of 0.0125×0.10 -6 farads. Assuming that it is desired to limit the temperature rise of the corona wire to 10° C., then for such a corona unit and power supply, the minimum resistance Rs to prevent corona wire breakage is determined as follows.
The total energy stored in the capacitor Co is: ##EQU7##
Solving For Rs with Eq. 15 yields: ##STR1##
The foregoing analysis and example indicates that all resistances greater than Rs=222Ω would prevent corona breakage. The foregoing also indicates that any large series resistance, even one megohm would prevent corona breakage. However, as pointed out above, it has been further discovered that corona breakage occurs with such extra large resistances, especially when high negative voltages are applied to the corona wire 4. It is believed that such extra large resistance lengthens the discharge RC time constant of capacitor Co to such a long time that a large number of ions are created by the corona arc.
When a corona wire 4 is negatively charged and an arc occurs, the arc ionizes air molecules between the corona wire 4 and the shield 3 and between the corona wire 4 and the photosensitive member 12. These ions are positively charged and possess a high energy that enables them to move rapidly toward the corona wire 4 and impact it in a time on the order of tens of microseconds. The impact of the positive ions on the negatively charged corona wire 4 blasts atoms off the corona wire 4 and liberates a number of free electrons while in turn creates more high energy positive ions that further bombard the corona wire 4. Hence, if an arc is not quickly extinguished, a large number of atoms will be blasted from the corona wire thereby causing it to break.
The length of time it takes to extinguish an arc is dependent upon the total resistance, Rt, and the power supply output capacitor, Co. It will be recalled that an arc function like a short circuit. When an arc occurs, the voltage across the capacitor Co begins to decay. The time (t) it takes for the initial capacitor voltage (Vo) to decay to a voltage (Ve) where the arc is extinguished can be calculated from the following formula:
t=Rt Co 1n (Ve/Vo) Eq. 18
It has been determined that the decay time, t, should be less than a predetermined time in order to prevent the corona wire from breaking under the ensuing ion bombardment. Accordingly, the foregoing equation can be solved for a total resistance (Rt) that will limit the decay time to such a predetermined time as follows: ##STR2##
It is readily apparent that ion bombardment will be most potentially damaging when the arc occurs at the end of the corona wire that is farthest from the power supply. At that position, the full length of the corona wire contributes its resistance toward prolonging the arc. Hence, the value of Rs that would keep Rt within the range necessary to minimize ion bombardment damage is the difference between the value of Rt given by Eq. 19 and the resistance of the entire corona wire, Rcw, or ##STR3##
It will be recalled that Rt=Rcw+Rs and when Rt is relatively small, the arc is quickly extinguished and relatively few high energy positive ions have time to bombard the corona wire 4. However, no matter how small Rt is, some ions will bombard the corona wire 4 and thereby cause some damage. Accordingly (since Rcw is fixed), the value of Rs should be chosen as small as possible and the diameter of the corona wire 4 should be as large as possible to give it strength and prolong its life.
Although Egs. 18-20 provide a way of calculating the maximum value of Rs, it is also possible to empirically arrive at a value of Rs that will satisfactorily minimize damage to a given corona wire. The latter is done by placing a corona wire in an altitude chamber and varying the value of Rs until the corona wire begins to glow red at the point of the arc, at the highest altitude where it is anticipated that the corona wire will be used. The red glow is indicative of ion bombardment and as the resistance R increases, the glow becomes redder and then whitens whereupon the corona wire breaks. One should then compare the empirical value of Rs with the calculated value of Rs that will minimize the temperature rise (Eq. 14). If the empirical value of Rs is greater than the calculated value, then any resistance between the two values is acceptable, and the calculated value is the preferred one. However, if the empirical value is greater than the calculated value, one should revaluate the acceptable temperature rise or change other parameters, such as wire diameter, the capacitance of Co, the material of the corona wire, the corona voltage, etc., all of which would be readily apparent to one skilled in the art in order to settle on a corona charging unit and power supply that will minimize cornona wire breakage.
For the typical corona wire mentioned above, it was empirically determined that a series resistance of 5 KΩ resulted in the beginning of a red glow on the corona wire at the point of the arc. Such a series resistance yielded a capacitor discharge time constant of 6.25×10 -5 seconds. Since it takes approximately five time constants for an arc to extinguish itself, the foregoing indicates that a decay time of less than 31.25×10 -5 seconds is needed in order to prevent the onset of observable ion bombardment. Hence, the previously calculated series resistance value of 222 Ω is preferred and any resistor greater than 222 Ω but less than 5 KΩ would be acceptable.
When the arc persists for a long time it is believed that the ions become unstable and cause an autocatalytically increasing corona current that melts or vaporizes the wire. Although extra large series resistors are normally to be avoided, under certain environmental conditions it is necessary to decrease the corona potential by adding a resistor in series between the power supply and the corona wire. In such cases the embodiment of the invention shown in FIG. 4 may be used.
There is shown another resistor Ra, connected in series with a normal energy limiting resistor Rs. A normally nonconductive metal oxide varistor (MOV) 22 is coupled in parallel across Ra. The MOV 22 acts as an arc sensing means so that when an arc occurs and the corona current increases, the voltage drop across Ra exceeds the threshold voltage of MOV 22. When that occurs, the MOV 22 becomes conductive, thereby shorting oout Ra. That will substantially reduce the impedance in series with the capacitor Vo, thereby shortening the RC discharge time constant and preventing the corona current from autocatalytically increasing.
With the benefit of the foregoing disclosure, those skilled in the art will recognize that the tolerable decay time for an arc on a given corona wire and the amount of energy that can safely be dissipated by a corona wire will vary depending upon many factors. Such factors include, but are not limited to, the gap between the corona wire and the grounded surface to which the arc travels, the diameter of the corona wire, the material used to make the wire, the corona charging potential, environmental conditions (altitude, humidity) and the characteristics of the power supply, especially its output capacitance. Accordingly, such obvious modifications to the physical parameter of the corona wire and its attachments are deemed within the spirit and scope of the invention as expressed in the following claims.
In addition to the foregoing embodiments, those skilled in the art will recognize that they may practice the invention by incorporating it directly into a power supply, or into a corona charging unit or by connecting an appropriate series resistor between a power supply and a corona charging unit.
Although the invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made as an example of the preferred and alternate embodiments and that changes in the details of construction and the combination and arrangement of elements may be resorted to without departing from the spirit and scope of the following claims. | Damage to corona wires in electrophotocopy machines is controlled by connecting an electrical resistance in series between the corona wire power supply and the corona wire. The impedance of the resistance is determined in accordance with formulae and empirical methods in order to control potential arcing damage due to resistive heating and ion bombardment. | Analyze the document's illustrations and descriptions to summarize the main idea's core structure and function. | [
"BACKGROUND OF THE INVENTION This invention relates to an improvement in corona charging units for electrophotocopy machines and more particularly to a damage control resistor for dissipating excess corona power supply energy when an arc occurs and for quickly extinguishing the arc in order to prevent a corona wire from becoming damaged due to ion bombardment.",
"Corona charging units can perform a number of essential functions in the electrophotocopying process.",
"That process includes the steps of charging a photosensitive member, exposing the charged member to an original to form a latent electrostatic image of the original on the photosensitive member, and developing the latent image.",
"In plain paper copiers, the latent image is usually developed on the photosensitive member and the developed image is transferred to a plain paper copy sheet after which the photosensitive member is cleaned before another copy is made.",
"Corona charging units are commonly used to initially charge the photosensitive member, to transfer the developed image to a copy sheet, and to discharge any residual charge on the photosensitive member so that it can be cleaned of untransferred developer before another copy cycle is begun.",
"Such corona charging units comprise an elongated fine wire that is maintained at a high electrical potential.",
"The wire is supported on insulating blocks and is positioned between a grounded backing plate (shield) and the photosensitive member.",
"A power supply with an output capacitance and capable of generating a high electrical (corona) potential is electrically connected to the corona wire.",
"The power supply raises the potential of the corona wire to several thousand volts in order to generate an effective electric field in the vicinity of that portion of the photosensitive member that passes by the corona wire.",
"An unresolved and recurring problem for copy machine users is the breaking of corona wires.",
"Broken corona wires must be replaced before the copy machine can resume production.",
"Although replacement or repair of the corona wire can be easily made, temporary loss of the use of the copy machine and the repair thereof cost the user both time and money.",
"Until now it has been assumed that the cause of corona wire breakage was due to one or more of a number of factors that were beyond control.",
"Such factors were believed to include arcing between the corona wire and the shield (or the photosensitive member which has a grounded, conductive backing), corrosion, vibration, and high mechanical stress in the corona wire which is tautly mounted between the insulating blocks.",
"Regarding corona arcing, in general, it has been suggested that an external series resistor can prevent arcing.",
"See, Leonard D. Loeb, Electrical Coronas, page 513 (1965).",
"Moreover, there are a number of patents that describe corona charging units and show a resistor connected in series with the corona wire;",
"see, e.g. U.S. Pat. Nos. 2,777,957 (Walkup), 2,868,989 (Haacke), 2,856,533 (Rosenthal), 3,604,925 (Snelling), 3,557,367 (Roth), 3,675,011 and 3,760,229 (both Silverberg).",
"Furthermore, some types of commercially available power supplies have a resistor at the output terminal that is connectable in series with the corona wire of the corona charging device while other types have no such resistor.",
"Nevertheless, experience with either type of supply has shown that corona wires will arc and break.",
"Hence, if arcing is a cause of corona wire damage, a series resistor did not appear to be a solution to the problem.",
"INTRODUCTION AND SUMMARY It has been discovered that corona wires can be damaged and broken as a result of at least one of two distinct arcing phenomena.",
"One phenomenon is resistive heating of the corona wire and the other phenomenon is bombardment of the corona wire by ions.",
"The invention described herein provides for a damage control resistor that is large enough to dissipate a significant portion of the resistive heat and still small enough to quickly extinguish the arc and thereby terminate ion bombardment of the corona wire.",
"When the problem of corona wire breakage was first investigated, only the first of the two phenomena were believed to be a cause of the breakage.",
"Accordingly, it was originally believed that arcing heated the corona wire and softened it.",
"The corona wire is always under a high mechanical stress since it is tautly mounted between its insulating blocks.",
"During an arc, a larger than normal current heats the wire, the wire softens and ultimately breaks under the mechanical stress.",
"It has also been observed that some arcs will melt or vaporize the corona wire, depending upon the position of the arc, the energy stored in the power supply capacitor and the electrical properties and mechanical dimensions (especially the diameter) of the wire itself.",
"In theory, the corona wire could be prevented from breaking by reducing the corona wire current and one means for reducing the current would be a resistance inserted in series between the corona wire power supply and the corona wire.",
"The energy stored in the output capacitance of the power supply will be dissipated in the series resistance and the corona wire resistance which is relatively small in comparison with the series resistance.",
"Thus, there should be little energy dissipated in the corona wire for very high series resistances and corona wire breakage should be eliminated or minimized by placing a large resistance in series with the corona wire.",
"The foregoing theory was tested by inserting increasingly larger resistances in series with a corona wire.",
"The results were surprisingly contrary to those that were expected.",
"Corona wires not only continued to break, but as the series resistance was increased, the corona wires broke sooner;",
"for very large resistances (e.g., 75KΩ and up), the corona broke almost instantaneously.",
"Hence, based on the foregoing, one might conclude that arcing and subsequent corona wire breaking would occur with or without a series resistor, and would occur sooner for increasingly larger values of series resistances.",
"However, it was also observed that the time it took for a corona wire to break became shorter as the series resistance became larger.",
"That observation led to another hypothesis that a second, unrelated phenomenon was occurring when the series resistance was very large.",
"It was subsequently discovered that the large resistance combined with the output capacitance of the power supply to yield a relatively long RC discharge time constant.",
"So, during an arc, it took a long time for the output voltage of the power supply to decay.",
"Such relatively long-lived arcs are believed to be a cause of ion bombardment that erodes the corona wire until it breaks.",
"It is now believed that ion bombardment occurs in the following manner A charged corona wire emits electrons that move toward the grounded shield.",
"In their passage toward the shield, the electrons ionize some of the molecules of air that are in the path of the electrons.",
"A portion of the ions migrate toward and impact the corona wire.",
"Upon impact, the ions liberate a large number of electrons which in turn produce more ions, some of which likewise impact the corona wire to liberate still more electrons.",
"It is believed that perhaps one hundred times as many electrons are liberated by ion impact than are liberated by normal corona wire emission.",
"Under normal conditions most of the ions diffuse into the air and the few ions that impact upon the corona wire cause little damage.",
"However, when an arc occurs, a large number of air molecules are ionized.",
"Unless the arc is extinguished in a short period of time, an ion bombardment will start eroding the corona wire until it breaks.",
"Arcs are extinguished by dropping the voltage across the corona wire below the corona generating potential.",
"The voltage to the corona is supplied by a high voltage dc power supply.",
"The output voltage of the supply is delivered across a capacitor.",
"When an arc occurs, the capacitor is effectively shorted out and begins to discharge.",
"The time it takes for the capacitor to discharge its voltage to below the corona generating potential is critical.",
"If the discharge time is too long, the arc will persist and runaway ion bombardment will occur.",
"That discharge time is lengthened whenever a series resistance is introduced between the power supply and the corona wire.",
"Hence, the solution to the problems caused by lack of any series resistance and too large a series resistance lies in choosing a series resistance small enough to result in a relatively short discharge time constant but still large enough to limit the temperature rise of the corona wire.",
"Accordingly, it is an object of this invention to provide a means and method for preventing corona wires from breaking when either of the aforementioned arcing phenomena occur.",
"It is another object of this invention to provide a resistance in series between a corona wire power supply and a corona wire, said resistance having an impedance large enough to dissipate excess power supply energy and small enough to terminate an arc before ion bombardment can damage the wire.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 represents a broken perspective view of a corona charging unit that is shown coupled to a schematic representation of a corona power supply and a series damage control resistor.",
"FIG. 2 is an elevation view of the corona charging unit of FIG. 1. FIG. 3 is a schematic representation of the corona power supply, the series damage control resistor, and the corona wire resistance at an arcing point.",
"FIG. 4 is a schematic representation of an another embodiment of this invention.",
"DETAILED DESCRIPTION With reference to FIG. 1, a series damage control resistor Rs is shown electrically connected between a high voltage corona power supply 1 and a corona charging unit 10.",
"The corona charging unit 10 comprises an electrically grounded backing plate or shield 3 that partially encloses a corona wire 4.",
"The corona wire 4 is mounted inside the shield 3 between insulating blocks (not shown) that are located one at each end of the shield 3.",
"A photosensitive member 12 is disposed in front of the opening in the shield 3 and spaced from the corona wire 4.",
"The output voltage of the power supply 1 is a constant, high dc potential Vo.",
"The output voltage Vo may be either positive or negative depending upon the nature of the photosensitive member 12 and upon the function of the corona charger.",
"An initial charging corona and a transfer corona will usually have the same polarity and a cleaning or discharge corona will usually have a polarity opposite to the initial charging corona.",
"The power supply output voltage Vo is coupled to the corona wire 4 through series damage control resistor Rs.",
"When Vo is high enough, the air around the corona wire is ionized.",
"The ions move toward the electrically neutral grounded shield 3, under the influence of an electric field that surrounds the corona wire.",
"Portions of a photosensitive member 12 are sequentially exposed to that field as the photosensitive member moves past the corona wire 4.",
"The photosensitive member 12 comprises an upper photosensitive surface and a lower conductive grounded surface.",
"The photosensitive member 12 moves past the corona charging unit 10 in the direction indicated by the arrow 14 with the upper photosensitive surface juxaposed to the corona wire 4.",
"The movement of ions from the proximity of the corona wire 4 to the corona shield 3 is known as corona current.",
"Under normal conditions, this current is small and of the order of several hundred microamperes so that the electrical connection between the corona wire 4 and the shield 3 normally functions like an open circuit.",
"However, when a spark or arc appears between the corona wire and the backing plate, the arc acts like a short circuit between the highly charged corona wire 4 and the grounded backing plate 3.",
"Such a short circuit causes a substantial increase in corona current that in turn causes a high current to flow in the corona wire 4.",
"In a corona charging device without a resistor Rs, the current carried in the corona wire during arcing is dissipated as heat and for very high corona wire currents the amount of heat that is generated is damaging to the corona wire.",
"In the invention, the resistor Rs dissipates enough of the damaging energy to keep the corona wire from melting or vaporizing or from softening and slacking.",
"When a corona wire slackens a portion of the wire may move closer, toward the shield 3 which can increase the corona wire current.",
"The invention is best explained with reference to FIGS. 2 and 3.",
"In FIG. 2 there is shown a representation of the corona wire 4 that is disposed between a grounded backing plate 3 on one side and a photosensitive member 12 on the other side.",
"There is also shown an arc 7 between the corona wire 4 and the shield 3 occurring at a length L along the corona wire 4 whose total length is Lmax.",
"An arc may also occur between the corona wire 4 and the grounded backing of the photosensitive member 12.",
"When the latter occurs, the photosensitive member is usually punctured and its usefulness impaired.",
"A schematic representation of the elements of FIG. 2 is shown in FIG. 3. High voltage dc supplies typically have an output capacitor across the output terminals of the supply and the high voltage dc power supply 1 has a capacitor Co at its output and the voltage Vo appears across output capacitor Co. One end of capacitor Co is grounded.",
"A damage control resistance Rs electrically connected in series between the other end of output capacitor Co and the corona wire 4.",
"The resistance of the corona wire up to the arc is represented by the potentiometer 8 comprising a resistance Rcw and a wiper arm 7.",
"The wiper arm 7 represents the arc and Rcw represents the resistance of the corona wire 4 up to the position of the arc at the distance L. Rcmax is the total resistance of the corona wires for its full length, Lmax.",
"For practical purposes, the arc has no resistance and the resistances of the conductors that interconnect the capacitor Co, resistor Rs and the corona wire 4 are so small in comparison to Rs and Rcw that such conductor resistance can be ignored.",
"Accordingly, the total resistance in circuit of FIG. 3 is the sum of Rs and Rcw, i.e., Rt=Rs+Rcw Eq.",
"1 When an arc occurs, the energy stored in the capacitor Co will be dissipated in the total resistance Rt and the amount of energy dissipated by any one element (Rs or Rcw) is proportional to the resistance of that element, i.e., Et=CoVo.",
"sup[.",
"].2 /2=Es+Ecw Eq.",
"2 where Et is the total energy stored in capacitor Co charged to the voltage Vo, Es is the portion of Et dissipated by Rs and EEcw is the portion of Et dissipated by Rcw.",
"Since the portion of energy dissipated by a resistive element is proportional to the resistance of the element, then (Rcw/Rt)=(Ecw/Et) Eq.",
"3 The foregoing equation can be rewritten to show that Ecw=(Rcw Et/Rt) Eq.",
"4 Recalling from Eq.",
"1 that Rt=Rcw+Rs, then ##EQU1## Since the output voltage Vo is a constant, from equation 6 it is apparent that the only variables influencing the amount of energy dissipated by the corona wire are Rcw and Rs, i.e. the length of the corona wire 3 up to the arc and the series resistor, respectively.",
"The temperature rise in an arcing corona wire is dependent upon the location of the arc along the length of the wire.",
"For arcs that occur close to the connection to the power supply, only a relatively small length of the whole corona wire is available to dissipate the energy discharge from the power supply capacitor.",
"It follows that, for all other conditions being constant, when an arc occurs at or near the end of the corona wire closest to the power supply, the energy dissipated over such a short segment of wire will cause the largest temperature rise in the wire.",
"Likewise, as an arc occurs further along the length of the wire, the corresponding temperature rise will lessen as the length increases until a minimal temperature rise occurs at the end of the wire farthest from the power supply.",
"Hence, the temperature rise ΔT is inversely proportional to Rcw and so ΔT will be a maximum when Rcw is a minimum, i.e., ΔT will approach its maximum value when an arc occurs at the end of the corona wire that is closest to the series resistor Rs, i.e., when Rs→0.",
"Accordingly, by choosing a large enough value of Rs, the maximum energy dissipated by corona wire 4 can be held to an amount small enough to prevent the corona wire 4 from being damaged.",
"The amount of energy supplied to the corona wire in the form of heat can be computed from the following formula.",
"E heat=SWLΔT/0.2389 Eq.",
"7 where S is the specific heat in calories/gram-C, W is the weight per unit length in centimeters, L is the length of the wire in centimeters, ΔT is the rise in temperature of the wire above the ambiant wire temperature (a predetermined, damage preventing value, such as 10° C.) and 0.2389 is a conversion factor from Joules to calories.",
"In order to prevent the wire from damage, the amount of energy dissipated in the corona wire 4, Ecw, should be equal to or less than the energy that would cause the predetermined temperature rise.",
"Hence, Ecw≦E heat Eq.",
"8 and substituting the value for Ecw from Eq.",
"5 into Eq.",
"8 yields Rcw Et/Rcw+Rs≦E heat Eq.",
"9 and by solving the foregoing for Rs, then ##EQU2## Recalling from Eq.",
"7 that E heat=SWLΔT/0.2389 then ##EQU3## Since Et=CoVo/2, then ##EQU4## For a given corona wire, the value of Rcw is the product of its length (L) and its resistance per unit length, a constant Kr, i.e. Rcw=KrL Eq.",
"13 Substituting Eq.",
"13 into the fractional expression of Eq.",
"11 yields ##EQU5## Since L appears in both the numerator and denominator of the fraction, the L's cancel out.",
"By considering the most potentially damaging case, i.e., where an arc occurs near the power supply and Rcw→0, then the value for Rs is given as follows: ##EQU6## For example, a typical corona unit consists of a 60 cm tungsten wire having a specific heat (S) of 0.034 cal/g-° C. The diameter of the wire is 0.005 cm, its mass per unit length is 0.0003885 gram/cm and its resistance per unit length (Kr) is 0.02853Ω/cm.",
"A typical power supply has an output voltage Vo of 8,300 volts across an output capacitor Co of 0.0125×0.10 -6 farads.",
"Assuming that it is desired to limit the temperature rise of the corona wire to 10° C., then for such a corona unit and power supply, the minimum resistance Rs to prevent corona wire breakage is determined as follows.",
"The total energy stored in the capacitor Co is: ##EQU7## Solving For Rs with Eq.",
"15 yields: ##STR1## The foregoing analysis and example indicates that all resistances greater than Rs=222Ω would prevent corona breakage.",
"The foregoing also indicates that any large series resistance, even one megohm would prevent corona breakage.",
"However, as pointed out above, it has been further discovered that corona breakage occurs with such extra large resistances, especially when high negative voltages are applied to the corona wire 4.",
"It is believed that such extra large resistance lengthens the discharge RC time constant of capacitor Co to such a long time that a large number of ions are created by the corona arc.",
"When a corona wire 4 is negatively charged and an arc occurs, the arc ionizes air molecules between the corona wire 4 and the shield 3 and between the corona wire 4 and the photosensitive member 12.",
"These ions are positively charged and possess a high energy that enables them to move rapidly toward the corona wire 4 and impact it in a time on the order of tens of microseconds.",
"The impact of the positive ions on the negatively charged corona wire 4 blasts atoms off the corona wire 4 and liberates a number of free electrons while in turn creates more high energy positive ions that further bombard the corona wire 4.",
"Hence, if an arc is not quickly extinguished, a large number of atoms will be blasted from the corona wire thereby causing it to break.",
"The length of time it takes to extinguish an arc is dependent upon the total resistance, Rt, and the power supply output capacitor, Co",
"It will be recalled that an arc function like a short circuit.",
"When an arc occurs, the voltage across the capacitor Co begins to decay.",
"The time (t) it takes for the initial capacitor voltage (Vo) to decay to a voltage (Ve) where the arc is extinguished can be calculated from the following formula: t=Rt Co 1n (Ve/Vo) Eq.",
"18 It has been determined that the decay time, t, should be less than a predetermined time in order to prevent the corona wire from breaking under the ensuing ion bombardment.",
"Accordingly, the foregoing equation can be solved for a total resistance (Rt) that will limit the decay time to such a predetermined time as follows: ##STR2## It is readily apparent that ion bombardment will be most potentially damaging when the arc occurs at the end of the corona wire that is farthest from the power supply.",
"At that position, the full length of the corona wire contributes its resistance toward prolonging the arc.",
"Hence, the value of Rs that would keep Rt within the range necessary to minimize ion bombardment damage is the difference between the value of Rt given by Eq.",
"19 and the resistance of the entire corona wire, Rcw, or ##STR3## It will be recalled that Rt=Rcw+Rs and when Rt is relatively small, the arc is quickly extinguished and relatively few high energy positive ions have time to bombard the corona wire 4.",
"However, no matter how small Rt is, some ions will bombard the corona wire 4 and thereby cause some damage.",
"Accordingly (since Rcw is fixed), the value of Rs should be chosen as small as possible and the diameter of the corona wire 4 should be as large as possible to give it strength and prolong its life.",
"Although Egs.",
"18-20 provide a way of calculating the maximum value of Rs, it is also possible to empirically arrive at a value of Rs that will satisfactorily minimize damage to a given corona wire.",
"The latter is done by placing a corona wire in an altitude chamber and varying the value of Rs until the corona wire begins to glow red at the point of the arc, at the highest altitude where it is anticipated that the corona wire will be used.",
"The red glow is indicative of ion bombardment and as the resistance R increases, the glow becomes redder and then whitens whereupon the corona wire breaks.",
"One should then compare the empirical value of Rs with the calculated value of Rs that will minimize the temperature rise (Eq.",
"14).",
"If the empirical value of Rs is greater than the calculated value, then any resistance between the two values is acceptable, and the calculated value is the preferred one.",
"However, if the empirical value is greater than the calculated value, one should revaluate the acceptable temperature rise or change other parameters, such as wire diameter, the capacitance of Co, the material of the corona wire, the corona voltage, etc.",
", all of which would be readily apparent to one skilled in the art in order to settle on a corona charging unit and power supply that will minimize cornona wire breakage.",
"For the typical corona wire mentioned above, it was empirically determined that a series resistance of 5 KΩ resulted in the beginning of a red glow on the corona wire at the point of the arc.",
"Such a series resistance yielded a capacitor discharge time constant of 6.25×10 -5 seconds.",
"Since it takes approximately five time constants for an arc to extinguish itself, the foregoing indicates that a decay time of less than 31.25×10 -5 seconds is needed in order to prevent the onset of observable ion bombardment.",
"Hence, the previously calculated series resistance value of 222 Ω is preferred and any resistor greater than 222 Ω but less than 5 KΩ would be acceptable.",
"When the arc persists for a long time it is believed that the ions become unstable and cause an autocatalytically increasing corona current that melts or vaporizes the wire.",
"Although extra large series resistors are normally to be avoided, under certain environmental conditions it is necessary to decrease the corona potential by adding a resistor in series between the power supply and the corona wire.",
"In such cases the embodiment of the invention shown in FIG. 4 may be used.",
"There is shown another resistor Ra, connected in series with a normal energy limiting resistor Rs.",
"A normally nonconductive metal oxide varistor (MOV) 22 is coupled in parallel across Ra.",
"The MOV 22 acts as an arc sensing means so that when an arc occurs and the corona current increases, the voltage drop across Ra exceeds the threshold voltage of MOV 22.",
"When that occurs, the MOV 22 becomes conductive, thereby shorting oout Ra.",
"That will substantially reduce the impedance in series with the capacitor Vo, thereby shortening the RC discharge time constant and preventing the corona current from autocatalytically increasing.",
"With the benefit of the foregoing disclosure, those skilled in the art will recognize that the tolerable decay time for an arc on a given corona wire and the amount of energy that can safely be dissipated by a corona wire will vary depending upon many factors.",
"Such factors include, but are not limited to, the gap between the corona wire and the grounded surface to which the arc travels, the diameter of the corona wire, the material used to make the wire, the corona charging potential, environmental conditions (altitude, humidity) and the characteristics of the power supply, especially its output capacitance.",
"Accordingly, such obvious modifications to the physical parameter of the corona wire and its attachments are deemed within the spirit and scope of the invention as expressed in the following claims.",
"In addition to the foregoing embodiments, those skilled in the art will recognize that they may practice the invention by incorporating it directly into a power supply, or into a corona charging unit or by connecting an appropriate series resistor between a power supply and a corona charging unit.",
"Although the invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made as an example of the preferred and alternate embodiments and that changes in the details of construction and the combination and arrangement of elements may be resorted to without departing from the spirit and scope of the following claims."
] |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 10/909,623, filed Aug. 2, 2004. All prior applications are hereby incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ambidextrous locking clamp system for use in connection with clamping instruments, such as surgical clamps, forceps, or hemostats. The ambidextrous locking clamp system has particular utility in connection with manipulating objects with a tool having removable and interchangeable locking assemblies.
2. Description of the Prior Art
Ambidextrous locking clamps, forceps or hemostats are desirable for allowing a right or left-handed user to use a single hand operated clamp, forceps or hemostat device. These hand operated devices have been manufactured in the past for either a right hand or left hand user. This manufacturing process has some disadvantages in that the manufacturer would have to make a decision to how many right handed and left handed devices to fabricate. In most cases the decision is made to manufacture more right-handed devices than left handed devices. Therefore, it is well known that it is very difficult for a left-handed user to operate a right-handed device.
Hand operated locking clamps, forceps, and hemostats are well known. These devices include a pair of elongated members joined by a hinge. The hinge is usually a hinge pin extending through both elongated members. One end of the elongated members features a working head, usually a griping jaw or cutting edges. The other end of the elongated members feature a finger engaging loop, with a set of ratchet teeth extending out therefrom towards the ratchet teeth of the finger loop of the second elongated member. The ratchet teeth are orientated so that they engage each other when the finger loop ends are brought together. These devices are mainly used in the medical industry for a wide variety of uses, but they are also used in the fly fishing, model building, and electrical industries.
During operation of a standard right handed hand operated device, the user inserts his or her thumb into one loop, the middle finger in the opposite loop, and the index finger would rest on the top of the middle finger loop for support and control of the device. To engage the working head the user squeezes the thumb and middle finger together guided by the index finger. The device is locked in the close position by further squeezing the loops together until the ratchet teeth members engage each other. To release, the thumb pushes away from the palm of the hand and the middle finger pulls toward the palm of the hand. This motion makes the ratchet teeth members flex away from each other and disengage.
The difficulty lies when a left-handed user tries to operate a right-handed device. It is difficult for a left-handed user to pull with the thumb and push with the middle finger. This is not a natural hand motion.
The use of locking clamps is known in the prior art. For example, U.S. Pat. No. 6,397,478 to Jose Carlos Mario Bornancini; U.S. Pat. No. 3,978,584 to John Mayer; U.S. Pat. No. 3,913,586 to Baumgarten; U.S. Pat. No. 6,223,440 to Rashman; United States Patent Application Publication 2004/0106947 to Propp et al.; U.S. Pat. No. 5,626,608 Cuny et al.; and U.S. Pat. No. 5,176,702 to Bales et al.
While the above-described devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not describe an ambidextrous hand operated device that allows the use of the device by a right or left handed user through the interchanging of components.
Therefore, a need exists for a new and improved ambidextrous locking clamp system that can be used for manipulating objects with a tool having removable and interchangeable components. In this regard, the present invention substantially fulfills this need. In this respect, the ambidextrous locking clamp system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of manipulating objects with a tool having removable and interchangeable locking assemblies.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of hand operated locking devices now present in the prior art, the present invention provides an improved ambidextrous locking clamp system, and overcomes the above-mentioned disadvantages and drawbacks of the prior art. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved ambidextrous locking clamp system and method which has all the advantages of the prior art mentioned heretofore and many novel features that result in a ambidextrous locking clamp system which is not anticipated, rendered obvious, suggested, or even implied by the prior art, either alone or in any combination thereof.
To attain this, the present invention essentially comprises an ambidextrous locking clamp system for providing a user the ability to alter the configuration of a hand operated device allowing a right hand or left hand user to operate the device, wherein the ambidextrous locking clamp system has a first elongated member including a working head and a finger engaging member including an indicator for identifying a first side, a second elongated member including a working head and a finger engaging member including an indicator for identifying a second side, wherein the second elongated member is hingedly connected to the first elongated member, and at least two latching members having notches for viewing the indicators, wherein the latching members are removably attachable to the first and second elongated members.
Additionally, the present invention may comprise an ambidextrous locking clamp system having a first elongated member including a finger engaging member receiving assembly and a working head opposite of the finger engaging member receiving assembly, a second elongated member including a finger engaging member receiving assembly and a working head opposite of the finger engaging member receiving assembly, at least two finger engaging members removably attachable to the finger engaging member receiving assemblies of the first and second elongated members, and at least two retaining caps for retaining the finger engaging members to the finger engaging member receiving assemblies. The second elongated member is hingedly connected to the first elongated member. Furthermore, the finger engaging member receiving assemblies have an indicator and the finger engaging members have a notch that is positionable over the indicator.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.
The invention may also include a variety of means to retain the latching members to the first and second elongated members, such as, but not limited to, rotating levers, removable retaining caps, and removable retaining pins. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.
Numerous embodiments, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an embodiment of the present invention to provide a new and improved ambidextrous locking clamp system that has all of the advantages of the prior art locking clamps and none of the disadvantages.
It is another embodiment of the present invention to provide a new and improved ambidextrous locking clamp system that may be easily and efficiently manufactured and marketed.
An even further embodiment of the present invention is to provide a new and improved ambidextrous locking clamp system that has a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such ambidextrous locking clamp system economically available to the buying public.
Still another embodiment of the present invention is to provide a new ambidextrous locking clamp system that provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Lastly another embodiment of the present invention is to provide an ambidextrous locking clamp system for manipulating objects with a tool having removable and interchangeable locking assemblies. This allows the use of the hand operated device by either a right or left handed user.
These together with other embodiments of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific embodiments attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a front elevational view of the ambidextrous locking clamp system constructed in accordance with the principles of the present invention.
FIG. 2 is an enlarged cross-sectional view of the ambidextrous locking clamp system of the present invention.
FIG. 3 is an exploded side plane view of the ambidextrous locking clamp system of the present invention.
FIG. 4 is a cross-sectional view the locking assembly of the ambidextrous locking clamp system of the present invention.
FIG. 5 is an exploded cross-sectional view of the locking assembly of the ambidextrous locking clamp system of the present invention.
FIG. 6 is a front elevational view of a second alternate embodiment of the ambidextrous locking clamp system of the present invention.
FIG. 7 is an enlarged cross-sectional view of the second alternate embodiment of the present invention.
FIG. 8 is an exploded side plane view of the second alternate embodiment of the second alternate embodiment of the present invention.
FIG. 9 is a cross-sectional view of the locking assembly of the second alternate embodiment of the present invention.
FIG. 10 is an exploded cross-sectional view of the locking assembly of the second alternate embodiment of the present invention.
FIG. 11 is a front elevational view of a third alternate embodiment of the ambidextrous locking clamp system of the present invention.
FIG. 12 is an enlarged cross-sectional view of the third alternate embodiment of the present invention.
FIG. 13 is a cross-sectional view of the locking assembly of the third alternate embodiment of the present invention.
FIG. 14 is an exploded front elevational view of the third alternate embodiment of the present invention.
FIG. 15 is a front elevational view of a fourth alternate embodiment of the ambidextrous locking clamp system of the present invention.
FIG. 16 is an enlarged cross-sectional view of the fourth alternate embodiment of the present invention.
FIG. 17 is an exploded cross-sectional view of the fourth alternate embodiment of the present invention.
FIG. 18 is a cross-sectional view of the locking assembly of the fourth alternate embodiment of the present invention.
FIG. 19 is a cross-sectional view of the locking assembly of the fourth alternate embodiment of the present invention.
FIG. 20 is a front elevational view of a fifth alternate embodiment of the ambidextrous locking clamp system of the present invention.
FIG. 21 is an enlarged cross-sectional view of the fifth alternate embodiment of the present invention.
FIG. 22 is a cross-sectional view of the locking assembly of the fifth alternate embodiment of the ambidextrous locking clamp system of the present invention.
FIG. 23 is an exploded cross-sectional view of the fifth alternate embodiment of the present invention.
FIG. 24 is a front elevational view of an alternate embodiment of the ambidextrous locking clamp system of FIG. 1 .
FIG. 25 is an exploded side elevational view of the locking assembly of the alternate embodiment of the present invention.
FIG. 26 is a cross-sectional view taken along the line 26 - 26 in FIG. 24 of the alternate embodiment of the present invention.
FIG. 27 is a front elevational view of an alternate embodiment of the second embodiment of the ambidextrous locking clamp system of FIG. 6 .
FIG. 28 is an exploded side elevational view of the alternate embodiment of the second embodiment of the present invention.
FIG. 29 is a cross-sectional view taken along the line 29 - 29 in FIG. 27 of the alternate embodiment of the second embodiment of the present invention.
FIG. 30 is a front elevational view of an alternate embodiment of the third embodiment of the ambidextrous locking clamp system of FIG. 11 .
FIG. 31 is an exploded side elevational view of the alternate embodiment of the third embodiment of the present invention.
FIG. 32 is a cross-sectional view taken along the line 32 - 32 in FIG. 30 of the alternate embodiment of the third embodiment of the present invention.
FIG. 33 is a front elevational view of an alternate embodiment of the fourth embodiment of the ambidextrous locking clamp system of FIG. 15 .
FIG. 34 is an exploded front elevational view of the alternate embodiment of the fourth embodiment of the present invention.
FIG. 35 is a cross-sectional view taken along the line 35 - 35 in FIG. 33 of the alternate embodiment of the fourth embodiment of the present invention.
FIG. 36 is a front elevational view of an alternate embodiment of the fifth embodiment of the ambidextrous locking clamp system of FIG. 20 .
FIG. 37 is an exploded front elevational view of the alternate embodiment of the fifth embodiment of the present invention.
FIG. 38 is a cross-sectional view taken along the line 38 - 38 in FIG. 36 of the alternate embodiment of the fifth embodiment of the present invention.
The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1-38 , a first embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 10 .
In FIG. 1 , a new and improved ambidextrous locking clamp system 10 of the present invention for allowing the use of a hand operated device by a right or left handed user is illustrated and will be described. More particularly, the ambidextrous locking clamp system 10 has a first elongated member 12 and a second elongated member 14 each having a working head 13 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge. The second elongated member 14 is connected to the first elongated member 12 via a hinge 15 . The first and second elongated members 12 and 14 each have a finger engaging member 17 and 18 located opposite of the working heads 13 . A first lever 30 and second lever 50 are pivotally attachable to the finger engaging members 17 and 18 , and are orientated so that the levers are facing each other. Additionally, a first latching member 20 is removably attachable to the finger engaging member 17 and a second latching member 40 is removably attachable to the finger engaging member 18 . The first and second elongated members 12 and 14 can be made from any suitable material having reflex memory.
The levers 30 and 50 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 17 and 18 . A pivot pin 32 and 52 extend from the finger engaging members 17 and 18 , and through levers 30 and 50 , allowing the levers to rotate. The levers 30 and 50 have an extension 31 and 51 for retaining the first and second latching members 20 and 40 on the finger engaging members 17 and 18 when the levers are aligned with the longitudinal axis of the first and second elongated members 12 and 14 . When the levers 30 and 50 are rotated to a position perpendicular to the first and second elongated members 12 and 14 , the extensions 31 and 51 are able to be moved out of engagement with the first and second latching members 20 and 40 , thereby allowing the first and second locking members to slide past the extensions 31 and be removed from finger engaging members 17 and 18 . This is best illustrated in FIGS. 2 and 3 .
The first and second latching members 20 and 40 each have an elongated base 22 and 42 and a latch arm 24 and 44 extending out from each elongated base. The latch arms 24 and 44 feature a plurality of teeth 26 and 46 , which are adapted to join and lock together when engaged. The teeth 26 and 46 are able to disengage when pulled apart by the flexing of the first and second elongated members 12 and 14 when an opposing force is applied to the finger engaging members 17 and 18 .
The elongated base 22 and 42 of the first and second latching members 20 and 40 each have a channel 28 and 48 running the length of the elongated base. The channels 28 and 48 are adapted to slide on and be retained by a protrusion 21 and 41 extending out from the finger engaging members 17 and 18 and adjacent to the levers 30 and 50 . The configuration of the channels 28 and 48 and the protrusions 21 and 41 allow the first and second latching members 20 and 40 to slide over the protrusion, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion. FIGS. 4 and 5 best illustrate one possible example of the channel and protrusion configuration.
The first and second latching members 20 and 40 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 10 . Furthermore, other configurations of the first and second latching members 20 and 40 maybe used in place of the above described latching members.
Referring now to FIG. 6 , a second alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 60 . More particularly, the ambidextrous locking clamp system 60 has a first elongated member 62 and a second elongated member 64 each having a working head 63 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge. The second elongated member 64 is connected to the first elongate member 62 via a hinge. The first and second elongated members 62 and 64 have a finger engaging member 65 and 66 located opposite of the working heads 63 . A first lever 80 and second lever 100 are pivotally attachable to the finger engaging members 65 and 66 , and are orientated so that the levers are facing each other. Additionally, a first latching member 70 is removably attachable to the finger engaging member 65 and a second latching member 90 is removably attachable to the finger engaging member 66 .
The levers 80 and 100 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 65 and 66 . A pivot pin 67 and 68 extend from the finger engaging members 65 and 66 , and through levers 80 and 100 , allowing the levers to rotate. The levers 80 and 100 have an extension 82 and 102 for retaining the first and second latching members 70 and 90 on the finger engaging members 65 and 66 when the levers are aligned with the longitudinal axis of the first and second elongated members 62 and 64 . A notch 84 and 104 is defined in the levers 80 and 100 for allowing the first and second latching members 70 and 90 to pass therethrough. When the levers 80 and 100 are rotated so they are perpendicular to the first and second elongated members 62 and 64 , the extensions 82 and 102 are moved out of engagement with the first and second latching members 70 and 90 , and the notches 84 and 104 are exposed to the first and second latching members, thereby allowing the first and second locking members to slide through the notches and removed from finger engaging members 65 and 66 . This is best illustrated in FIGS. 7 and 8 .
The first and second latching members 70 and 90 each have an elongated base 72 and 92 and a latch arm 74 and 94 extending out from each elongated base. The latch arms 74 and 94 feature a plurality of teeth 76 and 96 , which are adapted to join and lock together when engaged. The teeth 76 and 96 are able to disengage when pulled apart by the flexing of the first and second elongated members 62 and 64 when an opposing force is applied to the finger engaging members 65 and 66 .
The elongated base 72 and 92 of the first and second latching members 70 and 90 each have a channel 78 and 98 running the length of the elongated base. The channels 78 and 98 are adapted to slide and be retained by a protrusion 71 and 91 extending out from the finger engaging members 65 and 66 and adjacent to the levers 80 and 100 . The configuration of the channels 78 and 98 and the protrusions 71 and 91 allow the first and second latching members 70 and 90 to slide over the protrusion, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion. FIGS. 9 and 10 best illustrate one possible example of the channel and protrusion configuration.
The first and second latching members 70 and 90 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 60 . Furthermore, other configurations of the first and second latching members 70 and 90 may be used in place of the above described latching members.
Referring now to FIG. 11 , a third alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 110 . More particularly, the ambidextrous locking clamp system 110 has a first elongated member 112 and a second elongated member 113 each having a working head 115 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge. The second elongated member 113 is connected to the first elongate member 112 via a hinge. The first and second elongated members 112 and 113 have a finger engaging member 114 and 116 located opposite of the working heads 115 . A first retaining cap 140 and second retaining cap 160 are threadably attachable to the finger engaging members 114 and 116 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members 112 and 113 . The retaining caps 160 can also be orientated in any alternate position to the first and second elongated members 112 and 113 . Additionally, a first latching member 120 is removably attachable to the finger engaging member 114 and a second latching member 150 is removably attachable to the finger engaging member 116 .
The retaining caps 140 and 160 have an internal threaded bore 141 and 161 . The caps 140 and 160 are adapted to secure the first and second latching members 120 and 150 to the finger engaging members 114 and 116 . The caps 140 and 160 are removably attachable to the finger engaging members 114 and 116 by screwing the caps onto a threaded stud 142 and 162 which extends out from a protrusion 117 and 118 of the finger engaging members, and adjacent the first and second latching members 120 and 150 . This is best illustrated in FIGS. 12 and 14 . The caps 140 and 160 may have a smooth or textured surface, or a fastener driving configuration, such as a screw driver or alien wrench head.
The protrusions 117 and 118 extend out from the finger engaging members 114 and 116 , and are adapted to slidably receive the first and second latching members 120 and 150 . The threaded studs 142 and 162 extend out from the distal ends of protrusions 117 and 118 .
The first and second latching members 120 and 150 each have an elongated base 122 and 152 and a latch arm 124 and 154 extending out from each elongated base. The latch arms 124 and 154 feature a plurality of teeth 126 and 156 , which are adapted to join and lock together when engaged. The teeth 126 and 156 are able to disengage when pulled apart by the flexing of the first and second elongated members 112 and 113 when an opposing force is applied to the finger engaging members 114 and 116 .
The elongated base 122 and 152 of the first and second latching members 120 and 150 each have a channel 128 and 158 running the length of the elongated base. The channels 128 and 158 are adapted to slide on and be retained by the protrusions 117 and 118 extending out from the finger engaging members 114 and 116 and adjacent to the threaded studs 142 and 162 . The configuration of the channels 128 and 158 and the protrusions 117 and 118 allow the first and second latching members 120 and 150 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion. FIG. 13 best illustrate one possible channel and protrusion configuration.
The first and second latching members 120 and 150 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 110 . Furthermore, other configurations of the first and second latching members 120 and 150 may be used in place of the above described latching members.
Referring now to FIG. 15 , a fourth alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 200 . More particularly, the ambidextrous locking clamp system 200 has a first elongated member 202 and a second elongated member 204 each having a working head 205 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge. The second elongated member 204 is connected to the first elongate member 202 via a hinge. The first and second elongated members 202 and 204 each have a finger engaging member 206 and 208 located opposite of the working heads 205 . Additionally, a first latching member 220 is removably attachable to the finger engaging member 206 and a second latching member 240 is removably attachable to the finger engaging member 208 .
As illustrated in FIG. 16 , the first and second latching members 220 and 240 are illustrated in their assembled configuration. The first and second latching members 220 and 240 each have a base 222 and 242 and a latch arm 224 and 244 extending out from each base. The bases 222 and 242 each have an aperture 225 and 245 defined therethrough. A pair of threaded retaining pins 230 and 250 are insertable through a pair of threaded apertures 232 and 252 of the finger engaging members 206 and 208 , and through the apertures 225 and 245 of the bases 222 and 242 of the latching members 220 and 240 .
A more detailed illustration of the first latch member 220 and finger engaging member 206 assembly is shown in FIG. 17 , whereby the second latch member 240 and finger engaging member 208 assembly is a mirror image thereof and therefore not shown. The threaded retaining pins 230 and 237 have a threaded end 231 featuring a driving head or detent, and a non-threaded section 234 . The non-threaded section 234 is adapted to be received through a threaded aperture 232 and 252 of the finger engaging members 206 and 208 , and through the apertures 225 and 245 of the latching members 220 and 240 . The threaded end 231 engages the threaded apertures 232 and 252 to secure the retaining pins 230 and 250 in the finger engaging members 206 and 208 , thereby securing the latching members 220 and 240 in a notch 236 located in each of the finger engaging members. The latching members 220 and 240 are slidably insertable into notches 236 so that the bases 222 and 242 rest in the notches. The bases 222 and 242 of the latching members 220 and 240 have a pair of channels 228 running the length of the base parallel with the longitudinal axis of the latch arms 224 and 244 . As best illustrated in FIGS. 17 and 18 , the channels 228 are adapted to receive a set of protrusions 238 which extend into the notch 236 . The channel 228 and protrusion 238 connection is configured to retain the latching members 220 and 240 in the notch 236 and flush with the outer surface of the finger engaging members 206 and 208 . Additionally, the channel 228 and protrusion 238 connection prevents the latching members 220 and 240 from rotating out of alignment with the notch 236 . FIG. 18 best illustrate one possible channel and protrusion configuration.
The latch arms 224 and 244 feature a plurality of teeth 226 and 246 , which are adapted to join and lock together when engaged. The teeth 226 and 246 are able to disengage when pulled apart by the flexing of the first and second elongated members 202 and 204 when an opposing force is applied to the finger engaging members 206 and 208 . The first and second latching members 220 and 240 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 200 . Furthermore, other configurations of the first and second latching members 220 and 240 may be used in place of the above described latching members.
Referring now to FIG. 20 , a fifth alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 300 . More particularly, the ambidextrous locking clamp system 300 has a first elongated member 302 and a second elongated member 342 each having a working head 303 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge. The second elongated member 342 is connected to the first elongate member 302 via a hinge. The first and second elongated members 302 and 342 each have a removable finger engaging member 320 and 360 located opposite of the working heads 303 . Each removable finger engaging member 320 and 360 has a latching arm 326 and 346 extending out and towards each other. A first retaining cap 330 and second retaining cap 370 are threadably attachable to the first and second elongated members 302 and 342 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members. The retaining caps 330 and 370 can also be orientated in any alternate position to the first and second elongated members 302 and 342 . The first and second retaining caps 330 and 370 are adapted to secure the finger engaging members 320 and 360 to the first and second elongated members 302 and 342 .
The first and second elongated members 302 and 342 each have a finger engaging member receiving assembly 304 and 344 . The finger engaging member receiving assemblies 304 and 344 each have a protrusion 306 and 346 , and a retaining rod 308 and 348 . The retaining rods 308 and 348 include a stem 310 and 350 extending out therefrom, each with a threaded end 312 and 352 . The first and second retaining caps 330 and 370 have internally threaded bores 332 and 372 able to be threaded on to the treaded ends 312 and 352 of the stems 310 and 350 .
The finger engaging members 320 and 360 each have a bore 322 and 362 adapted to receive the protrusions 306 and 346 of the finger engaging member receiving assemblies 304 and 344 . The finger engaging members 320 and 360 also have an aperture 324 and 364 running parallel with the bores 322 and 344 , which correspond to the configuration of the stems 310 and 350 , and to the retaining rods 308 and 348 . The finger engaging members 320 and 360 are positioned on to the protrusions 306 and 346 , and to the retaining rods 308 and 348 , and are then secured to the finger engaging member receiving assemblies 304 and 344 by securing the retaining caps 330 and 370 on to the threaded ends 312 and 352 of stems 310 and 350 , as best illustrated in FIG. 23 .
The latching arms 326 and 366 each have a plurality of teeth 328 and 368 , which are adapted to join and lock together when engaged. The teeth 328 and 368 are able to disengage when pulled apart by the flexing of the first and second elongated members 302 and 342 when an opposing force is applied to the finger engaging members 320 and 360 . The first and second finger engaging members 320 and 360 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 300 . Furthermore, other configurations of the first and second finger engaging members 320 and 360 may be used in place of the above described latching members.
Referring now to FIG. 24 which illustrates an alternate embodiment 400 of the present invention shown in FIG. 1 . This alternate embodiment has a first elongated member 12 hingedly connected to a second elongated member 14 . Both the first and second elongated members 12 and 14 each have a working head 13 and a finger engaging member 17 and 18 located opposite of the working head (not shown). A first lever 30 and second lever 50 are pivotally attachable to the finger engaging members 17 and 18 , and are orientated-so that the levers are facing each other. Additionally, latching members 402 are removably attachable to the finger engaging members 17 and 18 . Each latching member 402 has a notch 408 for viewing an indicator located on the finger engaging members 17 and 18 . The first and second elongated members 12 and 14 can be made from any suitable material having reflex memory.
The levers 30 and 50 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 17 and. 18 . A pivot pin 32 extends from the finger engaging members 17 and 18 , and through levers 30 and 50 , allowing the levers to rotate. The levers 30 and 50 have an extension 31 for retaining the latching members 402 on the finger engaging members 17 and 18 when the levers are aligned with the longitudinal axis of the first and second elongated members 12 and 14 , as best illustrated in FIG. 25 . When the levers 30 and 50 are rotated to a position perpendicular to the first and second elongated members 12 and 14 , the extensions 31 are able to be moved out of engagement with the latching members 402 , thereby allowing the latching members to slide past the extensions 31 and be removed from finger engaging members 17 and 18 .
The latching members 402 each have an elongated base 404 and a latch arm 406 extending out from each elongated base. The latch arms 406 feature a plurality of teeth 410 , which are adapted to join and lock together when engaged. The teeth 410 are able to disengage when pulled apart by the flexing of the first and second elongated members 12 and 14 when an opposing force is applied to the finger engaging members 17 and 18 .
The elongated base 404 of the latching members 402 each have a channel 409 running the length of the elongated base. The channels 409 are adapted to slide on and be retained by protrusions 412 extending out from the finger engaging members 17 and 18 and adjacent to the levers 30 and 50 . The protrusions 412 each have an indicator 414 and 416 located on opposite sides of the protrusion. The indicators 414 and 416 have a marking or indicia thereon to indicate a right or left hand use. The marking or indicia can be, but not limited to, the letter “R” and “L”. The arrangement of indicators 414 and 416 are opposite for finger engaging members 17 and 18 , so that not similar indicators are facing the user. This allows the user to view, from either side, through the notch 408 what orientation the ambidextrous locking clamp 400 is set for, as best shown in FIG. 24 which illustrates a right and left handed orientation.
The notch 408 is located on the elongated base 404 on the same side as the teeth 410 . The notch 408 extends into the channel 409 . When the latching members 402 are positioned on the protrusions 412 , the notch 408 is located over either the indicator 414 or 416 , depending on what orientation the latching members are set at for use either by a left or right handed user. The configuration of the channel 409 and the protrusions 412 allow the latching members 402 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion. FIGS. 25 and 26 best illustrate one possible example of the channel, notch, indicator, and protrusion configuration. The latching members 402 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 400 .
Referring now to FIG. 27 which illustrates an alternate embodiment 450 of the second embodiment of the present invention shown in FIG. 6 . This alternate embodiment has a first elongated member 62 hingedly connected to a second elongated member 64 . Both the first and second elongated members 62 and 64 each have a working head (not shown) and a finger engaging member 65 and 66 located opposite of the working head 63 . A first lever 80 and second lever 100 are pivotally attachable to the finger engaging members 65 and 68 , and are orientated so that the levers are facing each other. Additionally, latching members 452 are removably attachable to the finger engaging members 65 and 66 . Each latching member 452 has a notch 458 for viewing an indicator located on the finger engaging members 65 and 66 . The first and second elongated members 62 and 64 can be made from any suitable material having reflex memory.
The levers 80 and 100 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 65 and 66 . A pivot pin 67 extends from the finger engaging members 65 and 66 , and through levers 80 and 100 , allowing the levers to rotate. The levers 80 and 100 have an extension 82 and 102 for retaining the first and second latching members 452 on the finger engaging members 65 and 66 when the levers are aligned with the longitudinal axis of the first and second elongated members 62 and 64 . A notch 84 and 104 is defined in the levers 80 and 100 for allowing the latching members 452 to pass therethrough. When the levers 80 and 100 are rotated so they are perpendicular to the first and second elongated members 62 and 64 , the extensions 82 and 102 are moved out of engagement with the latching members 452 , and the notches 84 and 104 are exposed to the latching members, thereby allowing the latching members to slide through the notches and be removed from finger engaging members 65 and 66 . This is best illustrated in FIG. 28 .
The latching members 452 each have an elongated base 454 and a latch arm 456 extending out from each elongated base. The latch arms 452 feature a plurality of teeth 462 , which are adapted to join and lock together when engaged. The teeth 462 are able to disengage when pulled apart by the flexing of the first and second elongated members 62 and 64 when an opposing force is applied to the finger engaging members 65 and 66 .
The elongated base 454 of the latching members 452 each have a channel 460 running the length of the elongated base. The channels 460 are adapted to slide on and be retained by protrusions 464 extending out from the finger engaging members 65 and 66 and adjacent to the levers 80 and 100 . The protrusions 464 each have an indicator 468 and 466 located on opposite sides of the protrusion. The indicators 468 and 466 have a marking or indicia thereon to indicate a right or left hand use. The marking or indicia can be, but not limited to, the letter “R” and “L”. The arrangement of indicators 468 and 466 are opposite for finger engaging members 65 and 66 , so that not similar indicators are facing the user. This allows the user to view, from either side, through the notch 458 what orientation the ambidextrous locking clamp 450 is set for, as best shown in FIG. 27 which illustrates a right and left handed orientation.
The notch 458 is located on the elongated base 454 on the same side as the teeth 462 . The notch 458 extends into the channel 460 . When the latching members 452 are positioned on the protrusions 464 , the notch 458 is located over either the indicator 468 or 466 , depending on what orientation the latching members are set at for use either by a left or right handed user. The configuration of the channel 460 and the protrusions 464 allow the latching members 452 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion. The latching members 452 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 450 . FIGS. 28 and 29 best illustrate one possible example of the channel, notch, indicator, and protrusion configuration.
Referring now to FIG. 30 which illustrates an alternate embodiment 500 of the third embodiment of the present invention shown in FIG. 11 . This alternate embodiment has a first elongated member 112 hingedly connected to a second elongated member 113 . Both the first and second elongated members 112 and 113 each have a working head (not shown) and a finger engaging member 114 and 116 located opposite of the working head. Retaining caps 140 are threadably attachable to the finger engaging members 114 and 116 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members 112 and 113 . Additionally, latching members 502 are removably attachable to the finger engaging members 114 and 116 . Each latching member 502 has a notch 508 for viewing an indicator located on the finger engaging members 114 and 116 . The first and second elongated members 112 and 113 can be made from any suitable material having reflex memory.
The retaining caps 140 have an internal threaded bore 141 . The caps 140 are adapted to secure the first latching members 502 to the finger engaging members 114 and 116 . The caps 140 are removably attachable to the finger engaging members 114 and 116 by screwing the caps onto a threaded stud 514 which extends out from a protrusion 516 of the finger engaging members 114 and 116 , and adjacent the latching members 502 . This is best illustrated in FIGS. 31 . The caps 140 may have a smooth or textured surface, or a fastener driving configuration, such as a screw driver or allen wrench head.
The elongated base 504 of the latching members 502 each have a channel 512 running the length of the elongated base. The channels 512 are adapted to slide on and be retained by the protrusions 516 extending out from the finger engaging members 114 and 116 and adjacent to the threaded studs 514 . The configuration of the channels 512 and the protrusions 516 allow the latching members 502 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.
The protrusions 516 extend out from the finger engaging members 114 and 116 , and are adapted to slidably receive the latching members 502 . The threaded studs 514 extend out from the distal ends of protrusions 516 . The protrusions 516 each have an indicator 518 and 520 located on opposite sides of the protrusion. The indicators 518 and 520 have a marking or indicia thereon to indicate a right or left hand use. The marking or indicia can be, but not limited to, the letter “R” and “L”. The arrangement of indicators 518 and 520 are opposite for finger engaging members 114 and 116 , so that not similar indicators are facing the user. This allows the user to view, from either side, through the notch 508 what orientation the ambidextrous locking clamp 500 is set for, as best shown in FIG. 31 which illustrates a right and left handed orientation.
The latching members 502 each have an elongated base 504 and a latch arm 506 extending out from each elongated base. The latch arms 506 feature a plurality of teeth 510 , which are adapted to join and lock together when engaged. The teeth 510 are able to disengage when pulled apart by the flexing of the first and second elongated members 112 and 113 when an opposing force is applied to the finger engaging members 114 and 116 . The latching members 502 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 500 .
The notch 508 is located on the elongated base 504 on the same side as the teeth 510 . The notch 508 extends into the channel 512 . When the latching members 502 are positioned on the protrusions 516 , the notch 508 is located over either the indicator 518 or 520 , depending on what orientation the latching members are set at for use either by a left or right handed user. FIGS. 31 and 32 best illustrate one possible example of the channel, notch, indicator, and protrusion configuration.
Referring now to FIG. 33 which illustrates an alternate embodiment 550 of the fourth embodiment of the present invention shown in FIG. 15 . This alternate embodiment has a first elongated member 202 hingedly connected to a second elongated member 204 . Both the first and second elongated members 202 and 204 each have a working head (not shown) and a finger engaging member 206 and 208 located opposite of the working head. Additionally, latching members 552 are removably attachable to the finger engaging members 206 and 208 . Each latching member 552 has a notch 558 for viewing an indicator located on the finger engaging members 206 and 208 . The first and second elongated members 202 and 204 can be made from any suitable material having reflex memory.
The latching members 552 each have a base 554 and a latch arm 556 extending out from the base. The base 554 each have an aperture 562 defined therethrough. Threaded retaining pins 230 are insertable through threaded apertures 569 of the finger engaging members 206 and 208 , and through the apertures 562 of the bases 554 of the latching members 552 , as best illustrated in FIG. 34 .
The threaded retaining pins 230 have a threaded section 231 featuring a driving head or detent, and a non-threaded section 234 . The non-threaded sections 234 are adapted to be received through the threaded apertures 569 of the finger engaging members 206 and 208 , and through the apertures 562 of the latching members 552 . The threaded ends 231 engage the threaded apertures 569 to secure the retaining pins 230 in the finger engaging members 206 and 208 , thereby securing the latching members 552 in notches 564 located in each of the finger engaging members. The latching members 552 are slidably insertable into notches 564 so that the base 554 rest in the notches and receives therein indicator ledges 568 located in the notches 564 . The base 554 of the latching members 552 have a pair of channels 570 running the length of the base parallel with the longitudinal axis of the latch arms 552 . As best illustrated in FIGS. 34 , the channels 570 are adapted to receive a set of protrusions 566 which extend into the notches 564 . The channel 570 and protrusion 566 connections are configured to retain the latching members 552 in the notches 564 and flush with the outer surface of the finger engaging members 206 and 208 . Additionally, the channel 570 and protrusion 566 connections prevent the latching members 552 from rotating out of alignment with the notches 564 .
The indicator ledges 568 have a marking or indicia thereon to indicate a right and left hand use. The markings or indicia can be, but not limited to, the letter “R” and “L”. The markings are located at either end of the indicator ledge 568 and on both sides of the indicator ledge so that both sides are mirror images. The indicator ledges 568 are mirrored for finger engaging members 206 and 208 , so that similar indicator ledges are facing the user. This allows the user to view, from either side, through the notches 558 what orientation the ambidextrous locking clamp 550 is set for, as best shown in FIG. 33 which illustrates a right and left handed orientation.
The notch 558 is located on one corner and on both sides of the base 554 . The notch 558 extends through one channel 570 of the base 554 . When the latching members 552 are positioned in the notches 564 , the notches 558 are located over the indicator ledges 568 thereby exposing one of the markings on that side. The marking that is exposed depends on what orientation the latching members 552 are set at, for use either by a left or right handed user. The configuration of the channels 570 , the protrusions 566 , retaining pins 230 , and the indicator ledges 568 allow the latching members 552 to slide into the notches 564 of the finger engaging members 206 and 208 , but at the same time not allowing the latching members to be pulled out of the notches 564 in a direction perpendicular to the sliding motion. The latching members 552 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 550 . FIGS. 34 and 35 best illustrate one possible example of the channel, retaining pin, notches, and indicator ledge configuration.
The latch arms 556 feature a plurality of teeth 560 , which are adapted to join and lock together when engaged. The teeth 560 are able to disengage when pulled apart by the flexing of the first and second elongated members 202 and 204 when an opposing force is applied to the finger engaging members 206 and 208 . The latching members 552 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 550 . Furthermore, other configurations of the first and second latching members 552 may be used in place of the above described latching members.
Referring now to FIG. 36 which illustrates an alternate embodiment 600 of the fifth embodiment of the present invention shown in FIG. 20 . This alternate embodiment has a first elongated member 302 hingedly connected to a second elongated member 342 . Both the first and second elongated members 302 and 342 each have a working head (not shown) and a finger engaging member 602 located opposite of the working head. The first and second elongated members 302 and 342 each has a removable finger engaging member 602 located opposite of the working heads. Each removable finger engaging member 602 has a latching arm 604 extending out and towards each other. Retaining caps 330 are threadably attachable to the first and second elongated members 302 and 342 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members. The retaining caps 330 can also be orientated in any alternate position to the first and second elongated members 302 and 342 . The first and second retaining caps 330 are adapted to secure the finger engaging members 602 to the first and second elongated members 302 and 342 . The first and second elongated members 302 and 342 can be made from any suitable material having reflex memory.
The first and second elongated members 302 and 342 each have a finger engaging member receiving assembly 304 and 344 . The finger engaging member receiving assemblies 304 and 344 each have a protrusion 306 , and a retaining rod 308 and 348 . The retaining rods 308 and 348 include a stem 614 extending out therefrom, each with a threaded end 620 . The stems 614 have indicators 616 and 618 located on both sides of the stem. The indicators 616 and 618 have a marking or indicia thereon to indicate a right or left hand use. The marking or indicia can be, but not limited to, the letter “R” and “L”. The indicators 616 and 618 are located between the threaded end 620 and the retaining rods 304 and 308 , so that similar indicators are facing the user. The indicators 616 and 618 are mirrored on both sides of the stem 614 . This allows the user to view, from either side, through the notches 608 what orientation the ambidextrous locking clamp 500 is set for, as best shown in FIG. 36 which illustrates a right and left handed orientation. The retaining caps 330 have internally threaded bores 332 able to be threaded on to the treaded ends 620 of the stems 614 . This is best illustrated in FIG. 37 .
The finger engaging members 602 each have a bore 606 adapted to receive the protrusions 306 of the finger engaging member receiving assemblies 304 and 344 , and a notch 608 for viewing an indicator located on the stem 614 . The finger engaging members 602 also have an aperture 612 running parallel with the bores 606 , which correspond to the configuration of the stems 614 , and to the retaining rods 308 and 348 . The finger engaging members 602 are positioned on to the protrusions 306 and 346 , and to the stems 614 , and are then secured to the finger engaging member receiving assemblies 304 and 344 by securing the retaining caps 330 on to the threaded ends 620 of stems 614 , as best illustrated in FIG. 37 .
The latching arms 604 each have a plurality of teeth 610 , which are adapted to join and lock together when engaged. The teeth 610 are able to disengage when pulled apart by the flexing of the first and second elongated members 302 and 342 when an opposing force is applied to the finger engaging members 602 . The finger engaging members 602 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 600 . Furthermore, other configurations of the first and second finger engaging members 602 may be used in place of the above described latching members.
The notches 608 are located on both sides of the finger engaging members 602 , adjacent the latching arms 604 . The notches 608 extend through the aperture 612 . When the finger engaging members 602 are positioned on the stems 614 , the notches 608 are located over either the indicators 616 or 618 , depending on what orientation the finger engaging members are set at for use either by a left or right handed user. The configuration of the bores 606 , the protrusions 306 , apertures 612 , and stems 614 allow the finger engaging members 602 to slide against the finger engaging member receiving assemblies 304 , but at the same time not allowing the finger engaging members 602 to be pulled out in a direction perpendicular to the sliding motion. FIGS. 37 and 38 best illustrate one possible example of the channel, retaining pin, notches, and indicator ledge configuration.
In use, it can now be understood that either a right hand or left hand user can use the ambidextrous locking clamp system while having the ability to view through the use of indicators what the orientation the clamp is configured for, either right or left handed use. The user would remove and reverse the orientation of the removable latching member or the removable finger engaging member which features a latching arm. By doing this, the user can change the operational configuration of the ambidextrous locking device. The ambidextrous locking clamp system can use a variety of retaining means, such as, but not limited to, a rotating lever, a threaded cap, or a retaining pin. All of these retaining means can be used to secure the removable latching member or the removable finger engaging member from the elongated members.
While a preferred embodiment of the ambidextrous locking clamp system has been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. For example, any suitable sturdy material may be used for the manufacture of the ambidextrous locking clamp system. And although manipulating objects with a tool having removable latching members have been described, it should be appreciated that the ambidextrous locking clamp system herein described is also suitable for all types of hand operated locking tools having a at least two hingedly connected arms.
Therefore, 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, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An ambidextrous locking clamp system for providing a user the ability to alter the configuration of a hand operated device allowing a right or left handed user to operate the device. The device has a hingedly connected first and second elongated member each with a finger engaging member, a working head, and an indicator for identifying if the clamp is setup for left or right handed operation. At least two inter-engaging latching members are removably attachable to the first and the second elongated members. The latching members are symmetrical, interchangeable, and reversible, allowing a user to change the configuration of the ambidextrous device. The latching members can be retained to the elongated members by a rotatably lever, a removable retaining cap, or a removable retaining pin. Additionally, the latching members can be incorporated into removable finger engaging members, thereby allowing the entire finger engaging member and latching member to be removed, interchanged or reversed. | Summarize the patent document, focusing on the invention's functionality and advantages. | [
"CROSS REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of U.S. patent application Ser.",
"No. 10/909,623, filed Aug. 2, 2004.",
"All prior applications are hereby incorporated by reference in their entireties.",
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention The present invention relates to an ambidextrous locking clamp system for use in connection with clamping instruments, such as surgical clamps, forceps, or hemostats.",
"The ambidextrous locking clamp system has particular utility in connection with manipulating objects with a tool having removable and interchangeable locking assemblies.",
"Description of the Prior Art Ambidextrous locking clamps, forceps or hemostats are desirable for allowing a right or left-handed user to use a single hand operated clamp, forceps or hemostat device.",
"These hand operated devices have been manufactured in the past for either a right hand or left hand user.",
"This manufacturing process has some disadvantages in that the manufacturer would have to make a decision to how many right handed and left handed devices to fabricate.",
"In most cases the decision is made to manufacture more right-handed devices than left handed devices.",
"Therefore, it is well known that it is very difficult for a left-handed user to operate a right-handed device.",
"Hand operated locking clamps, forceps, and hemostats are well known.",
"These devices include a pair of elongated members joined by a hinge.",
"The hinge is usually a hinge pin extending through both elongated members.",
"One end of the elongated members features a working head, usually a griping jaw or cutting edges.",
"The other end of the elongated members feature a finger engaging loop, with a set of ratchet teeth extending out therefrom towards the ratchet teeth of the finger loop of the second elongated member.",
"The ratchet teeth are orientated so that they engage each other when the finger loop ends are brought together.",
"These devices are mainly used in the medical industry for a wide variety of uses, but they are also used in the fly fishing, model building, and electrical industries.",
"During operation of a standard right handed hand operated device, the user inserts his or her thumb into one loop, the middle finger in the opposite loop, and the index finger would rest on the top of the middle finger loop for support and control of the device.",
"To engage the working head the user squeezes the thumb and middle finger together guided by the index finger.",
"The device is locked in the close position by further squeezing the loops together until the ratchet teeth members engage each other.",
"To release, the thumb pushes away from the palm of the hand and the middle finger pulls toward the palm of the hand.",
"This motion makes the ratchet teeth members flex away from each other and disengage.",
"The difficulty lies when a left-handed user tries to operate a right-handed device.",
"It is difficult for a left-handed user to pull with the thumb and push with the middle finger.",
"This is not a natural hand motion.",
"The use of locking clamps is known in the prior art.",
"For example, U.S. Pat. No. 6,397,478 to Jose Carlos Mario Bornancini;",
"U.S. Pat. No. 3,978,584 to John Mayer;",
"U.S. Pat. No. 3,913,586 to Baumgarten;",
"U.S. Pat. No. 6,223,440 to Rashman;",
"United States Patent Application Publication 2004/0106947 to Propp et al.",
"U.S. Pat. No. 5,626,608 Cuny et al.",
"and U.S. Pat. No. 5,176,702 to Bales et al.",
"While the above-described devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not describe an ambidextrous hand operated device that allows the use of the device by a right or left handed user through the interchanging of components.",
"Therefore, a need exists for a new and improved ambidextrous locking clamp system that can be used for manipulating objects with a tool having removable and interchangeable components.",
"In this regard, the present invention substantially fulfills this need.",
"In this respect, the ambidextrous locking clamp system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of manipulating objects with a tool having removable and interchangeable locking assemblies.",
"SUMMARY OF THE INVENTION In view of the foregoing disadvantages inherent in the known types of hand operated locking devices now present in the prior art, the present invention provides an improved ambidextrous locking clamp system, and overcomes the above-mentioned disadvantages and drawbacks of the prior art.",
"As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved ambidextrous locking clamp system and method which has all the advantages of the prior art mentioned heretofore and many novel features that result in a ambidextrous locking clamp system which is not anticipated, rendered obvious, suggested, or even implied by the prior art, either alone or in any combination thereof.",
"To attain this, the present invention essentially comprises an ambidextrous locking clamp system for providing a user the ability to alter the configuration of a hand operated device allowing a right hand or left hand user to operate the device, wherein the ambidextrous locking clamp system has a first elongated member including a working head and a finger engaging member including an indicator for identifying a first side, a second elongated member including a working head and a finger engaging member including an indicator for identifying a second side, wherein the second elongated member is hingedly connected to the first elongated member, and at least two latching members having notches for viewing the indicators, wherein the latching members are removably attachable to the first and second elongated members.",
"Additionally, the present invention may comprise an ambidextrous locking clamp system having a first elongated member including a finger engaging member receiving assembly and a working head opposite of the finger engaging member receiving assembly, a second elongated member including a finger engaging member receiving assembly and a working head opposite of the finger engaging member receiving assembly, at least two finger engaging members removably attachable to the finger engaging member receiving assemblies of the first and second elongated members, and at least two retaining caps for retaining the finger engaging members to the finger engaging member receiving assemblies.",
"The second elongated member is hingedly connected to the first elongated member.",
"Furthermore, the finger engaging member receiving assemblies have an indicator and the finger engaging members have a notch that is positionable over the indicator.",
"There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.",
"The invention may also include a variety of means to retain the latching members to the first and second elongated members, such as, but not limited to, rotating levers, removable retaining caps, and removable retaining pins.",
"There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.",
"Numerous embodiments, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings.",
"In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings.",
"The invention is capable of other embodiments and of being practiced and carried out in various ways.",
"Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.",
"As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention.",
"It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.",
"It is therefore an embodiment of the present invention to provide a new and improved ambidextrous locking clamp system that has all of the advantages of the prior art locking clamps and none of the disadvantages.",
"It is another embodiment of the present invention to provide a new and improved ambidextrous locking clamp system that may be easily and efficiently manufactured and marketed.",
"An even further embodiment of the present invention is to provide a new and improved ambidextrous locking clamp system that has a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such ambidextrous locking clamp system economically available to the buying public.",
"Still another embodiment of the present invention is to provide a new ambidextrous locking clamp system that provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.",
"Lastly another embodiment of the present invention is to provide an ambidextrous locking clamp system for manipulating objects with a tool having removable and interchangeable locking assemblies.",
"This allows the use of the hand operated device by either a right or left handed user.",
"These together with other embodiments of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure.",
"For a better understanding of the invention, its operating advantages and the specific embodiments attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.",
"BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof.",
"Such description makes reference to the annexed drawings wherein: FIG. 1 is a front elevational view of the ambidextrous locking clamp system constructed in accordance with the principles of the present invention.",
"FIG. 2 is an enlarged cross-sectional view of the ambidextrous locking clamp system of the present invention.",
"FIG. 3 is an exploded side plane view of the ambidextrous locking clamp system of the present invention.",
"FIG. 4 is a cross-sectional view the locking assembly of the ambidextrous locking clamp system of the present invention.",
"FIG. 5 is an exploded cross-sectional view of the locking assembly of the ambidextrous locking clamp system of the present invention.",
"FIG. 6 is a front elevational view of a second alternate embodiment of the ambidextrous locking clamp system of the present invention.",
"FIG. 7 is an enlarged cross-sectional view of the second alternate embodiment of the present invention.",
"FIG. 8 is an exploded side plane view of the second alternate embodiment of the second alternate embodiment of the present invention.",
"FIG. 9 is a cross-sectional view of the locking assembly of the second alternate embodiment of the present invention.",
"FIG. 10 is an exploded cross-sectional view of the locking assembly of the second alternate embodiment of the present invention.",
"FIG. 11 is a front elevational view of a third alternate embodiment of the ambidextrous locking clamp system of the present invention.",
"FIG. 12 is an enlarged cross-sectional view of the third alternate embodiment of the present invention.",
"FIG. 13 is a cross-sectional view of the locking assembly of the third alternate embodiment of the present invention.",
"FIG. 14 is an exploded front elevational view of the third alternate embodiment of the present invention.",
"FIG. 15 is a front elevational view of a fourth alternate embodiment of the ambidextrous locking clamp system of the present invention.",
"FIG. 16 is an enlarged cross-sectional view of the fourth alternate embodiment of the present invention.",
"FIG. 17 is an exploded cross-sectional view of the fourth alternate embodiment of the present invention.",
"FIG. 18 is a cross-sectional view of the locking assembly of the fourth alternate embodiment of the present invention.",
"FIG. 19 is a cross-sectional view of the locking assembly of the fourth alternate embodiment of the present invention.",
"FIG. 20 is a front elevational view of a fifth alternate embodiment of the ambidextrous locking clamp system of the present invention.",
"FIG. 21 is an enlarged cross-sectional view of the fifth alternate embodiment of the present invention.",
"FIG. 22 is a cross-sectional view of the locking assembly of the fifth alternate embodiment of the ambidextrous locking clamp system of the present invention.",
"FIG. 23 is an exploded cross-sectional view of the fifth alternate embodiment of the present invention.",
"FIG. 24 is a front elevational view of an alternate embodiment of the ambidextrous locking clamp system of FIG. 1 .",
"FIG. 25 is an exploded side elevational view of the locking assembly of the alternate embodiment of the present invention.",
"FIG. 26 is a cross-sectional view taken along the line 26 - 26 in FIG. 24 of the alternate embodiment of the present invention.",
"FIG. 27 is a front elevational view of an alternate embodiment of the second embodiment of the ambidextrous locking clamp system of FIG. 6 .",
"FIG. 28 is an exploded side elevational view of the alternate embodiment of the second embodiment of the present invention.",
"FIG. 29 is a cross-sectional view taken along the line 29 - 29 in FIG. 27 of the alternate embodiment of the second embodiment of the present invention.",
"FIG. 30 is a front elevational view of an alternate embodiment of the third embodiment of the ambidextrous locking clamp system of FIG. 11 .",
"FIG. 31 is an exploded side elevational view of the alternate embodiment of the third embodiment of the present invention.",
"FIG. 32 is a cross-sectional view taken along the line 32 - 32 in FIG. 30 of the alternate embodiment of the third embodiment of the present invention.",
"FIG. 33 is a front elevational view of an alternate embodiment of the fourth embodiment of the ambidextrous locking clamp system of FIG. 15 .",
"FIG. 34 is an exploded front elevational view of the alternate embodiment of the fourth embodiment of the present invention.",
"FIG. 35 is a cross-sectional view taken along the line 35 - 35 in FIG. 33 of the alternate embodiment of the fourth embodiment of the present invention.",
"FIG. 36 is a front elevational view of an alternate embodiment of the fifth embodiment of the ambidextrous locking clamp system of FIG. 20 .",
"FIG. 37 is an exploded front elevational view of the alternate embodiment of the fifth embodiment of the present invention.",
"FIG. 38 is a cross-sectional view taken along the line 38 - 38 in FIG. 36 of the alternate embodiment of the fifth embodiment of the present invention.",
"The same reference numerals refer to the same parts throughout the various figures.",
"DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings, and particularly to FIGS. 1-38 , a first embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 10 .",
"In FIG. 1 , a new and improved ambidextrous locking clamp system 10 of the present invention for allowing the use of a hand operated device by a right or left handed user is illustrated and will be described.",
"More particularly, the ambidextrous locking clamp system 10 has a first elongated member 12 and a second elongated member 14 each having a working head 13 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge.",
"The second elongated member 14 is connected to the first elongated member 12 via a hinge 15 .",
"The first and second elongated members 12 and 14 each have a finger engaging member 17 and 18 located opposite of the working heads 13 .",
"A first lever 30 and second lever 50 are pivotally attachable to the finger engaging members 17 and 18 , and are orientated so that the levers are facing each other.",
"Additionally, a first latching member 20 is removably attachable to the finger engaging member 17 and a second latching member 40 is removably attachable to the finger engaging member 18 .",
"The first and second elongated members 12 and 14 can be made from any suitable material having reflex memory.",
"The levers 30 and 50 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 17 and 18 .",
"A pivot pin 32 and 52 extend from the finger engaging members 17 and 18 , and through levers 30 and 50 , allowing the levers to rotate.",
"The levers 30 and 50 have an extension 31 and 51 for retaining the first and second latching members 20 and 40 on the finger engaging members 17 and 18 when the levers are aligned with the longitudinal axis of the first and second elongated members 12 and 14 .",
"When the levers 30 and 50 are rotated to a position perpendicular to the first and second elongated members 12 and 14 , the extensions 31 and 51 are able to be moved out of engagement with the first and second latching members 20 and 40 , thereby allowing the first and second locking members to slide past the extensions 31 and be removed from finger engaging members 17 and 18 .",
"This is best illustrated in FIGS. 2 and 3 .",
"The first and second latching members 20 and 40 each have an elongated base 22 and 42 and a latch arm 24 and 44 extending out from each elongated base.",
"The latch arms 24 and 44 feature a plurality of teeth 26 and 46 , which are adapted to join and lock together when engaged.",
"The teeth 26 and 46 are able to disengage when pulled apart by the flexing of the first and second elongated members 12 and 14 when an opposing force is applied to the finger engaging members 17 and 18 .",
"The elongated base 22 and 42 of the first and second latching members 20 and 40 each have a channel 28 and 48 running the length of the elongated base.",
"The channels 28 and 48 are adapted to slide on and be retained by a protrusion 21 and 41 extending out from the finger engaging members 17 and 18 and adjacent to the levers 30 and 50 .",
"The configuration of the channels 28 and 48 and the protrusions 21 and 41 allow the first and second latching members 20 and 40 to slide over the protrusion, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.",
"FIGS. 4 and 5 best illustrate one possible example of the channel and protrusion configuration.",
"The first and second latching members 20 and 40 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 10 .",
"Furthermore, other configurations of the first and second latching members 20 and 40 maybe used in place of the above described latching members.",
"Referring now to FIG. 6 , a second alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 60 .",
"More particularly, the ambidextrous locking clamp system 60 has a first elongated member 62 and a second elongated member 64 each having a working head 63 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge.",
"The second elongated member 64 is connected to the first elongate member 62 via a hinge.",
"The first and second elongated members 62 and 64 have a finger engaging member 65 and 66 located opposite of the working heads 63 .",
"A first lever 80 and second lever 100 are pivotally attachable to the finger engaging members 65 and 66 , and are orientated so that the levers are facing each other.",
"Additionally, a first latching member 70 is removably attachable to the finger engaging member 65 and a second latching member 90 is removably attachable to the finger engaging member 66 .",
"The levers 80 and 100 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 65 and 66 .",
"A pivot pin 67 and 68 extend from the finger engaging members 65 and 66 , and through levers 80 and 100 , allowing the levers to rotate.",
"The levers 80 and 100 have an extension 82 and 102 for retaining the first and second latching members 70 and 90 on the finger engaging members 65 and 66 when the levers are aligned with the longitudinal axis of the first and second elongated members 62 and 64 .",
"A notch 84 and 104 is defined in the levers 80 and 100 for allowing the first and second latching members 70 and 90 to pass therethrough.",
"When the levers 80 and 100 are rotated so they are perpendicular to the first and second elongated members 62 and 64 , the extensions 82 and 102 are moved out of engagement with the first and second latching members 70 and 90 , and the notches 84 and 104 are exposed to the first and second latching members, thereby allowing the first and second locking members to slide through the notches and removed from finger engaging members 65 and 66 .",
"This is best illustrated in FIGS. 7 and 8 .",
"The first and second latching members 70 and 90 each have an elongated base 72 and 92 and a latch arm 74 and 94 extending out from each elongated base.",
"The latch arms 74 and 94 feature a plurality of teeth 76 and 96 , which are adapted to join and lock together when engaged.",
"The teeth 76 and 96 are able to disengage when pulled apart by the flexing of the first and second elongated members 62 and 64 when an opposing force is applied to the finger engaging members 65 and 66 .",
"The elongated base 72 and 92 of the first and second latching members 70 and 90 each have a channel 78 and 98 running the length of the elongated base.",
"The channels 78 and 98 are adapted to slide and be retained by a protrusion 71 and 91 extending out from the finger engaging members 65 and 66 and adjacent to the levers 80 and 100 .",
"The configuration of the channels 78 and 98 and the protrusions 71 and 91 allow the first and second latching members 70 and 90 to slide over the protrusion, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.",
"FIGS. 9 and 10 best illustrate one possible example of the channel and protrusion configuration.",
"The first and second latching members 70 and 90 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 60 .",
"Furthermore, other configurations of the first and second latching members 70 and 90 may be used in place of the above described latching members.",
"Referring now to FIG. 11 , a third alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 110 .",
"More particularly, the ambidextrous locking clamp system 110 has a first elongated member 112 and a second elongated member 113 each having a working head 115 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge.",
"The second elongated member 113 is connected to the first elongate member 112 via a hinge.",
"The first and second elongated members 112 and 113 have a finger engaging member 114 and 116 located opposite of the working heads 115 .",
"A first retaining cap 140 and second retaining cap 160 are threadably attachable to the finger engaging members 114 and 116 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members 112 and 113 .",
"The retaining caps 160 can also be orientated in any alternate position to the first and second elongated members 112 and 113 .",
"Additionally, a first latching member 120 is removably attachable to the finger engaging member 114 and a second latching member 150 is removably attachable to the finger engaging member 116 .",
"The retaining caps 140 and 160 have an internal threaded bore 141 and 161 .",
"The caps 140 and 160 are adapted to secure the first and second latching members 120 and 150 to the finger engaging members 114 and 116 .",
"The caps 140 and 160 are removably attachable to the finger engaging members 114 and 116 by screwing the caps onto a threaded stud 142 and 162 which extends out from a protrusion 117 and 118 of the finger engaging members, and adjacent the first and second latching members 120 and 150 .",
"This is best illustrated in FIGS. 12 and 14 .",
"The caps 140 and 160 may have a smooth or textured surface, or a fastener driving configuration, such as a screw driver or alien wrench head.",
"The protrusions 117 and 118 extend out from the finger engaging members 114 and 116 , and are adapted to slidably receive the first and second latching members 120 and 150 .",
"The threaded studs 142 and 162 extend out from the distal ends of protrusions 117 and 118 .",
"The first and second latching members 120 and 150 each have an elongated base 122 and 152 and a latch arm 124 and 154 extending out from each elongated base.",
"The latch arms 124 and 154 feature a plurality of teeth 126 and 156 , which are adapted to join and lock together when engaged.",
"The teeth 126 and 156 are able to disengage when pulled apart by the flexing of the first and second elongated members 112 and 113 when an opposing force is applied to the finger engaging members 114 and 116 .",
"The elongated base 122 and 152 of the first and second latching members 120 and 150 each have a channel 128 and 158 running the length of the elongated base.",
"The channels 128 and 158 are adapted to slide on and be retained by the protrusions 117 and 118 extending out from the finger engaging members 114 and 116 and adjacent to the threaded studs 142 and 162 .",
"The configuration of the channels 128 and 158 and the protrusions 117 and 118 allow the first and second latching members 120 and 150 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.",
"FIG. 13 best illustrate one possible channel and protrusion configuration.",
"The first and second latching members 120 and 150 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 110 .",
"Furthermore, other configurations of the first and second latching members 120 and 150 may be used in place of the above described latching members.",
"Referring now to FIG. 15 , a fourth alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 200 .",
"More particularly, the ambidextrous locking clamp system 200 has a first elongated member 202 and a second elongated member 204 each having a working head 205 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge.",
"The second elongated member 204 is connected to the first elongate member 202 via a hinge.",
"The first and second elongated members 202 and 204 each have a finger engaging member 206 and 208 located opposite of the working heads 205 .",
"Additionally, a first latching member 220 is removably attachable to the finger engaging member 206 and a second latching member 240 is removably attachable to the finger engaging member 208 .",
"As illustrated in FIG. 16 , the first and second latching members 220 and 240 are illustrated in their assembled configuration.",
"The first and second latching members 220 and 240 each have a base 222 and 242 and a latch arm 224 and 244 extending out from each base.",
"The bases 222 and 242 each have an aperture 225 and 245 defined therethrough.",
"A pair of threaded retaining pins 230 and 250 are insertable through a pair of threaded apertures 232 and 252 of the finger engaging members 206 and 208 , and through the apertures 225 and 245 of the bases 222 and 242 of the latching members 220 and 240 .",
"A more detailed illustration of the first latch member 220 and finger engaging member 206 assembly is shown in FIG. 17 , whereby the second latch member 240 and finger engaging member 208 assembly is a mirror image thereof and therefore not shown.",
"The threaded retaining pins 230 and 237 have a threaded end 231 featuring a driving head or detent, and a non-threaded section 234 .",
"The non-threaded section 234 is adapted to be received through a threaded aperture 232 and 252 of the finger engaging members 206 and 208 , and through the apertures 225 and 245 of the latching members 220 and 240 .",
"The threaded end 231 engages the threaded apertures 232 and 252 to secure the retaining pins 230 and 250 in the finger engaging members 206 and 208 , thereby securing the latching members 220 and 240 in a notch 236 located in each of the finger engaging members.",
"The latching members 220 and 240 are slidably insertable into notches 236 so that the bases 222 and 242 rest in the notches.",
"The bases 222 and 242 of the latching members 220 and 240 have a pair of channels 228 running the length of the base parallel with the longitudinal axis of the latch arms 224 and 244 .",
"As best illustrated in FIGS. 17 and 18 , the channels 228 are adapted to receive a set of protrusions 238 which extend into the notch 236 .",
"The channel 228 and protrusion 238 connection is configured to retain the latching members 220 and 240 in the notch 236 and flush with the outer surface of the finger engaging members 206 and 208 .",
"Additionally, the channel 228 and protrusion 238 connection prevents the latching members 220 and 240 from rotating out of alignment with the notch 236 .",
"FIG. 18 best illustrate one possible channel and protrusion configuration.",
"The latch arms 224 and 244 feature a plurality of teeth 226 and 246 , which are adapted to join and lock together when engaged.",
"The teeth 226 and 246 are able to disengage when pulled apart by the flexing of the first and second elongated members 202 and 204 when an opposing force is applied to the finger engaging members 206 and 208 .",
"The first and second latching members 220 and 240 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 200 .",
"Furthermore, other configurations of the first and second latching members 220 and 240 may be used in place of the above described latching members.",
"Referring now to FIG. 20 , a fifth alternate embodiment of the ambidextrous locking clamp system of the present invention is shown and generally designated by the reference numeral 300 .",
"More particularly, the ambidextrous locking clamp system 300 has a first elongated member 302 and a second elongated member 342 each having a working head 303 , wherein the working heads can be, but not limited to, a gripping jaw or a cutting edge.",
"The second elongated member 342 is connected to the first elongate member 302 via a hinge.",
"The first and second elongated members 302 and 342 each have a removable finger engaging member 320 and 360 located opposite of the working heads 303 .",
"Each removable finger engaging member 320 and 360 has a latching arm 326 and 346 extending out and towards each other.",
"A first retaining cap 330 and second retaining cap 370 are threadably attachable to the first and second elongated members 302 and 342 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members.",
"The retaining caps 330 and 370 can also be orientated in any alternate position to the first and second elongated members 302 and 342 .",
"The first and second retaining caps 330 and 370 are adapted to secure the finger engaging members 320 and 360 to the first and second elongated members 302 and 342 .",
"The first and second elongated members 302 and 342 each have a finger engaging member receiving assembly 304 and 344 .",
"The finger engaging member receiving assemblies 304 and 344 each have a protrusion 306 and 346 , and a retaining rod 308 and 348 .",
"The retaining rods 308 and 348 include a stem 310 and 350 extending out therefrom, each with a threaded end 312 and 352 .",
"The first and second retaining caps 330 and 370 have internally threaded bores 332 and 372 able to be threaded on to the treaded ends 312 and 352 of the stems 310 and 350 .",
"The finger engaging members 320 and 360 each have a bore 322 and 362 adapted to receive the protrusions 306 and 346 of the finger engaging member receiving assemblies 304 and 344 .",
"The finger engaging members 320 and 360 also have an aperture 324 and 364 running parallel with the bores 322 and 344 , which correspond to the configuration of the stems 310 and 350 , and to the retaining rods 308 and 348 .",
"The finger engaging members 320 and 360 are positioned on to the protrusions 306 and 346 , and to the retaining rods 308 and 348 , and are then secured to the finger engaging member receiving assemblies 304 and 344 by securing the retaining caps 330 and 370 on to the threaded ends 312 and 352 of stems 310 and 350 , as best illustrated in FIG. 23 .",
"The latching arms 326 and 366 each have a plurality of teeth 328 and 368 , which are adapted to join and lock together when engaged.",
"The teeth 328 and 368 are able to disengage when pulled apart by the flexing of the first and second elongated members 302 and 342 when an opposing force is applied to the finger engaging members 320 and 360 .",
"The first and second finger engaging members 320 and 360 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 300 .",
"Furthermore, other configurations of the first and second finger engaging members 320 and 360 may be used in place of the above described latching members.",
"Referring now to FIG. 24 which illustrates an alternate embodiment 400 of the present invention shown in FIG. 1 .",
"This alternate embodiment has a first elongated member 12 hingedly connected to a second elongated member 14 .",
"Both the first and second elongated members 12 and 14 each have a working head 13 and a finger engaging member 17 and 18 located opposite of the working head (not shown).",
"A first lever 30 and second lever 50 are pivotally attachable to the finger engaging members 17 and 18 , and are orientated-so that the levers are facing each other.",
"Additionally, latching members 402 are removably attachable to the finger engaging members 17 and 18 .",
"Each latching member 402 has a notch 408 for viewing an indicator located on the finger engaging members 17 and 18 .",
"The first and second elongated members 12 and 14 can be made from any suitable material having reflex memory.",
"The levers 30 and 50 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 17 and.",
"18 .",
"A pivot pin 32 extends from the finger engaging members 17 and 18 , and through levers 30 and 50 , allowing the levers to rotate.",
"The levers 30 and 50 have an extension 31 for retaining the latching members 402 on the finger engaging members 17 and 18 when the levers are aligned with the longitudinal axis of the first and second elongated members 12 and 14 , as best illustrated in FIG. 25 .",
"When the levers 30 and 50 are rotated to a position perpendicular to the first and second elongated members 12 and 14 , the extensions 31 are able to be moved out of engagement with the latching members 402 , thereby allowing the latching members to slide past the extensions 31 and be removed from finger engaging members 17 and 18 .",
"The latching members 402 each have an elongated base 404 and a latch arm 406 extending out from each elongated base.",
"The latch arms 406 feature a plurality of teeth 410 , which are adapted to join and lock together when engaged.",
"The teeth 410 are able to disengage when pulled apart by the flexing of the first and second elongated members 12 and 14 when an opposing force is applied to the finger engaging members 17 and 18 .",
"The elongated base 404 of the latching members 402 each have a channel 409 running the length of the elongated base.",
"The channels 409 are adapted to slide on and be retained by protrusions 412 extending out from the finger engaging members 17 and 18 and adjacent to the levers 30 and 50 .",
"The protrusions 412 each have an indicator 414 and 416 located on opposite sides of the protrusion.",
"The indicators 414 and 416 have a marking or indicia thereon to indicate a right or left hand use.",
"The marking or indicia can be, but not limited to, the letter “R”",
"and “L.”",
"The arrangement of indicators 414 and 416 are opposite for finger engaging members 17 and 18 , so that not similar indicators are facing the user.",
"This allows the user to view, from either side, through the notch 408 what orientation the ambidextrous locking clamp 400 is set for, as best shown in FIG. 24 which illustrates a right and left handed orientation.",
"The notch 408 is located on the elongated base 404 on the same side as the teeth 410 .",
"The notch 408 extends into the channel 409 .",
"When the latching members 402 are positioned on the protrusions 412 , the notch 408 is located over either the indicator 414 or 416 , depending on what orientation the latching members are set at for use either by a left or right handed user.",
"The configuration of the channel 409 and the protrusions 412 allow the latching members 402 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.",
"FIGS. 25 and 26 best illustrate one possible example of the channel, notch, indicator, and protrusion configuration.",
"The latching members 402 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 400 .",
"Referring now to FIG. 27 which illustrates an alternate embodiment 450 of the second embodiment of the present invention shown in FIG. 6 .",
"This alternate embodiment has a first elongated member 62 hingedly connected to a second elongated member 64 .",
"Both the first and second elongated members 62 and 64 each have a working head (not shown) and a finger engaging member 65 and 66 located opposite of the working head 63 .",
"A first lever 80 and second lever 100 are pivotally attachable to the finger engaging members 65 and 68 , and are orientated so that the levers are facing each other.",
"Additionally, latching members 452 are removably attachable to the finger engaging members 65 and 66 .",
"Each latching member 452 has a notch 458 for viewing an indicator located on the finger engaging members 65 and 66 .",
"The first and second elongated members 62 and 64 can be made from any suitable material having reflex memory.",
"The levers 80 and 100 have an extended portion for easy operation by the fingers of a user, and are contoured to conform to the shape of the finger engaging members 65 and 66 .",
"A pivot pin 67 extends from the finger engaging members 65 and 66 , and through levers 80 and 100 , allowing the levers to rotate.",
"The levers 80 and 100 have an extension 82 and 102 for retaining the first and second latching members 452 on the finger engaging members 65 and 66 when the levers are aligned with the longitudinal axis of the first and second elongated members 62 and 64 .",
"A notch 84 and 104 is defined in the levers 80 and 100 for allowing the latching members 452 to pass therethrough.",
"When the levers 80 and 100 are rotated so they are perpendicular to the first and second elongated members 62 and 64 , the extensions 82 and 102 are moved out of engagement with the latching members 452 , and the notches 84 and 104 are exposed to the latching members, thereby allowing the latching members to slide through the notches and be removed from finger engaging members 65 and 66 .",
"This is best illustrated in FIG. 28 .",
"The latching members 452 each have an elongated base 454 and a latch arm 456 extending out from each elongated base.",
"The latch arms 452 feature a plurality of teeth 462 , which are adapted to join and lock together when engaged.",
"The teeth 462 are able to disengage when pulled apart by the flexing of the first and second elongated members 62 and 64 when an opposing force is applied to the finger engaging members 65 and 66 .",
"The elongated base 454 of the latching members 452 each have a channel 460 running the length of the elongated base.",
"The channels 460 are adapted to slide on and be retained by protrusions 464 extending out from the finger engaging members 65 and 66 and adjacent to the levers 80 and 100 .",
"The protrusions 464 each have an indicator 468 and 466 located on opposite sides of the protrusion.",
"The indicators 468 and 466 have a marking or indicia thereon to indicate a right or left hand use.",
"The marking or indicia can be, but not limited to, the letter “R”",
"and “L.”",
"The arrangement of indicators 468 and 466 are opposite for finger engaging members 65 and 66 , so that not similar indicators are facing the user.",
"This allows the user to view, from either side, through the notch 458 what orientation the ambidextrous locking clamp 450 is set for, as best shown in FIG. 27 which illustrates a right and left handed orientation.",
"The notch 458 is located on the elongated base 454 on the same side as the teeth 462 .",
"The notch 458 extends into the channel 460 .",
"When the latching members 452 are positioned on the protrusions 464 , the notch 458 is located over either the indicator 468 or 466 , depending on what orientation the latching members are set at for use either by a left or right handed user.",
"The configuration of the channel 460 and the protrusions 464 allow the latching members 452 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.",
"The latching members 452 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 450 .",
"FIGS. 28 and 29 best illustrate one possible example of the channel, notch, indicator, and protrusion configuration.",
"Referring now to FIG. 30 which illustrates an alternate embodiment 500 of the third embodiment of the present invention shown in FIG. 11 .",
"This alternate embodiment has a first elongated member 112 hingedly connected to a second elongated member 113 .",
"Both the first and second elongated members 112 and 113 each have a working head (not shown) and a finger engaging member 114 and 116 located opposite of the working head.",
"Retaining caps 140 are threadably attachable to the finger engaging members 114 and 116 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members 112 and 113 .",
"Additionally, latching members 502 are removably attachable to the finger engaging members 114 and 116 .",
"Each latching member 502 has a notch 508 for viewing an indicator located on the finger engaging members 114 and 116 .",
"The first and second elongated members 112 and 113 can be made from any suitable material having reflex memory.",
"The retaining caps 140 have an internal threaded bore 141 .",
"The caps 140 are adapted to secure the first latching members 502 to the finger engaging members 114 and 116 .",
"The caps 140 are removably attachable to the finger engaging members 114 and 116 by screwing the caps onto a threaded stud 514 which extends out from a protrusion 516 of the finger engaging members 114 and 116 , and adjacent the latching members 502 .",
"This is best illustrated in FIGS. 31 .",
"The caps 140 may have a smooth or textured surface, or a fastener driving configuration, such as a screw driver or allen wrench head.",
"The elongated base 504 of the latching members 502 each have a channel 512 running the length of the elongated base.",
"The channels 512 are adapted to slide on and be retained by the protrusions 516 extending out from the finger engaging members 114 and 116 and adjacent to the threaded studs 514 .",
"The configuration of the channels 512 and the protrusions 516 allow the latching members 502 to slide over the protrusions, but at the same time not allowing the latching members to be pulled off the protrusions in a direction perpendicular to the sliding motion.",
"The protrusions 516 extend out from the finger engaging members 114 and 116 , and are adapted to slidably receive the latching members 502 .",
"The threaded studs 514 extend out from the distal ends of protrusions 516 .",
"The protrusions 516 each have an indicator 518 and 520 located on opposite sides of the protrusion.",
"The indicators 518 and 520 have a marking or indicia thereon to indicate a right or left hand use.",
"The marking or indicia can be, but not limited to, the letter “R”",
"and “L.”",
"The arrangement of indicators 518 and 520 are opposite for finger engaging members 114 and 116 , so that not similar indicators are facing the user.",
"This allows the user to view, from either side, through the notch 508 what orientation the ambidextrous locking clamp 500 is set for, as best shown in FIG. 31 which illustrates a right and left handed orientation.",
"The latching members 502 each have an elongated base 504 and a latch arm 506 extending out from each elongated base.",
"The latch arms 506 feature a plurality of teeth 510 , which are adapted to join and lock together when engaged.",
"The teeth 510 are able to disengage when pulled apart by the flexing of the first and second elongated members 112 and 113 when an opposing force is applied to the finger engaging members 114 and 116 .",
"The latching members 502 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 500 .",
"The notch 508 is located on the elongated base 504 on the same side as the teeth 510 .",
"The notch 508 extends into the channel 512 .",
"When the latching members 502 are positioned on the protrusions 516 , the notch 508 is located over either the indicator 518 or 520 , depending on what orientation the latching members are set at for use either by a left or right handed user.",
"FIGS. 31 and 32 best illustrate one possible example of the channel, notch, indicator, and protrusion configuration.",
"Referring now to FIG. 33 which illustrates an alternate embodiment 550 of the fourth embodiment of the present invention shown in FIG. 15 .",
"This alternate embodiment has a first elongated member 202 hingedly connected to a second elongated member 204 .",
"Both the first and second elongated members 202 and 204 each have a working head (not shown) and a finger engaging member 206 and 208 located opposite of the working head.",
"Additionally, latching members 552 are removably attachable to the finger engaging members 206 and 208 .",
"Each latching member 552 has a notch 558 for viewing an indicator located on the finger engaging members 206 and 208 .",
"The first and second elongated members 202 and 204 can be made from any suitable material having reflex memory.",
"The latching members 552 each have a base 554 and a latch arm 556 extending out from the base.",
"The base 554 each have an aperture 562 defined therethrough.",
"Threaded retaining pins 230 are insertable through threaded apertures 569 of the finger engaging members 206 and 208 , and through the apertures 562 of the bases 554 of the latching members 552 , as best illustrated in FIG. 34 .",
"The threaded retaining pins 230 have a threaded section 231 featuring a driving head or detent, and a non-threaded section 234 .",
"The non-threaded sections 234 are adapted to be received through the threaded apertures 569 of the finger engaging members 206 and 208 , and through the apertures 562 of the latching members 552 .",
"The threaded ends 231 engage the threaded apertures 569 to secure the retaining pins 230 in the finger engaging members 206 and 208 , thereby securing the latching members 552 in notches 564 located in each of the finger engaging members.",
"The latching members 552 are slidably insertable into notches 564 so that the base 554 rest in the notches and receives therein indicator ledges 568 located in the notches 564 .",
"The base 554 of the latching members 552 have a pair of channels 570 running the length of the base parallel with the longitudinal axis of the latch arms 552 .",
"As best illustrated in FIGS. 34 , the channels 570 are adapted to receive a set of protrusions 566 which extend into the notches 564 .",
"The channel 570 and protrusion 566 connections are configured to retain the latching members 552 in the notches 564 and flush with the outer surface of the finger engaging members 206 and 208 .",
"Additionally, the channel 570 and protrusion 566 connections prevent the latching members 552 from rotating out of alignment with the notches 564 .",
"The indicator ledges 568 have a marking or indicia thereon to indicate a right and left hand use.",
"The markings or indicia can be, but not limited to, the letter “R”",
"and “L.”",
"The markings are located at either end of the indicator ledge 568 and on both sides of the indicator ledge so that both sides are mirror images.",
"The indicator ledges 568 are mirrored for finger engaging members 206 and 208 , so that similar indicator ledges are facing the user.",
"This allows the user to view, from either side, through the notches 558 what orientation the ambidextrous locking clamp 550 is set for, as best shown in FIG. 33 which illustrates a right and left handed orientation.",
"The notch 558 is located on one corner and on both sides of the base 554 .",
"The notch 558 extends through one channel 570 of the base 554 .",
"When the latching members 552 are positioned in the notches 564 , the notches 558 are located over the indicator ledges 568 thereby exposing one of the markings on that side.",
"The marking that is exposed depends on what orientation the latching members 552 are set at, for use either by a left or right handed user.",
"The configuration of the channels 570 , the protrusions 566 , retaining pins 230 , and the indicator ledges 568 allow the latching members 552 to slide into the notches 564 of the finger engaging members 206 and 208 , but at the same time not allowing the latching members to be pulled out of the notches 564 in a direction perpendicular to the sliding motion.",
"The latching members 552 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 550 .",
"FIGS. 34 and 35 best illustrate one possible example of the channel, retaining pin, notches, and indicator ledge configuration.",
"The latch arms 556 feature a plurality of teeth 560 , which are adapted to join and lock together when engaged.",
"The teeth 560 are able to disengage when pulled apart by the flexing of the first and second elongated members 202 and 204 when an opposing force is applied to the finger engaging members 206 and 208 .",
"The latching members 552 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 550 .",
"Furthermore, other configurations of the first and second latching members 552 may be used in place of the above described latching members.",
"Referring now to FIG. 36 which illustrates an alternate embodiment 600 of the fifth embodiment of the present invention shown in FIG. 20 .",
"This alternate embodiment has a first elongated member 302 hingedly connected to a second elongated member 342 .",
"Both the first and second elongated members 302 and 342 each have a working head (not shown) and a finger engaging member 602 located opposite of the working head.",
"The first and second elongated members 302 and 342 each has a removable finger engaging member 602 located opposite of the working heads.",
"Each removable finger engaging member 602 has a latching arm 604 extending out and towards each other.",
"Retaining caps 330 are threadably attachable to the first and second elongated members 302 and 342 , and are orientated so that the centerline of the caps are aligned with the longitudinal axis of the first and second elongated members.",
"The retaining caps 330 can also be orientated in any alternate position to the first and second elongated members 302 and 342 .",
"The first and second retaining caps 330 are adapted to secure the finger engaging members 602 to the first and second elongated members 302 and 342 .",
"The first and second elongated members 302 and 342 can be made from any suitable material having reflex memory.",
"The first and second elongated members 302 and 342 each have a finger engaging member receiving assembly 304 and 344 .",
"The finger engaging member receiving assemblies 304 and 344 each have a protrusion 306 , and a retaining rod 308 and 348 .",
"The retaining rods 308 and 348 include a stem 614 extending out therefrom, each with a threaded end 620 .",
"The stems 614 have indicators 616 and 618 located on both sides of the stem.",
"The indicators 616 and 618 have a marking or indicia thereon to indicate a right or left hand use.",
"The marking or indicia can be, but not limited to, the letter “R”",
"and “L.”",
"The indicators 616 and 618 are located between the threaded end 620 and the retaining rods 304 and 308 , so that similar indicators are facing the user.",
"The indicators 616 and 618 are mirrored on both sides of the stem 614 .",
"This allows the user to view, from either side, through the notches 608 what orientation the ambidextrous locking clamp 500 is set for, as best shown in FIG. 36 which illustrates a right and left handed orientation.",
"The retaining caps 330 have internally threaded bores 332 able to be threaded on to the treaded ends 620 of the stems 614 .",
"This is best illustrated in FIG. 37 .",
"The finger engaging members 602 each have a bore 606 adapted to receive the protrusions 306 of the finger engaging member receiving assemblies 304 and 344 , and a notch 608 for viewing an indicator located on the stem 614 .",
"The finger engaging members 602 also have an aperture 612 running parallel with the bores 606 , which correspond to the configuration of the stems 614 , and to the retaining rods 308 and 348 .",
"The finger engaging members 602 are positioned on to the protrusions 306 and 346 , and to the stems 614 , and are then secured to the finger engaging member receiving assemblies 304 and 344 by securing the retaining caps 330 on to the threaded ends 620 of stems 614 , as best illustrated in FIG. 37 .",
"The latching arms 604 each have a plurality of teeth 610 , which are adapted to join and lock together when engaged.",
"The teeth 610 are able to disengage when pulled apart by the flexing of the first and second elongated members 302 and 342 when an opposing force is applied to the finger engaging members 602 .",
"The finger engaging members 602 are symmetrical so that they may be removed, inverted and then replaced, thereby changing the orientation of the latching members and allowing a right or left handed user to operate the device 600 .",
"Furthermore, other configurations of the first and second finger engaging members 602 may be used in place of the above described latching members.",
"The notches 608 are located on both sides of the finger engaging members 602 , adjacent the latching arms 604 .",
"The notches 608 extend through the aperture 612 .",
"When the finger engaging members 602 are positioned on the stems 614 , the notches 608 are located over either the indicators 616 or 618 , depending on what orientation the finger engaging members are set at for use either by a left or right handed user.",
"The configuration of the bores 606 , the protrusions 306 , apertures 612 , and stems 614 allow the finger engaging members 602 to slide against the finger engaging member receiving assemblies 304 , but at the same time not allowing the finger engaging members 602 to be pulled out in a direction perpendicular to the sliding motion.",
"FIGS. 37 and 38 best illustrate one possible example of the channel, retaining pin, notches, and indicator ledge configuration.",
"In use, it can now be understood that either a right hand or left hand user can use the ambidextrous locking clamp system while having the ability to view through the use of indicators what the orientation the clamp is configured for, either right or left handed use.",
"The user would remove and reverse the orientation of the removable latching member or the removable finger engaging member which features a latching arm.",
"By doing this, the user can change the operational configuration of the ambidextrous locking device.",
"The ambidextrous locking clamp system can use a variety of retaining means, such as, but not limited to, a rotating lever, a threaded cap, or a retaining pin.",
"All of these retaining means can be used to secure the removable latching member or the removable finger engaging member from the elongated members.",
"While a preferred embodiment of the ambidextrous locking clamp system has been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention.",
"With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.",
"For example, any suitable sturdy material may be used for the manufacture of the ambidextrous locking clamp system.",
"And although manipulating objects with a tool having removable latching members have been described, it should be appreciated that the ambidextrous locking clamp system herein described is also suitable for all types of hand operated locking tools having a at least two hingedly connected arms.",
"Therefore, 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, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention."
] |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application is based on Japanese patent application, No. 2005-339871 filed on Nov. 25, 2005 in the Japan Patent Office, the entire contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Exemplary aspects of the present invention relate to a method and apparatus for image forming, and more particularly to a method and an apparatus for toner image forming capable of detecting a reference signal used for a lighting control.
[0004] 2. Description of the Related Art
[0005] A related art image forming apparatus such as a laser printer, a digital copying machine, a facsimile, etc., has employed an optical beam scanning method for an image writing. According to the optical beam scanning method, a lighting (light emission) of a laser diode (LD) outputting a plurality of optical beams is controlled by image data, and a rotation polygon mirror deflects the plurality of optical beams to scan periodically in a main scanning direction. Thereby the optical beams irradiate a photoconductor moving towards in a sub-scanning direction so as to write an image on the photoconductor by each line.
[0006] When the image is written on the photoconductor by the optical beam scanning method, the photoconductor has an image writing start position thereon to begin the image writing. Since this image writing position needs to remain constant for each scanning line, a synchronous detection sensor is used to detect that the optical beams are disposed outside an image region of the photoconductor in an image writing start position side. The synchronous detection sensor detects a passage of the optical beams scanned in the main scanning direction (also referred to as a main scanning line) by the rotation polygon mirror, and instructs a lighting timing of the LD for each main scanning line with a synchronous detection signal generated thereby as a reference so as to control the image writing start position to be constant.
[0007] Regarding a color image formed by a related art color image forming apparatus, in general, a number of the photoconductors to be used is substantially equal to a number of color components. The photoconductors are scanned by the optical beams of respective color components, and images of different colors are superimposed by a transfer process so as to form a full color image. This formation of the full color image is referred to as a tandem system, and has been widely used.
[0008] As the tandem system exposes the photoconductors of respective color components to the optical beams, the image writing is controlled for each color component based on the synchronous detection signals generated by the synchronous detection sensors.
[0009] Therefore, the related art color image forming apparatus employing the tandem system generally superimposes the images of four colors, i.e., yellow, magenta, cyan, and black, formed on respective photoconductors so as to form the full color image. Thereby, the synchronous detection signals for the four colors are generated by using four different synchronous detection sensors.
[0010] In addition to using the four synchronous detection sensors with respect to the optical beams of respective colors, one example has attempted to use two synchronous detection sensors in another related art color image forming apparatus. Each synchronous detection sensor is commonly used for two color components.
[0011] According to this example of using the two synchronous detection sensors, one polygon mirror capable of scanning the four color components is employed. The four optical beams for the four color components are divided into two groups, for example, black and cyan, and magenta and yellow. The one polygon mirror has a plurality of mirror faces into which the optical beams are entered with respect to each group. The two optical beams of different color components in each group are detected by one of the two synchronous detection sensors. Each of the two synchronous detection sensors outputs the synchronous detection signals of the two optical beams which can be separated based on a time period by shifting a detection timing of each optical beam.
SUMMARY OF THE INVENTION
[0012] According to an aspect of the invention, an image forming apparatus includes a light emission source, a rotary polygon mirror, a plurality of image carrying members, an optical detection mechanism, and an instruction mechanism. The light emission source outputs a plurality of optical beams in accordance with image data. The rotary polygon mirror receives the plurality of optical beams at different mirror points with different mirror positions, and deflects the beams into a first plurality of scanning optical beams in given directions to cyclically scan on a plurality of predetermined scanning lines in a main scanning direction. The plurality of image carrying members rotate in a sub-scanning direction line by line, and respectively receive the first plurality of scanning optical beams to form a plurality of primary separate color images. The optical detection mechanism detects at a specific point a second plurality of scanning optical beams included in the first plurality of scanning optical beams. The instruction mechanism instructs the light emission source to light on and off at timings determined based on a plurality of detection signals from the optical detection mechanism.
[0013] According to another aspect of the invention, a method of image forming includes providing, rotating, diving, detecting, and instructing. The proving step provides a light emission source to output a plurality of optical beams in accordance with image data. The rotating step rotates a rotary polygon mirror to receive the plurality of optical beams at different mirror points with different mirror positions so as to deflect the beams into a first plurality of scanning optical beams in given directions to cyclically scan on a plurality of predetermined scanning lines in a main scanning direction. The driving step drives a plurality of image carrying members to rotate in a sub-scanning direction line by line so as to respectively receive the first plurality of scanning optical beams to form a plurality of primary separate color images. The detecting step detects at a specific point a second plurality of scanning optical beams included in the first plurality of scanning optical beams with an optical detection mechanism. The instructing step instructs the light emission source to light on and off at timings determined based on the plurality of detection signals from the optical detection mechanism.
[0014] According to another aspect of the invention, an optical writing apparatus includes a light emission source, a rotary polygon mirror, an optical detection mechanism, and an instruction mechanism. The light emission source outputs a plurality of optical beams in accordance with image data. The rotary polygon mirror receives the plurality of optical beams at different mirror points with different mirror positions, and deflects the beams into a first plurality of scanning optical beams in given directions so as to cyclically scan along a plurality of predetermined scanning lines in a main scanning direction on a plurality of image carrying members provided to rotate in a sub-scanning direction line by line and to respectively receive the first plurality of scanning optical beams to form a plurality of primary separate color images. The optical detection mechanism detects at a specific point a second plurality of scanning optical beams included in the first plurality of scanning optical beams. The instruction mechanism instructs the light emission source to light on and off at timings determined based on a plurality of detection signals from the optical detection mechanism.
[0015] According to still another aspect of the invention, an image forming apparatus includes plural light emission sources each configured to output an optical beam, a light reflecting unit configured to receive the optical beam from each light emission source of the plural light emission sources and to reflect the optical beam, plural image carrying members each configured to receive a corresponding optical beam reflected by the light reflecting unit, a single optical detection mechanism configured to receive each optical beam of at least half of the plural light emission sources prior to arriving at the plural image carrying members, and to generate detection signals, each corresponding to one of the at least half of the plural light emission sources, and an instruction mechanism configured to instruct each light emission source when to light on and off, at different timings, based on the detection signals corresponding to the at least half of the plural light emission sources.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A more complete appreciation of the exemplary aspects of the invention and many of the attendant advantage thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0017] FIG. 1 is a schematic diagram illustrating a color image forming apparatus according to an exemplary embodiment of the present invention;
[0018] FIG. 2 is a schematic diagram illustrating an optical beam scanning device and an image forming unit included in the image forming apparatus of FIG. 1 ;
[0019] FIG. 3 is a schematic diagram illustrating a synchronous detection of an optical beam;
[0020] FIG. 4 is a schematic diagram illustrating an example of synchronous detection signals generated by a synchronous detection sensor in the image forming apparatus of FIG. 1 ;
[0021] FIG. 5 is a schematic diagram illustrating a separation of the synchronous detection signals by a time base;
[0022] FIG. 6 is a schematic diagram illustrating another example of the synchronous detection signals generated by the single synchronous detection sensor according to another exemplary embodiment of the present invention; and
[0023] FIG. 7 is a schematic diagram illustrating a state of the optical beam entering into the synchronous detection sensor.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0024] In describing exemplary embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, a color image forming apparatus according to an exemplary embodiment of the present invention is described.
[0025] Referring to FIG. 1 , the color image forming apparatus includes an optical beam scanning device 20 , image forming units 200 BK, 200 C, 200 M, and 200 Y, and a transfer belt 36 . The optical beam scanning device 20 includes a plurality of optical elements such as a polygon mirror 22 , a polygon motor 22 m , fθ lenses 23 BKC and 23 MY, first mirrors 251 BK, 251 C, 251 M, and 251 Y, second mirrors 252 BK, 252 C, 252 M, and 252 Y, barrel toroidal lenses (BTL) 24 BK, 24 C, 24 M, and 24 Y, laser diodes 10 BK, 10 C, 10 M, and 10 Y (shown in FIG. 4 ), a synchronous detection sensor 7 (shown in FIG. 3 ) and third mirrors 253 BK, 253 C, 253 M, and 253 Y. The image forming units 200 BK, 200 C, 200 M, and 200 Y respectively includes photoconductors 29 BK, 29 C, 29 M, and 29 Y, charging devices 30 BK, 30 C, 30 M, and 30 Y, discharge devices 34 BK, 34 C, 34 M, and 34 Y, cleaning units 33 BK, 33 C, 33 M, and 33 Y, transfer devices 32 BK, 32 C, 32 M, and 321 Y, and development units 31 BK, 31 C, 31 M, and 31 Y as image forming elements. This color image forming apparatus of the exemplary embodiment employs a tandem system having the four image forming units 200 BK, 200 C, 200 M, and 200 Y for respective four color components, black, cyan, magenta, and yellow which are respectively abbreviated as BK, C, M, and Y. These abbreviations may be omitted as necessary.
[0026] The optical beam scanning device 20 emits optical beams of the four color components BK, C, M, and Y to irradiate respective photoconductors 29 BK, 29 C, 29 M, and 29 Y. The image forming unit 200 BK, 200 C, 200 M, and 200 Y form and develop electrostatic latent images to form the toner images so as to transfer the toner images onto a transfer sheet. The transfer belt 36 conveys the transfer sheet (not shown).
[0027] As stated above, the optical beam scanning device 20 includes the plurality of optical elements as follows. The polygon mirror 22 deflects the optical beams of four color components. The polygon motor 22 m drives the polygon mirror 22 . The fθ lenses 23 BKC and 23 MY correct scanning speeds of the optical beams. The first mirrors 251 BK, 251 C, 251 M, and 251 Y, the second mirrors 252 BK, 252 C, 252 M, and 252 Y, and the third mirrors 253 BK, 253 C, 253 M, and 253 Y reflect the optical beams. The laser diodes 10 BK, 10 C, 10 M, and 10 Y are light emission sources. The synchronous detection sensor 7 detects the optical beams and generates synchronous detection signals. The barrel toroidal lenses (BTL) 24 BK, 24 C, 24 M, and 24 Y correct, for example, a focusing function and an optical face tangle error in a sub-scanning direction.
[0028] Like the optical beam scanning device 20 including the plurality of optical elements, the image forming image forming units 200 BK, 200 C, 200 M, and 200 Y include the plurality of image forming elements as follows. The photoconductors 29 BK, 29 C, 29 M, and 29 Y form electrostatic latent images thereon by the optical beams emitted from the optical device 20 . The charging devices 30 BK, 30 C, 30 M, and 30 Y uniformly charge surfaces of the photoconductor 29 BK, 29 C, 29 M, and 29 Y. The discharge devices 34 BK, 34 C, 34 M, and 34 Y discharge residual charges of the photoconductors. The cleaning units 33 BK, 33 C, 33 M, and 33 Y remove remaining toners from the surfaces of the photoconductors. The transfer devices 32 BK, 32 C, 32 M, and 32 Y transfer the toner images onto the transfer sheet. The development units 31 BK, 31 C, 31 M, and 31 Y develop the electrostatic latent images on the photoconductors to form the toner images.
[0029] This color image forming apparatus employs an electrophotographic method with the tandem system to form the full color image. The color image forming apparatus controls a lighting of each laser diode 10 by image data of respective color component, writes images on photoconductors 29 BK, 29 C, 29 M, and 29 Y by a plurality of optical beams emitted from the optical beam scanning device 20 , develops the images on the photoconductors with toners by development units 31 BK, 31 C, 31 M, and 31 Y, and superimposes the toner images of four colors so as to form the full color image on the transfer sheet.
[0030] Since this color image forming apparatus with the tandem system superimposes the toner images of four color components to form the full color image, the four image forming units 200 BK, 200 C, 200 M, and 200 Y for respective four color components are disposed therein. As stated above, the photoconductors 29 BK, 29 C, 29 M, and 29 Y form the electrostatic latent images thereon by irradiation of the optical beams. The irradiation of the optical beams is provided by one polygon mirror 22 instead of four polygon mirrors as deflecting devices for the four color components. Thereby, a configuration of the color image forming apparatus may be simplified, and a cost thereof may be reduced.
[0031] As shown in FIG. 1 , the optical beam scanning device 20 deflects the optical beams of different colors by using the polygon mirror 22 that is driven by the polygon motor 22 m . The polygon mirror 22 has a plurality of mirror faces. One of the plurality of mirror faces deflects the optical beams of two colors at upper and lower portions thereof. In other words, each one of the optical beams of two colors is deflected by either upper portion or lower portion of the mirror face. Another mirror face deflects the optical beams of other two colors at upper and lower portions thereof. These two mirror faces are opposed each other. Thereby, the optical beams deflected by the polygon mirror 22 are spread and centered opposite to each other around the polygon mirror 22 . Consequently, each color of the optical beams is deflected by the polygon mirror 22 , passes through the fθ lens 23 , is reflected off the first mirrors 251 and second mirror 252 , passes through the BTL 24 , is reflected off the third mirror 253 , and scans the photoconductor 29 . Thereby, the optical beams of four color components scan respective photoconductors 29 BK, 29 C, 29 M, and 29 Y.
[0032] When the electrostatic latent images on the photoconductors 29 are developed and transferred onto the transfer sheet by respective image forming units 200 , the transfer belt 36 conveys the transfer sheet in a direction shown with an arrow in FIG. 1 so that a first color image is transferred onto the transfer sheet. As the transfer sheet is further conveyed in the arrow direction, second, third, and fourth color images are sequentially transferred onto the transfer sheet. Thereby, the full color image is formed on the transfer sheet by superimposing one image on another. The full color image on the transfer sheet is fixed by a fixing device (not shown).
[0033] In the exemplary embodiment shown in FIG. 1 , the images are directly transferred from the photoconductors 29 to the transfer sheet to form the full color image. However, an image forming apparatus having an intermediate transfer member can be applied to this exemplary embodiment. When the intermediate transfer member is used, the images are transferred from the photoconductors to the intermediate transfer member, and the images transferred on the intermediate transfer member are secondarily transferred onto the transfer sheet.
[0034] Referring to FIG. 2 , the optical beam scanning device 20 and one of the four image forming units 200 BK, 200 C, 200 M, and 200 Y included in FIG. 1 are explained in detail. Since each of the four image forming units 200 BK, 200 C, 200 M, and 200 Y is similar to other, except for the color components, one of the image forming units is shown as an example without the color abbreviation.
[0035] In the optical beam scanning device 20 , the laser diode 10 (shown in FIG. 3 ), the lighting of which is controlled by the image data, outputs the optical beams, and a collimate lens (not shown) collimates the optical beams output from the laser diode 10 . As shown in FIG. 2 , after the optical beams pass through a cylinder lens (not shown), the optical beams enter into the mirror faces of the polygon mirror 22 . The optical beams are deflected by the polygon mirror 22 , pass through the fθ lens 23 and the barrel toroidal lens 24 , are reflected off the third mirror 253 , and irradiate the photoconductor 29 .
[0036] As also shown in FIG. 2 , the image forming unit 200 includes the image forming elements such as the photoconductor 29 , the charging device 30 , the development unit 31 , the transfer device 32 , the cleaning unit 33 , and the discharge device 34 . The photoconductor 29 includes other image forming elements in a vicinity thereof.
[0037] The image forming unit 200 using the electrophotographic method forms the full color image on the transfer sheet by carrying out an image forming process such as charging the photoconductor 29 by the charging device 30 , irradiating on the photoconductor 29 by the optical beam scanning device 20 so as to form the electrostatic latent image, developing the electrostatic latent image on the photoconductor 29 with toner by the development unit 31 , transferring the toner image onto the transfer sheet by the transfer device 32 , fixing the toner image on the transfer sheet by the fixing device (not shown), removing a residual toner from the photoconductor 29 by the cleaning unit 33 , and discharging the photoconductor 29 by the discharge device 34 to prepare for a next image forming.
[0038] The optical beams output from the laser diode 10 , which are deflected by the polygon mirror 22 , periodically scan a surface of the photoconductor 29 in a main scanning direction by a line scanning, and irradiate a receiving surface of the photoconductor 29 moving in a sub-scanning direction by each line so as to write a two-dimensional image on the receiving surface.
[0039] When the photoconductor 29 is irradiated, the image writing position on the photoconductor 29 needs to be constant (the same) for each scanning line so that an occurrence of an image misregistration may be reduced. The synchronous detection sensor 7 (shown in FIG. 3 ) is disposed to detect the optical beams at a certain position on the scanning line of an image writing start side and generate a synchronous detection signal.
[0040] Referring to FIG. 3 , the synchronous detection sensor 7 detects the optical beams. The color abbreviations BK, C, M, and Y for the optical elements may be omitted as necessary.
[0041] As shown in FIG. 3 , the plurality of optical beams emitted from the laser diode 10 in the optical beam scanning device 20 are deflected by the polygon mirror 22 , pass through the fθ lens 23 , are reflected off the first mirror 251 so as to scan the photoconductor 29 of FIGS. 1 and 2 in the main scanning direction. One of the optical beams, for example, is directed towards the synchronous detection sensor 7 by reflecting off a mirror 71 which is disposed at a location before the optical beams enter into the first mirror 251 . In other words, the mirror 71 is disposed outside the photoconductor 29 in the image writing start side. The synchronous detection sensor 7 detects the optical beam entering at the certain position on the scanning line, and generates the synchronous detection signal.
[0042] The synchronous detection sensor 7 detects the optical beams, and instructs a lighting timing of the laser diode 10 for each main scanning line with the synchronous detection signal as a reference in such a manner that the image writing is controlled to begin at the certain position. The lighting timing of the laser diode 10 is based on the image data written in an effective image area. The control of the image writing, for example, may be provided with using the synchronous detection signal as a trigger to begin the image writing after a given time. The given time may be determined by a predetermined clock period.
[0043] When the image forming apparatus with the tandem system forms the full color image, a number of the photoconductors to be used is equal to a number of color components. Consequently, a synchronous detection signal may be needed for each color component.
[0044] When the images are written on the photoconductors 29 BK, 29 C, 29 M, and 29 Y by the optical beams, the synchronous detection sensor 7 detects the optical beams and controls writing timings based on synchronous detection signals for respective color components so that image writing positions on the photoconductors 29 BK, 29 C, 29 M, and 29 Y may be constant for respective scanning lines.
[0045] According to this exemplary embodiment, a single synchronous detection sensor 7 is disposed to detect all the optical beams and generate all the synchronous detection signals for all the colors. Thereby, the configuration of the color image forming apparatus may be simplified, and the cost thereof may be reduced.
[0046] Referring to FIG. 4 , the color image forming apparatus shown in FIG. 1 of the exemplary embodiment of the present invention is provided with synchronous detection signals generated by the synchronous detection sensor 7 for respective color components. As stated above in FIG. 1 , the optical beam scanning device 20 uses the opposite mirror faces of the polygon mirror 22 to scan and spread the deflected optical beams in opposite directions. Each mirror face deflects the optical beams of two different color components at the upper and lower portions thereof. This exemplary embodiment, for example, the optical beams of cyan and black are respectively entered into the upper and lower portions of the same mirror face while the optical beams of magenta and yellow are respectively entered into the upper and lower portions of another mirror face. The another mirror face may be directly opposite to the same mirror face.
[0047] As shown in FIG. 4 , the optical beams of cyan, black, magenta and yellow are respectively output from the laser diodes 10 C, 10 BK, 10 M, and 10 Y. The laser diode 10 C is disposed above the laser diode 10 BK while the laser diode 10 M is disposed above the laser diode 10 Y so that the optical beams are deflected by respective portions of the opposite mirror faces. The deflected optical beams pass the fθ lenses 23 BKC and 23 MY and are reflected off by the first mirrors 251 BK, 251 C, 251 M, and 251 Y towards respective photoconductors 29 BK, 29 C, 29 M and 29 Y. Here, a pair of deflected optical beams of cyan and black and another pair of deflected optical beams of magenta and yellow are spread symmetrically around the polygon mirror 22 , in opposite directions, so that the optical beams scan respective photoconductors 29 BK, 29 C, 29 M and 29 Y.
[0048] The optical beams of the four color components to scan periodically are deflected by the polygon mirror 22 , and are directed towards the synchronous detection sensor 7 by the mirrors 71 BK, 71 C, 71 M, and 71 Y. As stated above, the mirrors 71 are disposed at locations before the optical beams are entered into the first mirrors 251 . In other words, the mirrors 71 are disposed outside the photoconductors 29 in the image writing start sides. The synchronous detection sensor 7 detects the optical beams of the four color components entering at the certain positions on the scanning lines, and generates the synchronous detection signals for respective color components.
[0049] Since the synchronous detection sensor 7 generates the synchronous detection signals, the optical beams may need to be entered into the synchronous detection sensor 7 at different timings in such a manner that the optical beams of four color components are separated by the time base.
[0050] Referring to FIG. 5 , the synchronous detection signals generated by the synchronous detection sensor 7 from the respective optical beams are separated by the time base. The optical elements including mirrors to reflect the optical beams may be omitted as necessary in FIG. 5 .
[0051] The optical beams of yellow and black, for example, are reflected off the opposite mirror faces of the polygon mirror 22 , and incident beams to the synchronous detection sensor 7 are fluctuated as shown in situations 1 and 2 of FIG. 5 .
[0052] The situation 1 of FIG. 5 shows the optical beams at a certain timing at which, for example, the polygon mirror 22 is in a position rotated by θ from a reference position. The optical beam emitted from the laser diode 10 Y is deflected by the polygon mirror 22 and is entered into the synchronous detection sensor 7 at the timing at which the polygon mirror 22 is in the position of the θ rotation. At the same time, the optical beam BK emitted by the laser diode 10 BK is not deflected towards the synchronous detection sensor 7 .
[0053] The situation 2 of FIG. 5 shows the optical beams at another timing at which the polygon mirror 22 is in a position rotated by θ+Δθ from the reference position. The optical beam emitted from the laser diode 11 BK is deflected by the polygon mirror 22 and is entered to the synchronous detection sensor 7 at this timing and the optical beam Y is not deflected towards the synchronous detection sensor 7 . The optical beams emitted from the laser diodes 10 Y and 10 BK are stated as examples. However, the optical beams of cyan and magenta are similar to those of black and yellow. For example, the optical beams emitted from the laser diodes 10 C and 10 M are entered to the synchronous detection sensor 7 at timings at which the polygon mirror 22 is in a position rotated by θ+2Δθ and θ+3Δθ respectively from the reference position.
[0054] As the polygon mirror 22 is rotated in different positions by different angles, the optical beams of the four color components are detected at different timings. Thereby, the synchronous detection signals are separated one from another by the time base.
[0055] The synchronous detection signals separated by the time base are used as reference signals for respective color components so as to instruct lighting timings of laser diodes 10 Y, 10 M, 10 C, and 10 BK and control the beginning of image writing at the certain positions. The lighting timings of laser diodes 10 Y, 10 M, 10 C, and 10 BK are based on the image data written in the effective image areas for respective main scanning lines.
[0056] A related art image forming apparatus applies a synchronous detection signal of only a single color to commonly use for all four color components so that optical beams are spread and opposed. In other words, only the optical beams of the single color are deflected by one mirror face of a polygon mirror, and are detected by a detection sensor so as to be commonly used for all the four color components. However, the related art image forming apparatus has generated a jitter that disturbs the image.
[0057] The image forming apparatus of this exemplary embodiment shown in FIG. 1 though FIG. 5 , on the other hand, employs the polygon mirror 22 that generates the synchronous detection signals of each of the four color components from the optical beams of respective color components. Therefore, an occurrence of the jitter may be reduced and a quality of the writing image may remain high.
[0058] This exemplary embodiment of the present invention stated above uses the polygon mirror 22 to deflect the optical beams. The deflected optical beams are spread and (symmetrically) centered opposite to each other around the polygon mirror 22 . For example, when the images are written on the four photoconductors, the sensor outputs of the optical beams of the four colors are used as the synchronous detection signals of respective colors. As shown in FIG. 1 and FIG. 5 , the optical beams of the four color components are spread and opposed to scan, and each of the optical beams of two color components are entered into one of the mirror faces of the polygon mirror 22 . Each mirror face has upper and lower portions to deflect the optical beams of the two colors. When one mirror face deflects a plurality of optical beams in this exemplary embodiment shown FIG. 1 through FIG. 5 , a likelihood of an error occurrence between the plurality of optical beams may be significantly small. Therefore, the color image forming apparatus of this embodiment may be simplified so as to, for example, reduce costs thereof by another exemplary embodiment shown in FIG. 6 .
[0059] In the exemplary embodiment shown in FIG. 6 , the synchronous detection sensor 7 , detecting the optical beam of one color component deflected by one mirror face of the polygon mirror 22 , generates the synchronous detection sensor that may be commonly used for the optical beam of another color component deflected by the same mirror face. Thereby, a number of the optical beams to be detected may be reduced, and the color image forming apparatus may be configured to be simplified, for example, without having the mirrors 71 C and 71 Y. In other words, only one control signal is generated for those optical beams reflected on faces provided on a same side of the polygon mirror 22 .
[0060] Referring to FIG. 6 , another exemplary embodiment of the present invention employing another method to generate the synchronous detection signal by the synchronous detection sensor 7 in the color image forming apparatus with the tandem system of FIG. 1 is described. As the optical elements of FIG. 6 are similar to those of FIG. 4 , except for the mirrors 71 C and 71 Y, reference numbers used in FIG. 4 and FIG. 6 may be similar.
[0061] Similar to FIG. 4 , the optical beam scanning device 20 of this exemplary embodiment shown in FIG. 6 uses the polygon mirror 22 having the mirror faces. Thereby, the optical beams of two color components are entered into one of the mirror faces while the optical beams of other two color components are entered into another mirror face so that the optical beams emitted from the laser diodes 10 BK, 10 C, 10 Y, and 10 M are spread into two, for example, black and cyan, and magenta and yellow. The optical beams of black and cyan, and magenta and yellow scan respective photoconductors in opposite directions. As these optical elements are similar to those of FIG. 4 , a detailed description of each optical element may be omitted.
[0062] As shown in FIG. 6 , the synchronous detection sensor 7 detects the optical beams of black and magenta. The optical beams of four color components are deflected by the polygon mirror 22 . However, the optical beams of black and magenta out of the four colors are respectively reflected off the mirrors 71 BK and 71 M so as to be directed towards the synchronous detection sensor 7 . The mirrors 71 BK and 71 K are disposed at the locations before the optical beams are entered into the first mirrors 251 BK and 251 M. In other words, the mirrors 71 BK and 71 M are disposed outside the photoconductors 29 in the image writing start sides. The synchronous detection sensor 7 detects the optical beams of black and magenta entering at the certain positions on the scanning lines, and generates the synchronous detection signals for respective color components.
[0063] Since one piece of the synchronous detection sensor 7 generates the synchronous detection signals of different color components, the optical beams may need to be entered into the synchronous detection sensor 7 at different timings in such a manner that the optical beams of different color components are separated by the time base. That is similar to the exemplary embodiment previously stated in FIG. 5 .
[0064] The synchronous detection signals of the optical beams of black and magenta detected by the synchronous detection sensor 7 are separated by the time base and are used as the reference signals for respective color components so as to instruct the lighting timings of the laser diodes 10 BK and 10 M and control the beginning of the image writing at the certain positions. The lighting timings of laser diodes 10 BK and 10 M are based on the image data written in the effective image areas for respective main scanning lines.
[0065] The optical beams of other color components such as cyan and yellow are described as follows. The optical beam of cyan is deflected by the mirror face of the polygon mirror 22 by which the optical beam of black is deflected. The optical beams of cyan and black use the same mirror face so as to be deflected. Similarly, the optical beams of yellow and magenta are deflected by another mirror face of the polygon mirror 22 . The optical beams of cyan and yellow respectively use the synchronous detection signals of the optical beams of black and magenta.
[0066] In other words, the synchronous detection signal of black is commonly used for the optical beams of cyan and black while the synchronous detection signal of magenta is commonly used for the optical beams of yellow and magenta. Thereby, the optical beams of cyan and yellow respectively use the synchronous detection signals of black and magenta to instruct the lighting timings of the laser diodes 10 C and 10 Y, and control the beginning of the image writing at the certain positions.
[0067] According to this exemplary embodiment, the synchronous detection sensor 7 detecting the optical beam of one color component deflected by one mirror face of the polygon mirror 22 generates the synchronous detection signal that may be commonly used for the optical beam of another color component deflected by the same mirror face. Therefore, an occurrence of the jitter stated above in the related art image forming apparatus may be reduced, and the quality of the writing image may remain high.
[0068] Still another exemplary embodiment of the present invention will be described in FIG. 7 . This exemplary embodiment of FIG. 7 includes an adjustment process to reduce an error occurrence when the synchronous detection sensor 7 shown in the exemplary embodiments of FIG. 4 and FIG. 6 is used to detect the synchronous detection signals of a plurality of the optical beams.
[0069] These exemplary embodiments shown in FIG. 4 and FIG. 6 respectively detect the optical beams of four and two color components by the synchronous detection sensor 7 . Regardless of FIG. 4 and FIG. 6 , the optical beams entering into the synchronous detection sensor 7 are inclined against a detection face of the synchronous detection sensor 7 because of an arrangement of the optical elements.
[0070] Referring to FIG. 7 , the optical beams are entered into the synchronous detection sensor 7 in a state that the optical beams are inclined relative to a normal to the surface of the synchronous detection sensor 7 . When the inclined optical beams are entered into the synchronous detection sensor 7 , a detection light intensity detected by the synchronous detection sensor 7 may be reduced compared to a largest light intensity which may be detected in a case where the optical beams are vertically entered. Consequently, the synchronous detection signals from the synchronous detection sensor 7 may have an error. When the detection amount fluctuates with a variation in an incident angle that is an angle of the optical beam to enter into the synchronous detection sensor 7 , timings of the synchronous detection signals may be slightly fluctuated.
[0071] When the inclined optical beams are entered into the synchronous detection sensor 7 , the light intensity of the inclined optical beams are adjusted in such a manner that a suitable light intensity is provided. For example, when the optical beams are spread and opposed to scan as shown in FIG. 7 , one side of the optical beams is called an optical beam 1 , and another side of the optical beams is called an optical beam 2 . The optical beams 1 and 2 are assumed to have incident angles α and β degrees respectively. When the optical beam 1 is entered at the α degree of incident angle, the light intensity may be reduced by α% from a case where the optical beam is vertically entered. When the optical beam 2 is entered at the β degree, the light intensity may be reduced by β% from a case where optical beam is vertically entered. The reduction of the light intensity may be controlled by a lighting control unit 12 of the laser diode as shown in FIG. 3 . Therefore, the lighting control unit 12 controlling the lighting of the laser diode 10 transmits an intensity adjustment signal to a driving unit 14 of the laser diode so as to adjust the light intensity of the laser diode and obtain the suitable light intensity. The intensity adjustment signals are transmitted to, for example, increase the optical beams 1 and 2 by α% and β% respectively in this exemplary embodiment. Therefore, an occurrence of shifting the writing timing between the optical beams 1 and 2 may be reduced.
[0072] Each exemplary embodiment of the present invention above is illustrated by applying to the color image forming apparatus with the electrophotographic method that the images are written by the optical beams having the image data of the four color components. However, the stated disclosure and description of the exemplary embodiments are illustrative only and are not to be considered limiting. The present invention may be applied to an area employing an optical writing method by using a plurality of optical beams, for example, an area in which data is written and/or recorded to an optical recording medium utilizing a photo-magnetic effect.
[0073] Numerous additional modifications and variation are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the disclosure of this patent specification may be practiced otherwise than as specifically described herein. | An image forming apparatus includes a light emission source, a polygon mirror, a plurality of image carrying members, an optical detection mechanism, and an instruction mechanism. The light emission source outputs a plurality of optical beams in accordance with image data. The polygon mirror receives the optical beams at different mirror points, and deflects the beams into a first plurality of scanning optical beams in given directions to scan on predetermined scanning lines in a main scanning direction. The plurality of image carrying members rotating in a sub-scanning direction receive the first plurality of scanning optical beams to form primary separate color images. The optical detection mechanism detects a second plurality of scanning optical beams included in the first plurality of scanning optical beams. The instruction mechanism instructs the light emission source to light on and off at timings based on a plurality of detection signals from the optical detection mechanism. | Briefly summarize the main idea's components and working principles as described in the context. | [
"CROSS-REFERENCE TO RELATED APPLICATION [0001] This patent application is based on Japanese patent application, No. 2005-339871 filed on Nov. 25, 2005 in the Japan Patent Office, the entire contents of which are incorporated by reference herein.",
"BACKGROUND OF THE INVENTION [0002] 1.",
"Field of the Invention [0003] Exemplary aspects of the present invention relate to a method and apparatus for image forming, and more particularly to a method and an apparatus for toner image forming capable of detecting a reference signal used for a lighting control.",
"[0004] 2.",
"Description of the Related Art [0005] A related art image forming apparatus such as a laser printer, a digital copying machine, a facsimile, etc.",
", has employed an optical beam scanning method for an image writing.",
"According to the optical beam scanning method, a lighting (light emission) of a laser diode (LD) outputting a plurality of optical beams is controlled by image data, and a rotation polygon mirror deflects the plurality of optical beams to scan periodically in a main scanning direction.",
"Thereby the optical beams irradiate a photoconductor moving towards in a sub-scanning direction so as to write an image on the photoconductor by each line.",
"[0006] When the image is written on the photoconductor by the optical beam scanning method, the photoconductor has an image writing start position thereon to begin the image writing.",
"Since this image writing position needs to remain constant for each scanning line, a synchronous detection sensor is used to detect that the optical beams are disposed outside an image region of the photoconductor in an image writing start position side.",
"The synchronous detection sensor detects a passage of the optical beams scanned in the main scanning direction (also referred to as a main scanning line) by the rotation polygon mirror, and instructs a lighting timing of the LD for each main scanning line with a synchronous detection signal generated thereby as a reference so as to control the image writing start position to be constant.",
"[0007] Regarding a color image formed by a related art color image forming apparatus, in general, a number of the photoconductors to be used is substantially equal to a number of color components.",
"The photoconductors are scanned by the optical beams of respective color components, and images of different colors are superimposed by a transfer process so as to form a full color image.",
"This formation of the full color image is referred to as a tandem system, and has been widely used.",
"[0008] As the tandem system exposes the photoconductors of respective color components to the optical beams, the image writing is controlled for each color component based on the synchronous detection signals generated by the synchronous detection sensors.",
"[0009] Therefore, the related art color image forming apparatus employing the tandem system generally superimposes the images of four colors, i.e., yellow, magenta, cyan, and black, formed on respective photoconductors so as to form the full color image.",
"Thereby, the synchronous detection signals for the four colors are generated by using four different synchronous detection sensors.",
"[0010] In addition to using the four synchronous detection sensors with respect to the optical beams of respective colors, one example has attempted to use two synchronous detection sensors in another related art color image forming apparatus.",
"Each synchronous detection sensor is commonly used for two color components.",
"[0011] According to this example of using the two synchronous detection sensors, one polygon mirror capable of scanning the four color components is employed.",
"The four optical beams for the four color components are divided into two groups, for example, black and cyan, and magenta and yellow.",
"The one polygon mirror has a plurality of mirror faces into which the optical beams are entered with respect to each group.",
"The two optical beams of different color components in each group are detected by one of the two synchronous detection sensors.",
"Each of the two synchronous detection sensors outputs the synchronous detection signals of the two optical beams which can be separated based on a time period by shifting a detection timing of each optical beam.",
"SUMMARY OF THE INVENTION [0012] According to an aspect of the invention, an image forming apparatus includes a light emission source, a rotary polygon mirror, a plurality of image carrying members, an optical detection mechanism, and an instruction mechanism.",
"The light emission source outputs a plurality of optical beams in accordance with image data.",
"The rotary polygon mirror receives the plurality of optical beams at different mirror points with different mirror positions, and deflects the beams into a first plurality of scanning optical beams in given directions to cyclically scan on a plurality of predetermined scanning lines in a main scanning direction.",
"The plurality of image carrying members rotate in a sub-scanning direction line by line, and respectively receive the first plurality of scanning optical beams to form a plurality of primary separate color images.",
"The optical detection mechanism detects at a specific point a second plurality of scanning optical beams included in the first plurality of scanning optical beams.",
"The instruction mechanism instructs the light emission source to light on and off at timings determined based on a plurality of detection signals from the optical detection mechanism.",
"[0013] According to another aspect of the invention, a method of image forming includes providing, rotating, diving, detecting, and instructing.",
"The proving step provides a light emission source to output a plurality of optical beams in accordance with image data.",
"The rotating step rotates a rotary polygon mirror to receive the plurality of optical beams at different mirror points with different mirror positions so as to deflect the beams into a first plurality of scanning optical beams in given directions to cyclically scan on a plurality of predetermined scanning lines in a main scanning direction.",
"The driving step drives a plurality of image carrying members to rotate in a sub-scanning direction line by line so as to respectively receive the first plurality of scanning optical beams to form a plurality of primary separate color images.",
"The detecting step detects at a specific point a second plurality of scanning optical beams included in the first plurality of scanning optical beams with an optical detection mechanism.",
"The instructing step instructs the light emission source to light on and off at timings determined based on the plurality of detection signals from the optical detection mechanism.",
"[0014] According to another aspect of the invention, an optical writing apparatus includes a light emission source, a rotary polygon mirror, an optical detection mechanism, and an instruction mechanism.",
"The light emission source outputs a plurality of optical beams in accordance with image data.",
"The rotary polygon mirror receives the plurality of optical beams at different mirror points with different mirror positions, and deflects the beams into a first plurality of scanning optical beams in given directions so as to cyclically scan along a plurality of predetermined scanning lines in a main scanning direction on a plurality of image carrying members provided to rotate in a sub-scanning direction line by line and to respectively receive the first plurality of scanning optical beams to form a plurality of primary separate color images.",
"The optical detection mechanism detects at a specific point a second plurality of scanning optical beams included in the first plurality of scanning optical beams.",
"The instruction mechanism instructs the light emission source to light on and off at timings determined based on a plurality of detection signals from the optical detection mechanism.",
"[0015] According to still another aspect of the invention, an image forming apparatus includes plural light emission sources each configured to output an optical beam, a light reflecting unit configured to receive the optical beam from each light emission source of the plural light emission sources and to reflect the optical beam, plural image carrying members each configured to receive a corresponding optical beam reflected by the light reflecting unit, a single optical detection mechanism configured to receive each optical beam of at least half of the plural light emission sources prior to arriving at the plural image carrying members, and to generate detection signals, each corresponding to one of the at least half of the plural light emission sources, and an instruction mechanism configured to instruct each light emission source when to light on and off, at different timings, based on the detection signals corresponding to the at least half of the plural light emission sources.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0016] A more complete appreciation of the exemplary aspects of the invention and many of the attendant advantage thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: [0017] FIG. 1 is a schematic diagram illustrating a color image forming apparatus according to an exemplary embodiment of the present invention;",
"[0018] FIG. 2 is a schematic diagram illustrating an optical beam scanning device and an image forming unit included in the image forming apparatus of FIG. 1 ;",
"[0019] FIG. 3 is a schematic diagram illustrating a synchronous detection of an optical beam;",
"[0020] FIG. 4 is a schematic diagram illustrating an example of synchronous detection signals generated by a synchronous detection sensor in the image forming apparatus of FIG. 1 ;",
"[0021] FIG. 5 is a schematic diagram illustrating a separation of the synchronous detection signals by a time base;",
"[0022] FIG. 6 is a schematic diagram illustrating another example of the synchronous detection signals generated by the single synchronous detection sensor according to another exemplary embodiment of the present invention;",
"and [0023] FIG. 7 is a schematic diagram illustrating a state of the optical beam entering into the synchronous detection sensor.",
"DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS [0024] In describing exemplary embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity.",
"However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner.",
"Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, a color image forming apparatus according to an exemplary embodiment of the present invention is described.",
"[0025] Referring to FIG. 1 , the color image forming apparatus includes an optical beam scanning device 20 , image forming units 200 BK, 200 C, 200 M, and 200 Y, and a transfer belt 36 .",
"The optical beam scanning device 20 includes a plurality of optical elements such as a polygon mirror 22 , a polygon motor 22 m , fθ lenses 23 BKC and 23 MY, first mirrors 251 BK, 251 C, 251 M, and 251 Y, second mirrors 252 BK, 252 C, 252 M, and 252 Y, barrel toroidal lenses (BTL) 24 BK, 24 C, 24 M, and 24 Y, laser diodes 10 BK, 10 C, 10 M, and 10 Y (shown in FIG. 4 ), a synchronous detection sensor 7 (shown in FIG. 3 ) and third mirrors 253 BK, 253 C, 253 M, and 253 Y. The image forming units 200 BK, 200 C, 200 M, and 200 Y respectively includes photoconductors 29 BK, 29 C, 29 M, and 29 Y, charging devices 30 BK, 30 C, 30 M, and 30 Y, discharge devices 34 BK, 34 C, 34 M, and 34 Y, cleaning units 33 BK, 33 C, 33 M, and 33 Y, transfer devices 32 BK, 32 C, 32 M, and 321 Y, and development units 31 BK, 31 C, 31 M, and 31 Y as image forming elements.",
"This color image forming apparatus of the exemplary embodiment employs a tandem system having the four image forming units 200 BK, 200 C, 200 M, and 200 Y for respective four color components, black, cyan, magenta, and yellow which are respectively abbreviated as BK, C, M, and Y. These abbreviations may be omitted as necessary.",
"[0026] The optical beam scanning device 20 emits optical beams of the four color components BK, C, M, and Y to irradiate respective photoconductors 29 BK, 29 C, 29 M, and 29 Y. The image forming unit 200 BK, 200 C, 200 M, and 200 Y form and develop electrostatic latent images to form the toner images so as to transfer the toner images onto a transfer sheet.",
"The transfer belt 36 conveys the transfer sheet (not shown).",
"[0027] As stated above, the optical beam scanning device 20 includes the plurality of optical elements as follows.",
"The polygon mirror 22 deflects the optical beams of four color components.",
"The polygon motor 22 m drives the polygon mirror 22 .",
"The fθ lenses 23 BKC and 23 MY correct scanning speeds of the optical beams.",
"The first mirrors 251 BK, 251 C, 251 M, and 251 Y, the second mirrors 252 BK, 252 C, 252 M, and 252 Y, and the third mirrors 253 BK, 253 C, 253 M, and 253 Y reflect the optical beams.",
"The laser diodes 10 BK, 10 C, 10 M, and 10 Y are light emission sources.",
"The synchronous detection sensor 7 detects the optical beams and generates synchronous detection signals.",
"The barrel toroidal lenses (BTL) 24 BK, 24 C, 24 M, and 24 Y correct, for example, a focusing function and an optical face tangle error in a sub-scanning direction.",
"[0028] Like the optical beam scanning device 20 including the plurality of optical elements, the image forming image forming units 200 BK, 200 C, 200 M, and 200 Y include the plurality of image forming elements as follows.",
"The photoconductors 29 BK, 29 C, 29 M, and 29 Y form electrostatic latent images thereon by the optical beams emitted from the optical device 20 .",
"The charging devices 30 BK, 30 C, 30 M, and 30 Y uniformly charge surfaces of the photoconductor 29 BK, 29 C, 29 M, and 29 Y. The discharge devices 34 BK, 34 C, 34 M, and 34 Y discharge residual charges of the photoconductors.",
"The cleaning units 33 BK, 33 C, 33 M, and 33 Y remove remaining toners from the surfaces of the photoconductors.",
"The transfer devices 32 BK, 32 C, 32 M, and 32 Y transfer the toner images onto the transfer sheet.",
"The development units 31 BK, 31 C, 31 M, and 31 Y develop the electrostatic latent images on the photoconductors to form the toner images.",
"[0029] This color image forming apparatus employs an electrophotographic method with the tandem system to form the full color image.",
"The color image forming apparatus controls a lighting of each laser diode 10 by image data of respective color component, writes images on photoconductors 29 BK, 29 C, 29 M, and 29 Y by a plurality of optical beams emitted from the optical beam scanning device 20 , develops the images on the photoconductors with toners by development units 31 BK, 31 C, 31 M, and 31 Y, and superimposes the toner images of four colors so as to form the full color image on the transfer sheet.",
"[0030] Since this color image forming apparatus with the tandem system superimposes the toner images of four color components to form the full color image, the four image forming units 200 BK, 200 C, 200 M, and 200 Y for respective four color components are disposed therein.",
"As stated above, the photoconductors 29 BK, 29 C, 29 M, and 29 Y form the electrostatic latent images thereon by irradiation of the optical beams.",
"The irradiation of the optical beams is provided by one polygon mirror 22 instead of four polygon mirrors as deflecting devices for the four color components.",
"Thereby, a configuration of the color image forming apparatus may be simplified, and a cost thereof may be reduced.",
"[0031] As shown in FIG. 1 , the optical beam scanning device 20 deflects the optical beams of different colors by using the polygon mirror 22 that is driven by the polygon motor 22 m .",
"The polygon mirror 22 has a plurality of mirror faces.",
"One of the plurality of mirror faces deflects the optical beams of two colors at upper and lower portions thereof.",
"In other words, each one of the optical beams of two colors is deflected by either upper portion or lower portion of the mirror face.",
"Another mirror face deflects the optical beams of other two colors at upper and lower portions thereof.",
"These two mirror faces are opposed each other.",
"Thereby, the optical beams deflected by the polygon mirror 22 are spread and centered opposite to each other around the polygon mirror 22 .",
"Consequently, each color of the optical beams is deflected by the polygon mirror 22 , passes through the fθ lens 23 , is reflected off the first mirrors 251 and second mirror 252 , passes through the BTL 24 , is reflected off the third mirror 253 , and scans the photoconductor 29 .",
"Thereby, the optical beams of four color components scan respective photoconductors 29 BK, 29 C, 29 M, and 29 Y. [0032] When the electrostatic latent images on the photoconductors 29 are developed and transferred onto the transfer sheet by respective image forming units 200 , the transfer belt 36 conveys the transfer sheet in a direction shown with an arrow in FIG. 1 so that a first color image is transferred onto the transfer sheet.",
"As the transfer sheet is further conveyed in the arrow direction, second, third, and fourth color images are sequentially transferred onto the transfer sheet.",
"Thereby, the full color image is formed on the transfer sheet by superimposing one image on another.",
"The full color image on the transfer sheet is fixed by a fixing device (not shown).",
"[0033] In the exemplary embodiment shown in FIG. 1 , the images are directly transferred from the photoconductors 29 to the transfer sheet to form the full color image.",
"However, an image forming apparatus having an intermediate transfer member can be applied to this exemplary embodiment.",
"When the intermediate transfer member is used, the images are transferred from the photoconductors to the intermediate transfer member, and the images transferred on the intermediate transfer member are secondarily transferred onto the transfer sheet.",
"[0034] Referring to FIG. 2 , the optical beam scanning device 20 and one of the four image forming units 200 BK, 200 C, 200 M, and 200 Y included in FIG. 1 are explained in detail.",
"Since each of the four image forming units 200 BK, 200 C, 200 M, and 200 Y is similar to other, except for the color components, one of the image forming units is shown as an example without the color abbreviation.",
"[0035] In the optical beam scanning device 20 , the laser diode 10 (shown in FIG. 3 ), the lighting of which is controlled by the image data, outputs the optical beams, and a collimate lens (not shown) collimates the optical beams output from the laser diode 10 .",
"As shown in FIG. 2 , after the optical beams pass through a cylinder lens (not shown), the optical beams enter into the mirror faces of the polygon mirror 22 .",
"The optical beams are deflected by the polygon mirror 22 , pass through the fθ lens 23 and the barrel toroidal lens 24 , are reflected off the third mirror 253 , and irradiate the photoconductor 29 .",
"[0036] As also shown in FIG. 2 , the image forming unit 200 includes the image forming elements such as the photoconductor 29 , the charging device 30 , the development unit 31 , the transfer device 32 , the cleaning unit 33 , and the discharge device 34 .",
"The photoconductor 29 includes other image forming elements in a vicinity thereof.",
"[0037] The image forming unit 200 using the electrophotographic method forms the full color image on the transfer sheet by carrying out an image forming process such as charging the photoconductor 29 by the charging device 30 , irradiating on the photoconductor 29 by the optical beam scanning device 20 so as to form the electrostatic latent image, developing the electrostatic latent image on the photoconductor 29 with toner by the development unit 31 , transferring the toner image onto the transfer sheet by the transfer device 32 , fixing the toner image on the transfer sheet by the fixing device (not shown), removing a residual toner from the photoconductor 29 by the cleaning unit 33 , and discharging the photoconductor 29 by the discharge device 34 to prepare for a next image forming.",
"[0038] The optical beams output from the laser diode 10 , which are deflected by the polygon mirror 22 , periodically scan a surface of the photoconductor 29 in a main scanning direction by a line scanning, and irradiate a receiving surface of the photoconductor 29 moving in a sub-scanning direction by each line so as to write a two-dimensional image on the receiving surface.",
"[0039] When the photoconductor 29 is irradiated, the image writing position on the photoconductor 29 needs to be constant (the same) for each scanning line so that an occurrence of an image misregistration may be reduced.",
"The synchronous detection sensor 7 (shown in FIG. 3 ) is disposed to detect the optical beams at a certain position on the scanning line of an image writing start side and generate a synchronous detection signal.",
"[0040] Referring to FIG. 3 , the synchronous detection sensor 7 detects the optical beams.",
"The color abbreviations BK, C, M, and Y for the optical elements may be omitted as necessary.",
"[0041] As shown in FIG. 3 , the plurality of optical beams emitted from the laser diode 10 in the optical beam scanning device 20 are deflected by the polygon mirror 22 , pass through the fθ lens 23 , are reflected off the first mirror 251 so as to scan the photoconductor 29 of FIGS. 1 and 2 in the main scanning direction.",
"One of the optical beams, for example, is directed towards the synchronous detection sensor 7 by reflecting off a mirror 71 which is disposed at a location before the optical beams enter into the first mirror 251 .",
"In other words, the mirror 71 is disposed outside the photoconductor 29 in the image writing start side.",
"The synchronous detection sensor 7 detects the optical beam entering at the certain position on the scanning line, and generates the synchronous detection signal.",
"[0042] The synchronous detection sensor 7 detects the optical beams, and instructs a lighting timing of the laser diode 10 for each main scanning line with the synchronous detection signal as a reference in such a manner that the image writing is controlled to begin at the certain position.",
"The lighting timing of the laser diode 10 is based on the image data written in an effective image area.",
"The control of the image writing, for example, may be provided with using the synchronous detection signal as a trigger to begin the image writing after a given time.",
"The given time may be determined by a predetermined clock period.",
"[0043] When the image forming apparatus with the tandem system forms the full color image, a number of the photoconductors to be used is equal to a number of color components.",
"Consequently, a synchronous detection signal may be needed for each color component.",
"[0044] When the images are written on the photoconductors 29 BK, 29 C, 29 M, and 29 Y by the optical beams, the synchronous detection sensor 7 detects the optical beams and controls writing timings based on synchronous detection signals for respective color components so that image writing positions on the photoconductors 29 BK, 29 C, 29 M, and 29 Y may be constant for respective scanning lines.",
"[0045] According to this exemplary embodiment, a single synchronous detection sensor 7 is disposed to detect all the optical beams and generate all the synchronous detection signals for all the colors.",
"Thereby, the configuration of the color image forming apparatus may be simplified, and the cost thereof may be reduced.",
"[0046] Referring to FIG. 4 , the color image forming apparatus shown in FIG. 1 of the exemplary embodiment of the present invention is provided with synchronous detection signals generated by the synchronous detection sensor 7 for respective color components.",
"As stated above in FIG. 1 , the optical beam scanning device 20 uses the opposite mirror faces of the polygon mirror 22 to scan and spread the deflected optical beams in opposite directions.",
"Each mirror face deflects the optical beams of two different color components at the upper and lower portions thereof.",
"This exemplary embodiment, for example, the optical beams of cyan and black are respectively entered into the upper and lower portions of the same mirror face while the optical beams of magenta and yellow are respectively entered into the upper and lower portions of another mirror face.",
"The another mirror face may be directly opposite to the same mirror face.",
"[0047] As shown in FIG. 4 , the optical beams of cyan, black, magenta and yellow are respectively output from the laser diodes 10 C, 10 BK, 10 M, and 10 Y. The laser diode 10 C is disposed above the laser diode 10 BK while the laser diode 10 M is disposed above the laser diode 10 Y so that the optical beams are deflected by respective portions of the opposite mirror faces.",
"The deflected optical beams pass the fθ lenses 23 BKC and 23 MY and are reflected off by the first mirrors 251 BK, 251 C, 251 M, and 251 Y towards respective photoconductors 29 BK, 29 C, 29 M and 29 Y. Here, a pair of deflected optical beams of cyan and black and another pair of deflected optical beams of magenta and yellow are spread symmetrically around the polygon mirror 22 , in opposite directions, so that the optical beams scan respective photoconductors 29 BK, 29 C, 29 M and 29 Y. [0048] The optical beams of the four color components to scan periodically are deflected by the polygon mirror 22 , and are directed towards the synchronous detection sensor 7 by the mirrors 71 BK, 71 C, 71 M, and 71 Y. As stated above, the mirrors 71 are disposed at locations before the optical beams are entered into the first mirrors 251 .",
"In other words, the mirrors 71 are disposed outside the photoconductors 29 in the image writing start sides.",
"The synchronous detection sensor 7 detects the optical beams of the four color components entering at the certain positions on the scanning lines, and generates the synchronous detection signals for respective color components.",
"[0049] Since the synchronous detection sensor 7 generates the synchronous detection signals, the optical beams may need to be entered into the synchronous detection sensor 7 at different timings in such a manner that the optical beams of four color components are separated by the time base.",
"[0050] Referring to FIG. 5 , the synchronous detection signals generated by the synchronous detection sensor 7 from the respective optical beams are separated by the time base.",
"The optical elements including mirrors to reflect the optical beams may be omitted as necessary in FIG. 5 .",
"[0051] The optical beams of yellow and black, for example, are reflected off the opposite mirror faces of the polygon mirror 22 , and incident beams to the synchronous detection sensor 7 are fluctuated as shown in situations 1 and 2 of FIG. 5 .",
"[0052] The situation 1 of FIG. 5 shows the optical beams at a certain timing at which, for example, the polygon mirror 22 is in a position rotated by θ from a reference position.",
"The optical beam emitted from the laser diode 10 Y is deflected by the polygon mirror 22 and is entered into the synchronous detection sensor 7 at the timing at which the polygon mirror 22 is in the position of the θ rotation.",
"At the same time, the optical beam BK emitted by the laser diode 10 BK is not deflected towards the synchronous detection sensor 7 .",
"[0053] The situation 2 of FIG. 5 shows the optical beams at another timing at which the polygon mirror 22 is in a position rotated by θ+Δθ from the reference position.",
"The optical beam emitted from the laser diode 11 BK is deflected by the polygon mirror 22 and is entered to the synchronous detection sensor 7 at this timing and the optical beam Y is not deflected towards the synchronous detection sensor 7 .",
"The optical beams emitted from the laser diodes 10 Y and 10 BK are stated as examples.",
"However, the optical beams of cyan and magenta are similar to those of black and yellow.",
"For example, the optical beams emitted from the laser diodes 10 C and 10 M are entered to the synchronous detection sensor 7 at timings at which the polygon mirror 22 is in a position rotated by θ+2Δθ and θ+3Δθ respectively from the reference position.",
"[0054] As the polygon mirror 22 is rotated in different positions by different angles, the optical beams of the four color components are detected at different timings.",
"Thereby, the synchronous detection signals are separated one from another by the time base.",
"[0055] The synchronous detection signals separated by the time base are used as reference signals for respective color components so as to instruct lighting timings of laser diodes 10 Y, 10 M, 10 C, and 10 BK and control the beginning of image writing at the certain positions.",
"The lighting timings of laser diodes 10 Y, 10 M, 10 C, and 10 BK are based on the image data written in the effective image areas for respective main scanning lines.",
"[0056] A related art image forming apparatus applies a synchronous detection signal of only a single color to commonly use for all four color components so that optical beams are spread and opposed.",
"In other words, only the optical beams of the single color are deflected by one mirror face of a polygon mirror, and are detected by a detection sensor so as to be commonly used for all the four color components.",
"However, the related art image forming apparatus has generated a jitter that disturbs the image.",
"[0057] The image forming apparatus of this exemplary embodiment shown in FIG. 1 though FIG. 5 , on the other hand, employs the polygon mirror 22 that generates the synchronous detection signals of each of the four color components from the optical beams of respective color components.",
"Therefore, an occurrence of the jitter may be reduced and a quality of the writing image may remain high.",
"[0058] This exemplary embodiment of the present invention stated above uses the polygon mirror 22 to deflect the optical beams.",
"The deflected optical beams are spread and (symmetrically) centered opposite to each other around the polygon mirror 22 .",
"For example, when the images are written on the four photoconductors, the sensor outputs of the optical beams of the four colors are used as the synchronous detection signals of respective colors.",
"As shown in FIG. 1 and FIG. 5 , the optical beams of the four color components are spread and opposed to scan, and each of the optical beams of two color components are entered into one of the mirror faces of the polygon mirror 22 .",
"Each mirror face has upper and lower portions to deflect the optical beams of the two colors.",
"When one mirror face deflects a plurality of optical beams in this exemplary embodiment shown FIG. 1 through FIG. 5 , a likelihood of an error occurrence between the plurality of optical beams may be significantly small.",
"Therefore, the color image forming apparatus of this embodiment may be simplified so as to, for example, reduce costs thereof by another exemplary embodiment shown in FIG. 6 .",
"[0059] In the exemplary embodiment shown in FIG. 6 , the synchronous detection sensor 7 , detecting the optical beam of one color component deflected by one mirror face of the polygon mirror 22 , generates the synchronous detection sensor that may be commonly used for the optical beam of another color component deflected by the same mirror face.",
"Thereby, a number of the optical beams to be detected may be reduced, and the color image forming apparatus may be configured to be simplified, for example, without having the mirrors 71 C and 71 Y. In other words, only one control signal is generated for those optical beams reflected on faces provided on a same side of the polygon mirror 22 .",
"[0060] Referring to FIG. 6 , another exemplary embodiment of the present invention employing another method to generate the synchronous detection signal by the synchronous detection sensor 7 in the color image forming apparatus with the tandem system of FIG. 1 is described.",
"As the optical elements of FIG. 6 are similar to those of FIG. 4 , except for the mirrors 71 C and 71 Y, reference numbers used in FIG. 4 and FIG. 6 may be similar.",
"[0061] Similar to FIG. 4 , the optical beam scanning device 20 of this exemplary embodiment shown in FIG. 6 uses the polygon mirror 22 having the mirror faces.",
"Thereby, the optical beams of two color components are entered into one of the mirror faces while the optical beams of other two color components are entered into another mirror face so that the optical beams emitted from the laser diodes 10 BK, 10 C, 10 Y, and 10 M are spread into two, for example, black and cyan, and magenta and yellow.",
"The optical beams of black and cyan, and magenta and yellow scan respective photoconductors in opposite directions.",
"As these optical elements are similar to those of FIG. 4 , a detailed description of each optical element may be omitted.",
"[0062] As shown in FIG. 6 , the synchronous detection sensor 7 detects the optical beams of black and magenta.",
"The optical beams of four color components are deflected by the polygon mirror 22 .",
"However, the optical beams of black and magenta out of the four colors are respectively reflected off the mirrors 71 BK and 71 M so as to be directed towards the synchronous detection sensor 7 .",
"The mirrors 71 BK and 71 K are disposed at the locations before the optical beams are entered into the first mirrors 251 BK and 251 M. In other words, the mirrors 71 BK and 71 M are disposed outside the photoconductors 29 in the image writing start sides.",
"The synchronous detection sensor 7 detects the optical beams of black and magenta entering at the certain positions on the scanning lines, and generates the synchronous detection signals for respective color components.",
"[0063] Since one piece of the synchronous detection sensor 7 generates the synchronous detection signals of different color components, the optical beams may need to be entered into the synchronous detection sensor 7 at different timings in such a manner that the optical beams of different color components are separated by the time base.",
"That is similar to the exemplary embodiment previously stated in FIG. 5 .",
"[0064] The synchronous detection signals of the optical beams of black and magenta detected by the synchronous detection sensor 7 are separated by the time base and are used as the reference signals for respective color components so as to instruct the lighting timings of the laser diodes 10 BK and 10 M and control the beginning of the image writing at the certain positions.",
"The lighting timings of laser diodes 10 BK and 10 M are based on the image data written in the effective image areas for respective main scanning lines.",
"[0065] The optical beams of other color components such as cyan and yellow are described as follows.",
"The optical beam of cyan is deflected by the mirror face of the polygon mirror 22 by which the optical beam of black is deflected.",
"The optical beams of cyan and black use the same mirror face so as to be deflected.",
"Similarly, the optical beams of yellow and magenta are deflected by another mirror face of the polygon mirror 22 .",
"The optical beams of cyan and yellow respectively use the synchronous detection signals of the optical beams of black and magenta.",
"[0066] In other words, the synchronous detection signal of black is commonly used for the optical beams of cyan and black while the synchronous detection signal of magenta is commonly used for the optical beams of yellow and magenta.",
"Thereby, the optical beams of cyan and yellow respectively use the synchronous detection signals of black and magenta to instruct the lighting timings of the laser diodes 10 C and 10 Y, and control the beginning of the image writing at the certain positions.",
"[0067] According to this exemplary embodiment, the synchronous detection sensor 7 detecting the optical beam of one color component deflected by one mirror face of the polygon mirror 22 generates the synchronous detection signal that may be commonly used for the optical beam of another color component deflected by the same mirror face.",
"Therefore, an occurrence of the jitter stated above in the related art image forming apparatus may be reduced, and the quality of the writing image may remain high.",
"[0068] Still another exemplary embodiment of the present invention will be described in FIG. 7 .",
"This exemplary embodiment of FIG. 7 includes an adjustment process to reduce an error occurrence when the synchronous detection sensor 7 shown in the exemplary embodiments of FIG. 4 and FIG. 6 is used to detect the synchronous detection signals of a plurality of the optical beams.",
"[0069] These exemplary embodiments shown in FIG. 4 and FIG. 6 respectively detect the optical beams of four and two color components by the synchronous detection sensor 7 .",
"Regardless of FIG. 4 and FIG. 6 , the optical beams entering into the synchronous detection sensor 7 are inclined against a detection face of the synchronous detection sensor 7 because of an arrangement of the optical elements.",
"[0070] Referring to FIG. 7 , the optical beams are entered into the synchronous detection sensor 7 in a state that the optical beams are inclined relative to a normal to the surface of the synchronous detection sensor 7 .",
"When the inclined optical beams are entered into the synchronous detection sensor 7 , a detection light intensity detected by the synchronous detection sensor 7 may be reduced compared to a largest light intensity which may be detected in a case where the optical beams are vertically entered.",
"Consequently, the synchronous detection signals from the synchronous detection sensor 7 may have an error.",
"When the detection amount fluctuates with a variation in an incident angle that is an angle of the optical beam to enter into the synchronous detection sensor 7 , timings of the synchronous detection signals may be slightly fluctuated.",
"[0071] When the inclined optical beams are entered into the synchronous detection sensor 7 , the light intensity of the inclined optical beams are adjusted in such a manner that a suitable light intensity is provided.",
"For example, when the optical beams are spread and opposed to scan as shown in FIG. 7 , one side of the optical beams is called an optical beam 1 , and another side of the optical beams is called an optical beam 2 .",
"The optical beams 1 and 2 are assumed to have incident angles α and β degrees respectively.",
"When the optical beam 1 is entered at the α degree of incident angle, the light intensity may be reduced by α% from a case where the optical beam is vertically entered.",
"When the optical beam 2 is entered at the β degree, the light intensity may be reduced by β% from a case where optical beam is vertically entered.",
"The reduction of the light intensity may be controlled by a lighting control unit 12 of the laser diode as shown in FIG. 3 .",
"Therefore, the lighting control unit 12 controlling the lighting of the laser diode 10 transmits an intensity adjustment signal to a driving unit 14 of the laser diode so as to adjust the light intensity of the laser diode and obtain the suitable light intensity.",
"The intensity adjustment signals are transmitted to, for example, increase the optical beams 1 and 2 by α% and β% respectively in this exemplary embodiment.",
"Therefore, an occurrence of shifting the writing timing between the optical beams 1 and 2 may be reduced.",
"[0072] Each exemplary embodiment of the present invention above is illustrated by applying to the color image forming apparatus with the electrophotographic method that the images are written by the optical beams having the image data of the four color components.",
"However, the stated disclosure and description of the exemplary embodiments are illustrative only and are not to be considered limiting.",
"The present invention may be applied to an area employing an optical writing method by using a plurality of optical beams, for example, an area in which data is written and/or recorded to an optical recording medium utilizing a photo-magnetic effect.",
"[0073] Numerous additional modifications and variation are possible in light of the above teachings.",
"It is therefore to be understood that within the scope of the appended claims, the disclosure of this patent specification may be practiced otherwise than as specifically described herein."
] |
This invention relates to a method for purifying molybdenum which involves water washng molybdenum dioxide to reduce the potassium content.
BACKGROUND OF THE INVENTION
Molybdenum compounds of high purity are required for various applications such as in catalysts, etc.
Heretofore there have been a number of procecesses for upgrading relatively impure molybdenum compounds.
U.S. Pat. No. 3,957,946 discloses a process for purifying molybdenum which involves subjecting impure concentrates of molybdenum trioxide to oxidative roasting, followed by ammoniacal leaching of the molybdic trioxide to produce ammonium molybdate which is further purified by passage through a chelating cation exchange resin.
U.S. Pat. Nos. 3,848,049 and 3,829,550 disclose purification processes for molybdenum which involve leaching of molybdenum trioxide with dilute nitric acid.
U.S. Pat. No. 3,694,147 discloses a process for purifying molybdenum trioxide of impurities such as lead, copper, iron, and zinc and some alkaline earths by leaching with an aqueous solution and an ammonium salt of the halide.
U.S. Pat. No. 3,860,419 relates to the process for recovering molybdenum from molybdenum concentrates by digesting the concentrate in an aqueous nitric acid solution containing ammonium nitrate, separating the solid phase from the liquid phase, and treating the solid phase with ammonium hydroxide to produce ammonium molybdate.
U.S. Pat. No. 4,079,116 relates to a process for producing high purity ammonium molybdate, ammonium heptamolybdate or ammonium dimolybdate from a molybdenum oxide concentrate by a series of operations which involve cation removal, leaching, etc.
In the above processes, some impurities remain to contaminate the product.
Potassium in molybdenum can interfere with sintering, resulting in low density. Potassium is a particularly difficult impurity to remove. When U.S. Pat. No. 3,860,419 is followed for purifying molybdenum, the potassium is not sufficiently reduced for use as high purity material.
U.S. Pat. No. 3,393,971 relates to a process of re-roasting molybdenum trioxide followed by water washing the molybdenum trioxide and then forming an ammonium molybdate (AM) solution from which ammonium paramolybdate (APM) is produced. The APM is then oxidized to produce pure molybdenum trioxide.
SUMMARY OF THE INVENTION
In accordance with one aspect of this invention, there is provided a method for purifying molybdenum which involves reducing a molybdenum compound selected from the group consisting of molybdenum trioxide, ammonium dimolybdate, and ammonium paramolybdate to molybdenum dioxide which is then water washed to remove potassium and produce a purified molybdenum dioxide having a potassium content of no greater than about 30 weight ppm, followed by separating the wash water from the purified molybdenum dioxide.
DETAILED DESCRIPTION OF THE INVENTION
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above description of some of the aspects of the invention.
This invention relates to the purification of molybdenum especially with respect to potassium. It is desirable that potassium in molybdenum be reduced as low as possible. Levels in the range of about 200 weight ppm and even as low as about 80 ppm are undesirable because they cause problems such as lower density after pressing and higher strain hardening coefficients in the molybdenum metal produced therefrom.
The starting molybdenum to be purified by the method of this invention is relatively pure molybdenum trioxide, ammonium dimolybdate or ammonium paramolybdate. The major criterion is that the potassium in the starting molybdenum compound be no greater than about 200 weight ppm. The method does not work efficiently if the potassium content is higher than this. It is sometimes desirable that these molybdenum compounds be prepurified by known methods to reduce the impurity levels to no greater than about 200 ppm.
The staring moybdenum compound of this invention can be pre-purified, that is the potassium content can be reduced to no greater than about 200 weight ppm in any number of ways. For example, technical grade molybdenum trioxide can be subjected to known purification methods. The pre-purified molybdenum trioxide which must have a potassium content of no greater than about 200 weight parts per million can then be subjected to the method of this invention to further reduce the potassium level.
One method of pre-purifying molybdenum trioxide is by washing it with water or acids to purify it before the reduction to the dioxide. This step is carried out if the potassium level is greater than about 200 weight ppm.
Acid leaching of technical grade molybdenum trioxide is a known method to remove potassium from molybdenum. However, all of the potassium is not removed by this processing.
Water washing of technical grade molybdenum trioxide is also used. A disadvantage of this is the significant loss of Mo to the water. The Mo must be recovered for economy. Also technical grade molybdenum trioxides are re-roasted to maximize separation of K from Mo. One method requires re-roasted trioxide to be cooled very quickly. The re-roasting and quick cooling are costly operations.
The starting molybdenum compound to be reduced according to the method of this invention to molybdenum dioxide is either molybdenum trioxide, ammonium dimolybdate, or ammonium paramolybdate.
The starting molybdenum compound is reduced to molybdenum dioxide by standard methods.
When the molybdenum dioxide is obtained, it is water washed to remove the potassium followed by removal of the wash water. This can be done by any technique known in the art. For example, it can be done by slurrying the molybdenum dioxide in water. It is preferred to have a relatively dilute slurry for optimum contact of the molybdenum dioxide particles with the water, But the amount of water, must not be excessive, so that the process remains cost effective. Typically, the slurry is such that the solids content is from about 20% to about 50% by weight. The resulting wash water is then separated from the purified molybdenum dioxide by any standard technique such as filtration or decantation.
Another technique of washing is discharging the molybdenum dioxide from the calciner after the reduction step to a belt filter that passes beneath a water spray. It is believed that the reason that the potassium can be reduced so low by washing the molybdenum dioxide is that the potassium is on the surface of the dioxide as a result of being exposed to the high temperatures of the prior reduction step. Therefore it can be washed off easily. If the potassium is in the bulk of the molybdenum dioxide, it would not be able to be washed off.
By the method of this invention, the potassium level is reduced to no greater than about 30 weight ppm. At these low levels, potassium does not pose problems in the molybdenum.
One prior art technique for removing K from molybdenum dioxide is to use temperature of final reduction to MoO 2 to Mo as the basis for removing the K. The disadvantage of this technique is the inability to use lower temperatures, at which certain desirable powder properties are obtained such as extremely fine particle sizes.
To more fully illustrate this invention, the following nonlimiting examples are presented.
EXAMPLE 1
ADM is reduced to molybdenum dioxide which contains 80 weight ppm potassium and 10 weight ppm sodium. Twenty grams of MoO 2 are slurried with 80 grams of pure water, rapidly at room temperature for about 1 hour. The MoO 2 is separated from the wash water and dried. The washed MoO 2 contains about 30 weight ppm K and <5 ppm Na.
EXAMPLE 2
ADM is reduced to molybdenum dioxide, which contains about 86 weight ppm K and about 6 weight ppm Na. About 81 g of molybdenum dioxide is stirred rapidly in about 400 ml of water for about 1 hour at room temperature. The molybdenum dioxide is separated from the water and dried. It contains about 30 weight ppm K and <5 weight ppm Na.
While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | A method is disclosed for purifying molybdenum which involves reducing a molybdenum compound selected from the group consisting of molybdenum trioxide, ammonium dimolybdate, and ammonium paramolybdate to molybdenum dioxide which is then water washed to remove potassium, and produce a purified molybdenum dioxide having a potassium content of no greater than about 30 weight ppm, followed by separating the wash water from the purified molybdenum dioxide. | Identify the most important claim in the given context and summarize it | [
"This invention relates to a method for purifying molybdenum which involves water washng molybdenum dioxide to reduce the potassium content.",
"BACKGROUND OF THE INVENTION Molybdenum compounds of high purity are required for various applications such as in catalysts, etc.",
"Heretofore there have been a number of procecesses for upgrading relatively impure molybdenum compounds.",
"U.S. Pat. No. 3,957,946 discloses a process for purifying molybdenum which involves subjecting impure concentrates of molybdenum trioxide to oxidative roasting, followed by ammoniacal leaching of the molybdic trioxide to produce ammonium molybdate which is further purified by passage through a chelating cation exchange resin.",
"U.S. Pat. Nos. 3,848,049 and 3,829,550 disclose purification processes for molybdenum which involve leaching of molybdenum trioxide with dilute nitric acid.",
"U.S. Pat. No. 3,694,147 discloses a process for purifying molybdenum trioxide of impurities such as lead, copper, iron, and zinc and some alkaline earths by leaching with an aqueous solution and an ammonium salt of the halide.",
"U.S. Pat. No. 3,860,419 relates to the process for recovering molybdenum from molybdenum concentrates by digesting the concentrate in an aqueous nitric acid solution containing ammonium nitrate, separating the solid phase from the liquid phase, and treating the solid phase with ammonium hydroxide to produce ammonium molybdate.",
"U.S. Pat. No. 4,079,116 relates to a process for producing high purity ammonium molybdate, ammonium heptamolybdate or ammonium dimolybdate from a molybdenum oxide concentrate by a series of operations which involve cation removal, leaching, etc.",
"In the above processes, some impurities remain to contaminate the product.",
"Potassium in molybdenum can interfere with sintering, resulting in low density.",
"Potassium is a particularly difficult impurity to remove.",
"When U.S. Pat. No. 3,860,419 is followed for purifying molybdenum, the potassium is not sufficiently reduced for use as high purity material.",
"U.S. Pat. No. 3,393,971 relates to a process of re-roasting molybdenum trioxide followed by water washing the molybdenum trioxide and then forming an ammonium molybdate (AM) solution from which ammonium paramolybdate (APM) is produced.",
"The APM is then oxidized to produce pure molybdenum trioxide.",
"SUMMARY OF THE INVENTION In accordance with one aspect of this invention, there is provided a method for purifying molybdenum which involves reducing a molybdenum compound selected from the group consisting of molybdenum trioxide, ammonium dimolybdate, and ammonium paramolybdate to molybdenum dioxide which is then water washed to remove potassium and produce a purified molybdenum dioxide having a potassium content of no greater than about 30 weight ppm, followed by separating the wash water from the purified molybdenum dioxide.",
"DETAILED DESCRIPTION OF THE INVENTION For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above description of some of the aspects of the invention.",
"This invention relates to the purification of molybdenum especially with respect to potassium.",
"It is desirable that potassium in molybdenum be reduced as low as possible.",
"Levels in the range of about 200 weight ppm and even as low as about 80 ppm are undesirable because they cause problems such as lower density after pressing and higher strain hardening coefficients in the molybdenum metal produced therefrom.",
"The starting molybdenum to be purified by the method of this invention is relatively pure molybdenum trioxide, ammonium dimolybdate or ammonium paramolybdate.",
"The major criterion is that the potassium in the starting molybdenum compound be no greater than about 200 weight ppm.",
"The method does not work efficiently if the potassium content is higher than this.",
"It is sometimes desirable that these molybdenum compounds be prepurified by known methods to reduce the impurity levels to no greater than about 200 ppm.",
"The staring moybdenum compound of this invention can be pre-purified, that is the potassium content can be reduced to no greater than about 200 weight ppm in any number of ways.",
"For example, technical grade molybdenum trioxide can be subjected to known purification methods.",
"The pre-purified molybdenum trioxide which must have a potassium content of no greater than about 200 weight parts per million can then be subjected to the method of this invention to further reduce the potassium level.",
"One method of pre-purifying molybdenum trioxide is by washing it with water or acids to purify it before the reduction to the dioxide.",
"This step is carried out if the potassium level is greater than about 200 weight ppm.",
"Acid leaching of technical grade molybdenum trioxide is a known method to remove potassium from molybdenum.",
"However, all of the potassium is not removed by this processing.",
"Water washing of technical grade molybdenum trioxide is also used.",
"A disadvantage of this is the significant loss of Mo to the water.",
"The Mo must be recovered for economy.",
"Also technical grade molybdenum trioxides are re-roasted to maximize separation of K from Mo.",
"One method requires re-roasted trioxide to be cooled very quickly.",
"The re-roasting and quick cooling are costly operations.",
"The starting molybdenum compound to be reduced according to the method of this invention to molybdenum dioxide is either molybdenum trioxide, ammonium dimolybdate, or ammonium paramolybdate.",
"The starting molybdenum compound is reduced to molybdenum dioxide by standard methods.",
"When the molybdenum dioxide is obtained, it is water washed to remove the potassium followed by removal of the wash water.",
"This can be done by any technique known in the art.",
"For example, it can be done by slurrying the molybdenum dioxide in water.",
"It is preferred to have a relatively dilute slurry for optimum contact of the molybdenum dioxide particles with the water, But the amount of water, must not be excessive, so that the process remains cost effective.",
"Typically, the slurry is such that the solids content is from about 20% to about 50% by weight.",
"The resulting wash water is then separated from the purified molybdenum dioxide by any standard technique such as filtration or decantation.",
"Another technique of washing is discharging the molybdenum dioxide from the calciner after the reduction step to a belt filter that passes beneath a water spray.",
"It is believed that the reason that the potassium can be reduced so low by washing the molybdenum dioxide is that the potassium is on the surface of the dioxide as a result of being exposed to the high temperatures of the prior reduction step.",
"Therefore it can be washed off easily.",
"If the potassium is in the bulk of the molybdenum dioxide, it would not be able to be washed off.",
"By the method of this invention, the potassium level is reduced to no greater than about 30 weight ppm.",
"At these low levels, potassium does not pose problems in the molybdenum.",
"One prior art technique for removing K from molybdenum dioxide is to use temperature of final reduction to MoO 2 to Mo as the basis for removing the K. The disadvantage of this technique is the inability to use lower temperatures, at which certain desirable powder properties are obtained such as extremely fine particle sizes.",
"To more fully illustrate this invention, the following nonlimiting examples are presented.",
"EXAMPLE 1 ADM is reduced to molybdenum dioxide which contains 80 weight ppm potassium and 10 weight ppm sodium.",
"Twenty grams of MoO 2 are slurried with 80 grams of pure water, rapidly at room temperature for about 1 hour.",
"The MoO 2 is separated from the wash water and dried.",
"The washed MoO 2 contains about 30 weight ppm K and <5 ppm Na.",
"EXAMPLE 2 ADM is reduced to molybdenum dioxide, which contains about 86 weight ppm K and about 6 weight ppm Na.",
"About 81 g of molybdenum dioxide is stirred rapidly in about 400 ml of water for about 1 hour at room temperature.",
"The molybdenum dioxide is separated from the water and dried.",
"It contains about 30 weight ppm K and <5 weight ppm Na.",
"While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims."
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 1,625, filed Jan. 8, 1979.
BACKGROUND OF THE INVENTION
This invention relates to a yarn finish composition. More particularly, this invention relates to a yarn finish composition for incorporation with synethetic organic polymer yarn or yarn products to render the same oil repellent and resistant to soiling. This invention further relates to emulsions which include the aforementioned yarn finish composition as a component thereof.
The treatment of textiles with fluorochemicals to impart oil repellency and soil resistance has been known for some time. U.S. application Ser. No. 861,372, filed Dec. 16, 1977, discloses that polycarboxybenzenes esterfied with certain partially fluorinated alcohols and with hydroxyl-containing organic radicals such as 2-hydroxyethyl, glyceryl, and chlorohydryl or bromohydryl, when incorporated with polyethylene terephthalate or synthetic long-chain polyamide fibers as by contact in a liquid medium, concentrate at the fiber surface, especially if the fiber is annealed. A relatively durable oil and water repellency is thus imparted to the fiber. Commonly assigned U.S. Pat. No. 4,134,839 to Marshall, hereby incorporated by reference, indicates that the oil repellent fluorocarbon compounds of U.S. application Ser. No. 861,372 are not compatible with the lubricating oils in spin finishes used in a conventional spin finish, and further, that the emulsifying componenets of some known spin finishes are not suitable for preparing an oil in water emulsion containing these oil repellent fluorocarbon compounds. U.S. Pat. No. 4,134,839 discloses a spin finish which has the oily properties of a conventional spin finish and which also imparts to the yarn the oil repellent properties of the fluorocarbon finish of U.S. application Ser. No. 861,372. However, we have found that the disclosed spin finish causes serious processing problems when a finish circulating pump is utilized in the finish circulation system of a conventional spinning process, i.e., the flurocarbon separates, clogs and stops the finish circulating pump. Accordingly, extensive research has been carried out to develop an improved spin finish which possesses the desirable properties of both of the aforementioned applications and which will not gradually separate in the finish circulation system during commercial processing of the yarn. As a by-product of this research, a yarn finish composition (applied separately from the lubricating spin finish) has been discovered which, when incorporated with synthetic organic polymer yarn or yarn products, renders the same oil repellent and resistant to soiling.
SUMMARY OF THE INVENTION
The present invention provides a yarn finish composition for incorporation with synthetic organic polymer yarn or yarn products to render the same oil repellent and resistant to soiling.
The yarn finish composition of the present invention comprises (a) about 15 to 80 weight percent of a nonhomogeneous mixture of a salt of dinonyl sulfosuccinate, a salt of dimethyl naphthalene sulfonate, and ammonium perfluoroalkyl carboxylate; and (b) about 20 to 85 weight percent of a fluorochemical compound. The fluorochemical compound has the formula ##STR1## wherein the attachment of the fluorinated radicals and the radicals CO 2 B to the nucleus is in asymmetrical positions with respect to rotation about the axis through the center of the nucleus; wherein "X" is fluorine, or perfluoroalkoxy of 1 to 6 carbon atoms, and m has arithmetic mean between 2 and 20; n is zero or unity; "W" and "Y" are alkylene, cycloalkylene or alkyleneoxy radicals of combined chain length from 2 to 20 atoms; (CF 2 ) m and "Y" have each at least 2 carbon atoms in the main chain; "Z" is oxygen and p is 1, or "Z" is nitrogen and p is 2; q is an integer of at least 2 but not greater than 5; "B" is CH 2 RCHOH or is CH 2 RCHOCH 2 RCHOH where "R" is hydrogen or methyl, or "B" is CH 2 CH(OH)CH 2 Q where Q is halogen, hydroxy, or nitrile, or " B" is CH 2 CH(OH)CH 2 OCH 2 CH(OH)CH 2 Q; and r is an integer of at least 1 but not greater than q; and X(CF 2 ) m , W and Y are straight chains, branched chains or cyclic; and wherein the substituent chains of the above general formulas are the same or different.
The nonhomogeneous mixture forming a part of the yarn finish composition preferably consists essentially of about 20 to 60 percent by weight of the salt of dinonyl sulfosuccinate, about 5 to 23 percent by weight of the salt of dimethyl naphthalene sulfonate, and about 17 to 60 percent by weight of ammonium perfluoroalkyl carboxylate.
The yarn finish composition of the present invention can be applied in any known manner to synthetic organic polymer fiber, yarn to yarn products, e.g., by spraying the fiber, yarn to yarn products or by dipping them into or otherwise contacting them with the composition. It is preferred that an emulsion of water and approximately 5 to 25 percent by weight of the emulsion of the composition, be formed for application to the yarn or yarn products. This emulsion can be applied during spinning of the yarn with, preferably, a conventional spin finish being applied to the yarn just prior to or subsequent to application of the emulsion, e.g., by tandem (in series) kiss rolls. The emulsion can alternatively be applied as an overfinish during beaming of the yarn or at any other processing stage. Staple fiber can be treated by spraying. Further, fabric or carpet made from synthetic organic polymer yarn can be treated with the emulsion, e.g., by spraying, padding, or dipping in a conventional manner.
This invention includes also polyamide and polyester and other polymer fibers, yarns and yarn products having incorporated therewith the yarn finish composition or emulsion as above defined. The yarn finish composition of the present invention renders yarn and resistant to soiling, especially by oily materials.
Throughout the present specification and claims, the term "yarn" is employed in a general sense to indicate strand material, either textile or otherwise, and including a continuous, often plied, strand composed of fibers or filaments, or a noncontinuous strand such as staple, and the like. The term "yarn" also is meant to include fiber, such as continuous single filaments of a yarn, or individual strands of staple fiber before drafting and spinning into a conventional staple yarn. The term "yarn product" is likewise used in a general sense to indicate the end use of the yarn, and includes both fabrics used in apparel, upholstery, draperies, and similar applications, as well as carpets, either prior to or subsequent to dyeing and/or printing. The phrase "synthetic organic polymer" generally includes any fiber-forming thermoplastic resin, such as polypropylene, polyamide, polyester, polyacrylonitrile and blends thereof. The phrase "during commercial processing of the yarn" refers generally to any yarn process which utilzes a finish circulating pump in its finish circulation system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred fluorochemical compounds which are useful in the yarn finish composition and emulsion of the present invention are trimellitates and pyromellitates. They can be represented by the following formulas, wherein A and A' represent the same or different radicals X(CF 2 ) m W(CONH) n Y of formula I above, and wherein each A and A' radical has a main chain containing at least six carbon atoms and contains at least four perfluorinated carbon atoms in the radical. In the following formulas, B is as previously defined with Formula I above and B' is the same or different radical. ##STR2##
The above fluorinated radicals A, A' are likewise preferred in the various other compounds of the invention, in particular in bis(diamide)/esters of trimellitic acid and of pyromellitic acid in accordance with this invention.
Fluorochemical compounds which are more particularly preferred are mixtures of substituted pyromellitic acid or trimellitic acid position isomers, especially mixtures of the para and meta pyromellitate position isomers, represented by Formulas III (a) and (b) above, with A═A' and B═B', and A containing at least six perfluorinated carbon atoms, and not over four other chain atoms therein; especially such mixtures containing about 50:50 molar proportions of each of the two-position isomers of Formula III. The attachment of the radicals in the para isomer (see Formula III (a) above) is symmetrical with respect to rotation 180 degrees about the axis through the center of the nucleus. This isomer, used alone, shows relatively low repellency. Nevertheless, when the para isomer is mixed in about 50:50 molar ratio with the meta isomer (which is unsymmetrical with respect to rotation about such axis), the mixture shows repellency essentially equal to the good repellency of the substantially pure meta isomer used alone in the same amount. The corresponding bis(diamide)/esters of the substituted acids are likewise preferred.
It will be appreciated that although overall the radicals A and A' will both be the same and the radicals B and B' will both be the same in the preferred fluorochemical compounds, they may nevertheless vary within individual molecules because a mixture of fluorinated alcohols will generally be used to obtain the fluorinated radicals A, and because epoxides used to obtain the radicals B may react further to form dimers or higher polymers of the B radicals.
In especially preferred radicals A and A', the fluorinated moiety has the formula CF 3 (CF 2 ) m or (CF 3 ) 2 CFO(CF 2 ) m ' where m independently at each occurrence has any integral value from 5 to 9, m' independently at each occurrence has any integral value from 2 to 16, and (CF 2 ) m and (CF 2 ) m ' are straight chains.
Preferred radicals B and B' are CH 2 CH 2 OH, CH 2 CH(OH)CH 2 Cl, CH 2 CH(OH)CH 2 OH and CH 2 CH(OH)CH 2 Br.
The fluorinated radicals in the fluorochemical compounds useful in this invention are provided in general by reaction between a benzene polycarboxylic acid anhydride or carboxy chloride/anhydride, which can be additionally substituted in the benzene ring, and an appropriate fluorinated alcohol or amine. The corresponding carboxylic acid/half ester containing a fluorinated esterifying radical and a carboxy group is produced from the anhydride group reacting with an alcohol; or when the compound is an amide rather than an ester, the appropriate fluorinated amine is used as reactant instead of the alcohol, with production of a fluorinated amido group and a carboxy group. All free carboxy groups can then be esterified by base-catalyzed reaction with the epoxide corresponding to the desired "B" group in the compound.
The invention will now be further described in the following specific examples which are to be regarded solely as illustrative and not as restricting the scope of the invention. In particular, although the examples are limited to polyamide and polyester yarns and yarn products, it will be appreciated that the yarn finish composition and emulsion of the present invention can be applied to yarn made from any synthetic organic polymer filaments and products thereof. Further, although the examples are limited to sodium dinonyl sulfosuccinate, the dinonyl sulfosuccinates useful in this invention are of the salts of dinonyl sulfosuccinates, especially the ammonium salt and the alkali metal, particularly sodium and potassium, salts of a dinonyl ester of sulfosuccinic acid. Likewise, while the examples are limited to dimethyl naphthalene sodium sulfonate, the dimethyl naphthalene sulfonates useful in this invention are of the salts of dimethyl naphthalene sulfonate, especially the ammonium salt and the alkali metal, particularly sodium and potassium, salts of dimethyl naphthalene sulfonate. In the following examples, parts and percentages employed are by weight unless otherwise indicated.
EXAMPLE 1
The fluorochemical used in this example was a mixture of pyromellitates having the following structure: ##STR3## For convenience, this mixture of pyromellitates is hereinafter called Fluorochemical Composition-1. About 46.3 parts of Fluorochemical Composition-1 were added to 53.7 parts of a nonhomogeneous mixture which consisted essentially of about 41.3 percent by weight of Nekal WS-25, about 17.4 percent by weight of dimethyl naphthalene sodium sulfonate and about 41.3 percent by weight of ammonium perfluoroalkyl carboxylate. Nekal WS-25 is General Aniline and Film Corporation's trade name for a solution of 75 percent by weight sodium dinonyl sulfosuccinate, 10 percent by weight isopropanol, and 15 percent by weight water. The ammonium perfluoroalkyl carboxylate is manufactured under the trade name of FC-143 and obtainable from the 3M Company, Chemical Division, 900 Bush Avenue, St. Paul, Minnesota. The Fluorochemical Composition-1 and mixture were heated to 80° C., at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous first noncontinuous phase. It is believed that the isopropanol vaporized, and is not present in the final composition. This first noncontinuous phase was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for at least 30 days without signs of separation. For convenience, this emulsion is called Emulsion-1.
It should be noted that in forming Emulsion-1 or the first noncontinuous phase above, Fluorochemical Composition-1 and the solution can be heated to a temperature of between approximately 75° C. and 90° C. The temperature of the water should correspond approximately to that of the first noncontinuous phase when it is added to the water. The resultant emulsion can be cooled to a temperature between approximately 50° C. and 70° C.
To Emulsion-1 was added 100 parts of a second noncontinuous phase consisting essentially of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 pecent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid. The resulting emulsion was stable for at least 30 days and was suitable for use as a spin finish as described hereinafter. For convenience, this emulsion is called Spin Finish-1.
EXAMPLE 2
The procedure of Example 1 is followed except that 46.3 parts of Fluorochemical Composition-1, 53.7 parts of the mixture, and 400 parts of water are used to form an emulsion, which is called Emulsion-2. The oil particles in this emulsion have a particle size of less than one micron, and the emulsion is stable for at least 30 days without signs of separation.
Emulsion-2 is then blended with 500 parts of another oil in water emulsion containing 20 percent of an oil composition consisting essentially of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 percent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid. The resulting emulsion is stable for at least 30 days and is suitable for use as a spin finish as described hereinafter. For convenience, this emulsion is called Spin Finish-2. Spin Finish-1 and Spin Finish-2 may be used in the same manner to coat yarn during or subsequent to spinning.
EXAMPLE 3
This example demonstrates use of Spin Finish-1 in a conventional spin-draw process for production of a polyamide yarn suitable for processing into bulked yarn that is oil repellent and resistant to soiling, especially by oily materials.
A typical procedure for obtaining polymer pellets for use in this example is as follows. A reactor equipped with a heater and stirrer is charged with a mixture of 1,520 parts of epsilon-caprolactam and 80 parts of aminocaproic acid. The mixture is then flushed with nitrogen and stirred and heated to 255° C. over a one-hour period at atmospheric pressure to produce a polymerization reaction. The heating and stirring is continued at atmospheric pressure under a nitrogen sweep for an additional four hours in order to complete the polymerization. Nitrogen is then admitted to the reactor and a small pressure is maintained while the polycaproamide polymer is extruded from the reactor in the form of a polymer ribbon. The polymer ribbon is subsequently cooled, pelletized, washed and dried. The polymer is a white solid having a relative viscosity of about 50 to 60 as determined at a concentration of 11 grams of polymer in 100 ml. of 90 percent formic acid at 25° C. (ASTM D-789-62T).
Polyamide polymer pellets prepared in accordance, generally, with the procedure above were melted at about 285° C. and melt extruded under pressure of about 1,500 psig. through a 70-orifice spinnerette to produce an undrawn yarn having about 3,600 denier. Spin Finish-1 of Example 1 was applied to the yarn as a spin finish in amount to provide about 1.0 percent by weight of oil on the yarn. The yarn was then drawn at about 3.2 times the extruded length and textured with a steam jet at a temperature of 140° C. to 180° C. to produce a bulked yarn that is particularly useful for production of carpets and upholstery fabrics.
In the finish circulation system, a finish circulating pump pumped Spin Finish-1 from a supply tank into a tray in which a kiss roll turned to pick up finish for application to the moving yarn in contact with the kiss roll. Finish from the tray overflowed into the supply tank. There was no separation of Spin Finish-1 in the finish circulation system.
The bulked yarn was visually inspected for mechanical quality after spinning and steam jet texturing. The visual inspection sighting was perpendicular to the wraps of yarn on a tube forming a yarn package. The rating was from 1 to 5 wherein 5 was excellent and represented no visible broken filaments, wherein 1 was poor and represented a fuzzy appearance due to a large number of broken filaments, and wherein 4 through 2 represented increasing numbers of broken filaments. Bulked yarn made in accordance with this example had a mechanical quality rating of 4.
The bulked yarn was made into a fabric by conventional means and evaluated for oil repellency by AATCC Test No. 118-1975 which involved wetting the fabric by a selected series of liquid hydrocarbons of different surface tensions. The test liquids were as follows:
______________________________________Oil RepellencyRating Number Test Liquid______________________________________1 "Nujol"2 65:35 "Nujol" n-hexadecane by volume3 n-Hexadecane4 n-Tetradecane5 n-Dodecane6 n-Decane7 n-Octane8 n-Heptane______________________________________ "Nujol" is the trademark of Plough, Inc. for a mineral oil having a Saybolt viscosity 360/390 at 38° C. and a specific gravity 0.880/0.900 at 15° C.
In the test, one test specimen, approximately 20 ×20 cm., was conditioned for a minimum of four hours at 21.sup.± 1° C. and 65.sup.± 2 percent relative humidity prior to testing. The test specimen was then placed on a smooth, horizontal surface and, beginning with the lowest numbered test liquid, a small drop -- approximately 5 mm. in diameter (0.05 ml. volume) -- was placed with a dropping bottle pipette on the test specimen in several locations. The drop was observed for 30 seconds at an angle of approximately 45 degrees.
If no penetration or wetting of the fabric at the liquid-fabric interface and no wicking around the drop occurred, a drop of the next higher-numbered test liquid was placed at a site adjacent on the fabric to the first drop, again observing the drop for 30 seconds. This procedure was continued until one of the test liquids showed obvious wetting of the fabric under or around the drop within 30 seconds.
The fabric made from polyamide yarn prepared in accordance with the present example had an oil repellency of 5-6.
EXAMPLE 4
There are three stages at which emulsion stability was measured. The first stage was after the initial oil in water emulsion was formed with Fluorochemical Composition-1. The second stage was after the second emulsion, optionally aqeous, had been added to the initial oil in water emulsion. And the third stage occurred during processing of the yarn when the spin finish was in a finish circulation system which utilized a finish circulating pump.
This example illustrates the importance of the particular emulsifier chosen with respect to the first step, i.e., the stability of the initial oil in water emulsion formed with Fluorochemical Composition-1. Table I lists the formulations tested for emulsion stability, eight of which (formulations A, B, C, D, E, F, G and H) exhibited excellent emulsion stability after 72 hours. As will be shown by later examples, these same formulations (A, B, C, D, E, F, G and H) showed excellent emulsion stability at the second measured stage depending on the choice of the second emulsion. At the third measured stage, however, only spin finishes incorporating formulations A, F, G, and H showed excellent emulsion stability, while spin finishes incorporating formulatons B, C, D and E gradually separated. Formulations F, G and H are the subject of a separate, commonly assigned patent application.
With the exception of formulation E, all of the formulations (A through V) had as one of their constituents a sulfosuccinate diester. With respect to this group of formulations, it can be seen that the sodium dinonyl sulfosuccinate, dimethyl naphthalene sodium sulfonate and ammonium perfluoroalkyl carboxylate comprising the nonhomogeneous mixture of Example 1 and a part of formulations A, B, C and D were apparently all necessary to the stable emulsification of Fluorochemcial Composition-1. This is highlighted by a comparison of formulations A and B (of the present invention) with formulation I, (necessity of sodium dinonyl sulfosuccinate), and by a comparison of formulations A and B with formulations J and S (necessity of dimethyl naphthalene sodium sulfonate and ammonium perfluoroalkyl carboxylate). Especially worthy of note is the noninterchangeability of sodium dinonyl sulfosuccinate and sodium dioctyl sulfosuccinate with respect to this first stage, as evidenced by the poor stabilities of formulations I and J when compared with, respectively, formulations B and H. This is unusual in light of the first-stage stabilities of formulations A, B, C, E, F, G and H.
TABLE I EMULSION STABILITY DATA Formulation (by parts) Component A B C D E F G H I J K L M N O P Q R S T U V Fluorochemical Composition-1 4.63 5.0 5.0 5.0 5.0 5.0 6.0 7.0 5.0 7.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 6.0 7.0 Nonhomogeneous Mixture-1.sup.1 5.37 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- Nonhomogeneous Mixture-2.sup.2 -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Nonhomogeneous Mixture-3.sup.3 -- -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Nonhomogeneous Mixture-4.sup.4 -- -- --5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Alkanol Amide.sup.5 -- -- -- --5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Aerosol OT-70-PG.sup.6 -- -- -- -- -- 5.0 4.0 3.0 -- -- -- -- -- -- -- -- -- 2.5 -- -- -- -- Nonhomogeneous Mixture-5.sup.7 -- -- -- -- -- -- -- -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- Solution.sup.8 -- -- -- -- -- -- -- -- --3.0 -- -- -- -- -- -- -- -- -- -- ----Aerosol OT-S.sup.9 -- -- -- -- -- -- -- -- -- --5.0 -- -- -- -- 2.5 2.5 -- -- -- -- -- Aerosol TR-70.sup.10 -- -- -- -- -- -- -- -- -- -- -- 5.0 -- -- -- 2.5 -- 2.5 -- -- -- -- Aerosol GPG.sup.11 -- -- -- -- -- -- -- -- -- -- -- -- 5.0 -- -- -- 2.5 -- -- -- -- -- Aerosol AY.sup.12 -- -- -- ---- -- -- -- -- -- -- -- -- 5.0 -- -- -- -- -- -- -- --Aerosol 1B.sup.13 -- -- -- -------- -- -- -------- -- 5.0-------- ------Nekal WS-25.sup.14-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- 5.0 -- -- -- Aerosol A-196 Extruded Modified.sup.15 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 5.0 4.0 3.0 POE(4).sup.POE(4(.sup.16 Lauryl Ether -- -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Tridecyl Alcohol + 5 Moles Ethylene Oxide, Phosphated, Potassium Salt -- -- -- 4.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Coconut Oil -- -- 5.0 6.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Water 90.0 90.0 80.0 80.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 Emulsion Stability* After 72 Hours E E E E E E E E P P P P P P P P P P P P P P .sup.1 Consisting of 41.3 percent Nekal WS25, 17.4 percent dimethyl naphthalene sodium sulfonate, and 41.3 percent ammonium perfluoroalkyl carboxylate. .sup.2 Consisting of 60 percent Nekal WS25, 20 percent dimethyl naphthalene sodium sulfonate, and 20 percent ammonium perfluoroalkyl carboxylate. .sup.3 Consisting of 40 percent Nekal WS25, 20 percent dimethyl naphthalene sodium sulfonate, and 40 percent ammonium perfluoroalkyl carboxylate. .sup.4 Consisting of 48 percent Nekal WS25, 20 percent dimethyl naphthalene sodium sulfonate, and 32 percent ammonium perfluoroalkyl carboxylate. .sup.5 Alkanol amide resulting from reaction of coco fatty acid containin about 6 to 18 carbon atoms and diethanolamine. .sup.6 American Cyanamid's trade name for solution consisting of 70 percent sodium dioctyl sulfosuccinate, 16 percent propylene glycol, and 1 percent water. .sup.7 Consisting of approximately 60 percent sodium dioctyl sulfosuccinate, 20 percent dimethyl naphthalene sodium sulfonate, and 20 percent ammonium perfluoroalkyl carboxylate. .sup.8 Consisting of 70 percent Nekal WS25, 16 percent propylene glycol, and 14 percent water. .sup.9 American Cyanamid's trade name for solution consisting of 70 percent dioctyl sulfosuccinate and 30 percent petroleum distillate. .sup.10 American Cyanamid's trade name for solution consisting of 70 percent sodium di(tridecyl(C.sub.13)) sulfosuccinate, 20 percent ethanol, and 10 percent water. .sup.11 American Cyanamid's trade name for solution consisting of 70 percent sodium dioctyl sulfosuccinate, 7 percent ethanol, and 23 percent water. .sup.12 American Cyanamid's trade name for waxy solid consisting of 100 percent sodium diamyl (C.sub.5) sulfosuccinate. .sup.13 American Cyanamid's trade name for solution consisting of 45 percent sodium dibutyl (C.sub.4) sulfosuccinate and 55 percent water. *E = Excellent no separation. *P = Poor separation. .sup.14 GAF's trade name for solution consisting of 75 percent sodium dinonyl sulfosuccinate, 10 percent isopropanol, and 15 percent water. .sup.15 Aerosol A196 Extruded is American Cyanamid's trade name for a solid consisting of sodium di(cyclohexyl) sulfosuccinate. Modified a solution is formed consisting of 70 percent sodium di(cyclohexyl)sulfosuccinate, 16 percent propylene glycol, and 14 percent water. .sup.16 Four moles of ethylene oxide per mole of lauryl alcohol.
EXAMPLE 5
The procedure of Example 1 was followed except that the 100 parts of the second noncontinuous phase which was added to Emulsion-1 consisted essentially of about 50 percent by weight of white mineral oil (350 SUS viscosity), about 48 percent by weight of sodium salt of polyoxyethylene oleyl phosphate containing about 7 moles of ethylene oxide per mole of oleyl alcohol, and about 2 percent by weight of sodium dinonyl sulfosuccinate. The resulting emulsion was stable for at least 3 days. For convenience, this emulsion is called Spin Finish-3.
EXAMPLE 6
The procedure of Example 2 is followed except that the 500 parts of the oil in water emulsion with which Emulsion-2 is blended contains 20 percent of an oil composition consisting essentially of about 50 percent by weight of white mineral oil (350 SUS viscosity), about 48 percent by weight of sodium salt of polyoxyethylene oleyl phosphate containing about 7 moles of ethylene oxide per mole of oleyl alcohol, and about 2 percent by weight of sodium dinonyl sulfosuccinate. The resulting emulsion is stable for at least 3 days. For convenience, this emulsion is called Spin Finish-4. Spin Finish-3 and Spin Finish-4 may be used in the same manner to coat yarn during an subsequent to spinning.
EXAMPLE 7
This example demonstrates use of Spin Finish-3 in a conventional spin-draw process for production of a polyamide yarn suitable for processing into bulked yarn that is oil repellent and resistant to soiling, especially by oily materials.
The procedure of Example 3 was followed with the substitution of Spin Finish-3 of Example 5 for Spin Finish-1. There was no separation of Spin Finish-3 in the finish circulation system. Bulked yarn made in accordance with this example had a mechanical quality rating of 4. Fabric made from polyamide yarn prepared in accordance with the present example had an oil repellency of 6.
EXAMPLE 8 (COMPARATIVE)
The procedure of Example 1 was followed except that the 100 parts of the second noncontinuous phase which was added to Emulsion-1 consisted essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol. (Reference U.S. Pat. No. 4,126,564 to Marshall et al., hereby incorporated by reference). The resulting emulsion was stable for at least 15 days. For convenience, this emulsion is called Spin Finish-5.
EXAMPLE 9 (COMPARATIVE)
The procedure of Example 2 is followed except that the 500 parts of the oil in water emulsion with which Emulsion-2 is blended contains 20 percent of an oil composition consisting essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol. The resulting emulsion is stable for at least 15 days. For convenience, this emulsion is called Spin Finish-6. Spin Finish-6 and Spin Finish-5 may be used in the same manner to coat yarn during and subsequent to spinning.
EXAMPLE 10 (COMPARATIVE)
This example demonstrates use of Spin Finish-5 in a conventional spin-draw process for production of a polyamide yarn suitable for processing into bulked yarn that is oil repellent and resistant to soiling, especially by oily materials.
The procedure of Example 3 was followed with the substitution of Spin Finish-5 of Example 8 for Spin Finish-1. There was no separation of Spin Finish-5 in the finish circulation system. Bulked yarn made in accordance with this example had a mechanical quality rating of 4. Fabric made from polyamide yarn prepared in accordance with the present example had an oil repellency of 1, due to the presence of hydrogenated castor oil.
EXAMPLE 11 (COMPARATIVE)
About 50 parts of Fluorochemical Composition-1 were added to a nonhomogeneous mixture consisting essentially of about 30 parts Nekal WS-25, 10 parts dimethyl naphthalene sodium sulfonate, and 10 parts ammonium perfluoroalkyl carboxylate. The mixture was heated to 80° C., at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous mixture. It is believed that the isopropanol (of Nekal WS-25) vaporized. The oil was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for more than 30 days without signs of separation. This emulsion was then blended with 100 parts of an oil composition consisting essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol. The resulting emulsion was stable for at least 30 days. For convenience, this emulsion is called Spin Finish-7.
The procedure of Example 3 was followed with the substitution of Spin Finish-7 for Spin Finish-1. Spin Finish-7 gradually separated in the finish circulation system during commercial processing of the yarn and stopped the finish circulating pump. Bulked yarn made in accordance with this example prior to stoppage of the pump had a mechanical quality rating of 3. Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had an oil repellency of 1, due to the presence of hydrogenated castor oil.
EXAMPLE 12 (COMPARATIVE)
An initial emulsion was formed according to the procedure of Example 11. This emulsion was then blended with 100 parts of an oil composition (second noncontinuous phase) consisting essentially of about 59 percent by weight of coconut oil, about 15.5 percent by weight of polyoxyethlene castor oil containing about 25 moles of ethylene oxide per mole of castor oil, about 7.5 percent by weight of decaglycerol tetraoleate, about 3 percent by weight of glycerol monooleate, about 5 percent by weight of polyoxyethylene sorbitan monooleate containing about 20 moles of ethylene oxide per mole of sorbitan monooleate, and about 10 percent of weight of sulfonated petroleum product (reference U.S. Pat. No. 3,781,202 to Marshall et al., hereby incorporated by reference). The resulting emulsion separated and was not evaluated further.
EXAMPLE 13
About 50 parts of Fluorochemical Composition-1 were added to a nonhomogeneous mixture consisting essentially of about 20 parts Nekal WS-25, 10 parts dimethyl naphthalene sodium sulfonate, 20 parts ammonium perfluoralkyl carboxylate, 50 parts polyoxyethylene lauryl ether containing 4 moles of ethylene oxide per mole of lauryl alcohol, and 50 parts of coconut oil. The mixture was heated to 80° C., at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous mixture. It is believed that the isopropanol (of Nekal WS-25) vaporized. This oil was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 28° C. The oil particles in this emulsion had a particle size of less than 3 microns and the emulsion was stable for more than seven days without signs of separation. For convenience, this emulsion is called Spin Finish-8.
The procedure of Example 3 was followed with the substitution of Spin Finish-8 for Spin Finish-1. Spin Finish-8 separated in the finish circulation system during processing of the yarn and stopped the finish circulating pump. Bulked yarn made in accordance with this example prior to stoppage of the pump had a mechanical quality rating of 3. Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had an oil repellency of 5-6.
EXAMPLE 14
About 50 parts of Fluorochemical Composition-1 were added to a nonhomogeneous mixture consisting essentially of about 24 parts Nekal WS-25, 10 parts dimethyl naphthalene sodium sulfonate, 16 parts ammonium perfluroalkyl carboxylate, 60 parts of coconut oil, and 40 parts of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol. The mixture was heated to 90° C., at which temperature the Fluorochemcial Composition-1 melted and formed a clear homogeneous mixture. It is believed that the isopropanol (of Nekal WS-25) varporized. This oil was then added to 800 parts of water heated to about 90° C., and the mixture was agitated to form an emulsion, which was then cooled to about 28° C. The emulsion was stable for at least three days without signs of separation. For convenience, this emulsion is called Spin Finish-9.
The procedure of Example 3 was followed with the substitution of Spin Finish-9 for Spin Finish-1. Spin Finish-9 separated in the finish circulation system during processing of the yarn and stopped the finish circulating pump. Bulked yarn made in accordance with this example prior to stoppage of the pump had a poor mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had excellent oil repellency.
EXAMPLE 15 (COMPARATIVE)
About 50 parts of Fluorochemical Composition-1 were added to 50 parts of an alkanol amide resulting from the reaction of coco fatty acid (containing about 6 to 18 carbon atoms) and diethanolamine, and the mixture was heated to 80° C. at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous mixture. This oil was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for more than thirty days without signs of separation. This emulsion was then blended with 100 parts of an oil composition consisting of about 44.5 percent by weight of butyl stearate, about 27.75 percent by weight of sorbitan monooleate, and about 27.75 percent by weight of polyoxyethylene tallow amine containing about 20 moles of ethylene oxide per mole of tallow amine. (Reference U.S. Pat. No. 4,134,839 to Marshall). The resulting emulsion was stable for at least 30 days. For convenience, this emulsion is called Spin Finish-10.
The procedure of Example 3 was followed with the substitution of Spin Finish-10 for Spin Finish-1. Spin Finish-10 gradually separated in the finish circulation system during processing of the yarn and stopped the finish circulating pump. Bulked yarn made in accordance with this example prior to stoppage of the pump had a mechanical quality rating of 1. Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had an oil repellency of 6.
EXAMPLE 16 (COMPARATIVE)
About 70 parts of Fluorochemcial Composition-1 were added to 30 parts of a solution which consisted essentially of about 70 percent by weight of sodium dioctyl sulfosuccinate, about 16 percent by weight of propylene glycol and about 14 percent by weight of water. This solution is manufactured under the trade name of Aerosol OT-70-PG and obtainable from the American Cyanamid Company, Industrial Chemical Division, Process Chemicals Department, Wayne, N.J 07470. The Fluorochemcial Composition-1 and solution were heated to 80° C., at which temperature the Fluorochemcial Composition-1 melted and formed a clear homogeneous first noncontinuous phase. This first noncontinuous phase was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for at least 30 days without signs of separation. This emulsion was then blended with 100 parts of a second noncontinuous phase consisting essentially of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 percent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid. The resulting emulsion was stable for at least 30 days. For convenience, this emulsion is called Spin Finish-11.
The procedure of Example 3 was followed with the substitution of Spin Finish-11 for Spin Finish-1 There was no separation of Spin Finish-11 in the finish circulation system. Bulked yarn made in accordance with this example had a mechanical quality rating of 5. Fabric made from polyamide yarn prepared in accordance with this example had an oil repellency of 5-6.
EXAMPLE 17 (COMPARATIVE)
An initial emulsion was prepared according to the procedure of Example 16. This emulsion was then blended with 100 parts of the oil composition (second noncontinuous phase) of Example 12. The resulting emulsion separated and was not further evaluated.
EXAMPLE 18 (COMPARATIVE)
An initial emulsion was prepared according to the procedure of Example 16. This emulsion was then blended with 100 parts of the oil composition (second noncontinuous phase) of Example 8. The resulting emulsion separated and was not further evaluated.
EXAMPLE 19 (CONTROL-1)
The procedure of Example 3 is followed except that the spin finish of U.S. Pat. No. 4,126,564 was substituted for Spin Finish-1. Bulked yarn made in accordance with this example had a mechanical quality rating of 5. Fabric made from polyamide yarn prepared in accordance with this example had an oil repellency of zero.
EXAMPLE 20 (CONTROL-2)
The procedure of Example 3 is followed except that the spin finish of U.S. Pat. No. 3,781,202 is substituted for Spin Finish-1. Bulked yarn made in accordance with this example has an acceptable mechanical quality rating. However, fabric made from polyamide yarn prepared in accordance with this example is not oil repellent.
EXAMPLES 21-34
About 50 parts of Fluorochemical Composition-1 are added to 50 parts of a nonhomogeneous mixture which consists essentially of about 60 percent by weight of Nekal WS-25, about 20 percent by weight of dimethyl naphthalene sodium sulfonate and about 20 percent by weight of ammonium perfluoroalkyl carboxylate. The Fluorochemical Composition-1 and nonhomogeneous mixture are heated to 80° C., at which temperature the Fluorochemical Composition-1 melts and forms a clear homogeneous noncontinuous phase. It is believed that the isopropanol (of Nekal WS-25) vaporizes. This noncontinuous phase is then added to 900 parts of water which has been heated to about 80° C., and the mixture is agitated to form an emulsion, which is then cooled to room temperature (about 28° C.). The oil particles in this emulsion have a particle size of less than one micron, and the emulsion is stable for at least 30 days without signs of separation. For convenience, this emulsion is called Emulsion-3.
EXAMPLE 21 (COMPARATIVE)
Polyamide polymer pellets prepared in accordance, generally, with the procedure set forth in Example 3, are melted at about 285° C. and are melt extruded under pressure of about 1,500 psig. through a 70-orifice spinnerette to produce an undrawn yarn having about 3,600 denier. Emulsion-3 is applied to the yarn via a first kiss roll in amount to provide about 0.35 percent by weight of oil on the yarn. A spin finish is applied to the yarn via a second kiss roll immediately subsequent to application of Emulsion-3, in amount to provide about 0.8 percent by weight of oil on the yarn. The spin finish applied by the second kiss roll is an oil in water emulsion of about 20 percent by weight of the roll portion. The oil consists essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol. The yarn is then drawn at about 3.2 times the extruded length and textured with a steam jet at a temperature of 140° C. to 180° C. to produce a bulked yarn that is particularly useful for production of carpets and upholstery fabrics.
The bulked yarn is visually inspected for mechanical quality after spinning and steam jet texturing as outlined in Example 3. Bulked yarn made in accordance with this example has an acceptable mechanical quality rating.
The bulked yarn is made into a fabric by conventional means and is evaluated for oil repellency by AATCC Test No. 118-1975, as set forth in Example 3. The fabric made from polyamide yarn prepared in accordance with the present example is not oil repellent, due to the presence of hydrogenated castor oil.
EXAMPLE 22 (COMPARATIVE)
The procedure of Example 21 is followed except that the spin finish is applied via the first kiss roll and Emulsion-3 is applied via the second kiss roll. The yarn mechanical quality rating and fabric oil repellency value are similar to Example 21.
EXAMPLES 23-24
The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 44.5 percent by weight of butyl stearate, about 27.75 percent by weight of sorbitan monooleate, and about 27.75 percent by weight of polyoxyethylene tallow amine containing about 20 moles of ethylene oxide per mole of tallow amine. In Example 23, the spin finish is applied via the second kiss roll, and in Example 24, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 25-26
The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 55 percent by weight of mineral oil, about 11 percent by weight of a fatty acid soap, about 15 percent by weight of a sulfonated ester ethoxylate, about 12 percent by weight of polyethylene glycol ester, about 6 percent by weight of polyethylene glycol ether, and about 1 percent by weight of triethanolamine. In Example 25, the spin finish is applied via the second kiss roll, and in Example 26, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 27-28
The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether contaning about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene oleate containing about 5 moles of ethylene oxide per mole of oleic acid, and about 15 percent by weight of polyoxyethylene castor oil containing about 5 moles of ethylene oxide per mole os castor oil. In Example 27, the spin finish is applied via the second kiss roll, and in Example 28, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 29-30
The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 59 percent by weight of coconut oil, about 15.5 percent by weight of polyoxyethylene castor oil containing about 25 moles of ethylene oxide per mole of castor oil, about 7.5 percent by weight of decaglycerol tetraoleate, about 3 percent by weight of glycerol monooleate, about 5 percent by weight of polyoxyethylene sorbitan monooleate containing about 20 moles of ethylene oxide per mole of sorbitan monooleate and about 10 percent by weight of sulfonated petroleum product. In Example 29, the spin finish is applied via the second kiss roll, and in Example 30, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 31-32
The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 percent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid. In Example 31, the spin finish is applied via the second kiss roll, and in Example 32, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 33-34
The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 50 percent by weight of white mineral oil (350 SUS viscosity), about 48 percent by weight of sodium salt of polyoxyethylene oleyl phosphate containing about 7 moles of ethylene oxide per mole of oleyl alcohol, and about 2 percent by weight of sodium dinonyl sulfosuccinate. In Example 33, the spin finish is applied via the second kiss roll, and in Example 32, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLE 35
Polyethylene terephthalate pellets are melted at about 290° C. and are melt extruded under a pressure of about 2500 psig. through a 34-orifice spinnerette to produce a partially oriented yarn having about 250 denier. Spin Finish-1 of Example 1 is applied to the yarn as a spin finish via a kiss roll in amount to provide about 0.6 percent by weight of oil on the yarn. The yarn is then draw-textured at about 1.3 times the extruded length and at a temperature of 150° C. to 175° C. to produce a bulked yarn having a drawn denier of about 150. Yarn produced in this manner is particularly useful for production of carpets and fine apparel. Bulked yarn made in accordance with this example has an acceptable mechanical quality rating. In accordance with the procedure of Example 3, the bulked yarn of this example is made into fabric for evaluation of oil repellency. Fabric so produced is oil repellent.
EXAMPLES 36-37
The procedure of Example 35 is followed except that in lieu of Spin Finish-1 are substituted Spin Finish-3 of Example 5 and Spin Finish-5 of Example 8 in each of, respectively, Examples 36 and 37. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with Example 36 is oil repellent while yarn prepared in accordance with Example 37 is not oil repellent.
EXAMPLE 38 (COMPARATIVE)
Polyethylene terephthalate pellets are melted at about 290° C. and are melt extruded under a pressure of about 2500 psig. through a 34-orifice spinnerette to produce a partially oriented yarn having about 250 denier. Emulsion-3 (of Examples 21-34) is applied to the yarn via a first kiss roll, and the spin finish of Example 21 is applied to the yarn via a second kiss roll immediately subsequent to application of Emulsion-3, in amount to provide a total of about 0.6 percent by weight of oil on the yarn. The yarn is then draw-textured at about 1.3 times the extruded length and at a temperature of 150° C. to 175° C. to produce a bulked yarn having a drawn denier of about 150. Yarn produced in this manner is particularly useful for production of carpets and fine apparel. Bulked yarn made in accordance with this example has an acceptable mechanical quality rating. In accordance with the produce of Example 3, the bulked yarn of this example is made into fabric for evaluation of oil repellency. Fabric so produced is not oil repellent, due to the presence of hydrogenated castor oil.
EXAMPLE 39 (COMPARATIVE)
The procedure of Example 38 is followed except that the spin finish is applied via the first kiss roll and Emulsion-3 is applied via the second kiss roll. The yarn mechanical quality rating is acceptable; however, the fabric is not oil repellent.
EXAMPLES 40-41
The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 23-24. In Example 40, the spin finish is applied via the second kiss roll, and in Example 41, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 42-43
The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 25-26. In Example 42, the spin finish is applied via the second kiss roll, and in Example 43, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 44-45
The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Exmples 27-28. In Example 44, the spin finish is applied via the second kiss roll, and in Example 45, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 46-47
The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 29-30. In Example 46, the spin finish is applied via the second kiss roll, and in Example 47, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 48-49
The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 31-32. In Example 48, the spin finish is applied via the second kiss roll, and in Example 49, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLES 50-51
The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 33-34. In Example 50, the spin finish is applied via the second kiss roll, and in Example 51, the spin finish is applied via the first kiss roll. Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating. Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.
EXAMPLE 52
About 46.3 parts of Fluorochemical Composition-1 are added to 53.7 parts of the nonhomogeneous mixture of Example 1, and the two are heated to 80° C., at which temperature the Fluorochemical Composition melts and forms a clear homogeneous yarn finish composition. This composition is sprayed onto 7-inch polyamide staple fiber, which has a denier per filament of 17 and which is produced by a conventional spinning and staple processing operation, prior to baling. The yarn is subsequently heat set and made into carpet by conventional means. Carpet made in accordance with this example is oil repellent.
EXAMPLE 53
The procedure of Example 52 is followed except that the yarn is polyethylene terephthalate staple fiber which has a denier per filament of 12. Carpet made in accordance with this procedure is also oil repellent.
EXAMPLE 54
Polyamide woven fibric is dipped into a pad box containing Emulsion-3 of Examples 21-34 diluted to 1 percent solids. The fabric is squeezed between a steel and a hard rubber roll with sufficient pressure to obtain a 50 percent wet pickup on the weight of the fabric. The fabric is then cured for 1 minute at 150° C. in a circulating air oven. The fluorine content of the finished fabric is 0.17 percent. This is Sample Number 1. This procedure is repeated, utilizing a polyethylene terephthalate fabric, which is Sample Number 2. After a standard home laundering, the oil repellency of both Sample Numbers 1 and 2, as measured by AATCC Test No. 118-1975 set forth in Example 3, is 6.
EXAMPLE 55
The procedure of Example 1 is followed except that in forming the first noncontinuous phase, 50 parts of Fluorochemcial Composition-1 are added to 50 parts of the nonhomogeneous mixture. The resulting emulsion is called Spin Finish-12. The procedure of Example 3 is then followed with substitution of Spin Finish-12 for Spin Finish-1. Spin Finish-12 gradually separates in the finish circulation system during commercial processing of the yarn and stops the finish circulating pump. Bulked yarn made in accordance with this example prior to stoppage of the pump has an acceptable mechanical quality rating. Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) is oil repellent.
DISCUSSION
As the preceding examples illustrate, the yarn finish composition of the present invention renders synthetic organic polymer yarn and/or yarn products with which it is incorporated oil repellent and resistant to soiling. Further, emulsions and spin finishes which include the aforementioned yarn finish composition exhibit exceptional emulsion stability for incorporation with synthetic organic polymer yarn and/or yarn products to achieve the same beneficial results. The examples which show little or no increase in soil repellency by virtue of utilizing the present invention in one of these forms, i.e., Examples 10, 11, 21, 22, 37, 38 and 39, have as a common spin finish componenet hydrogenated castor oil, the presence of which has been found to seriously diminish oil repellency.
In Example 4, there were defined three critical stages for emulsion stability. Example 4 demonstrated the excellent emulsion stability of the initial oil in water emulsion of the present invention. Examples 1, 2, 5, 6, 8, 9, 11, 13, 14, 15 and 16 demonstrate the second stage emulsion stability of, respectively, Spin Finishes -1,-2,-3,-4,-5,-6,-7,-8,-9,-10,and -11. Further examination of Examples 11, 13, 14, and 15 shows that each of their respective Spin Finishes (-7,-8,-9and-10) gradually separates at the third stage, i.e., in the finish circulation system at the finish circulating pump. A comparison of Spin Finishes -5 and -7 of, respectively, Examples 8 and 11, demonstrates the criticality of proportions of the Fluorochemical Composition-1 and nonhomogeneous mixture to third stage stability. However, application of the yarn finish composition (consisting essentially of these components) to yarn to some method not requiring third stage stability, e.g., by tandem kiss rolls, spraying, padding, etc., still effectively renders the yarn and yarn products oil repellent and resistant to soiling. In this regard, it should be noted that Spin Finish-10 of Example 15 is the subject of commonly assigned U.S. Pat. No. 4,134,839, and Spin Finish-11 of Example 16 is the subject of commonly assigned U.S. Application Ser. No. 974,203, filed Dec. 28, 1978. | A yarn finish composition is disclosed for incorporation with synthetic organic polymer yarn or yarn products to render the same oil repellent and resistant to soiling. The composition comprises (a) a nonhomogeneous mixture of a salt of dinonyl sulfosuccinate, a salt of dimethyl naphthalene sulfonate, and ammonium perfluoroalkyl carboxylate, and (b) a fluorochemical compound consisting of polycarboxybenzene esterified with certain partially fluorinated alcohols and with hydroxyl-containing organic radicals such as 2-hydroxyethyl, glyceryl, and chlorohydryl or bromohydryl. | Identify and summarize the most critical technical features from the given patent document. | [
"CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of application Ser.",
"No. 1,625, filed Jan. 8, 1979.",
"BACKGROUND OF THE INVENTION This invention relates to a yarn finish composition.",
"More particularly, this invention relates to a yarn finish composition for incorporation with synethetic organic polymer yarn or yarn products to render the same oil repellent and resistant to soiling.",
"This invention further relates to emulsions which include the aforementioned yarn finish composition as a component thereof.",
"The treatment of textiles with fluorochemicals to impart oil repellency and soil resistance has been known for some time.",
"U.S. application Ser.",
"No. 861,372, filed Dec. 16, 1977, discloses that polycarboxybenzenes esterfied with certain partially fluorinated alcohols and with hydroxyl-containing organic radicals such as 2-hydroxyethyl, glyceryl, and chlorohydryl or bromohydryl, when incorporated with polyethylene terephthalate or synthetic long-chain polyamide fibers as by contact in a liquid medium, concentrate at the fiber surface, especially if the fiber is annealed.",
"A relatively durable oil and water repellency is thus imparted to the fiber.",
"Commonly assigned U.S. Pat. No. 4,134,839 to Marshall, hereby incorporated by reference, indicates that the oil repellent fluorocarbon compounds of U.S. application Ser.",
"No. 861,372 are not compatible with the lubricating oils in spin finishes used in a conventional spin finish, and further, that the emulsifying componenets of some known spin finishes are not suitable for preparing an oil in water emulsion containing these oil repellent fluorocarbon compounds.",
"U.S. Pat. No. 4,134,839 discloses a spin finish which has the oily properties of a conventional spin finish and which also imparts to the yarn the oil repellent properties of the fluorocarbon finish of U.S. application Ser.",
"No. 861,372.",
"However, we have found that the disclosed spin finish causes serious processing problems when a finish circulating pump is utilized in the finish circulation system of a conventional spinning process, i.e., the flurocarbon separates, clogs and stops the finish circulating pump.",
"Accordingly, extensive research has been carried out to develop an improved spin finish which possesses the desirable properties of both of the aforementioned applications and which will not gradually separate in the finish circulation system during commercial processing of the yarn.",
"As a by-product of this research, a yarn finish composition (applied separately from the lubricating spin finish) has been discovered which, when incorporated with synthetic organic polymer yarn or yarn products, renders the same oil repellent and resistant to soiling.",
"SUMMARY OF THE INVENTION The present invention provides a yarn finish composition for incorporation with synthetic organic polymer yarn or yarn products to render the same oil repellent and resistant to soiling.",
"The yarn finish composition of the present invention comprises (a) about 15 to 80 weight percent of a nonhomogeneous mixture of a salt of dinonyl sulfosuccinate, a salt of dimethyl naphthalene sulfonate, and ammonium perfluoroalkyl carboxylate;",
"and (b) about 20 to 85 weight percent of a fluorochemical compound.",
"The fluorochemical compound has the formula ##STR1## wherein the attachment of the fluorinated radicals and the radicals CO 2 B to the nucleus is in asymmetrical positions with respect to rotation about the axis through the center of the nucleus;",
"wherein "X"",
"is fluorine, or perfluoroalkoxy of 1 to 6 carbon atoms, and m has arithmetic mean between 2 and 20;",
"n is zero or unity;",
""W"",
"and "Y"",
"are alkylene, cycloalkylene or alkyleneoxy radicals of combined chain length from 2 to 20 atoms;",
"(CF 2 ) m and "Y"",
"have each at least 2 carbon atoms in the main chain;",
""Z"",
"is oxygen and p is 1, or "Z"",
"is nitrogen and p is 2;",
"q is an integer of at least 2 but not greater than 5;",
""B"",
"is CH 2 RCHOH or is CH 2 RCHOCH 2 RCHOH where "R"",
"is hydrogen or methyl, or "B"",
"is CH 2 CH(OH)CH 2 Q where Q is halogen, hydroxy, or nitrile, or "",
"B"",
"is CH 2 CH(OH)CH 2 OCH 2 CH(OH)CH 2 Q;",
"and r is an integer of at least 1 but not greater than q;",
"and X(CF 2 ) m , W and Y are straight chains, branched chains or cyclic;",
"and wherein the substituent chains of the above general formulas are the same or different.",
"The nonhomogeneous mixture forming a part of the yarn finish composition preferably consists essentially of about 20 to 60 percent by weight of the salt of dinonyl sulfosuccinate, about 5 to 23 percent by weight of the salt of dimethyl naphthalene sulfonate, and about 17 to 60 percent by weight of ammonium perfluoroalkyl carboxylate.",
"The yarn finish composition of the present invention can be applied in any known manner to synthetic organic polymer fiber, yarn to yarn products, e.g., by spraying the fiber, yarn to yarn products or by dipping them into or otherwise contacting them with the composition.",
"It is preferred that an emulsion of water and approximately 5 to 25 percent by weight of the emulsion of the composition, be formed for application to the yarn or yarn products.",
"This emulsion can be applied during spinning of the yarn with, preferably, a conventional spin finish being applied to the yarn just prior to or subsequent to application of the emulsion, e.g., by tandem (in series) kiss rolls.",
"The emulsion can alternatively be applied as an overfinish during beaming of the yarn or at any other processing stage.",
"Staple fiber can be treated by spraying.",
"Further, fabric or carpet made from synthetic organic polymer yarn can be treated with the emulsion, e.g., by spraying, padding, or dipping in a conventional manner.",
"This invention includes also polyamide and polyester and other polymer fibers, yarns and yarn products having incorporated therewith the yarn finish composition or emulsion as above defined.",
"The yarn finish composition of the present invention renders yarn and resistant to soiling, especially by oily materials.",
"Throughout the present specification and claims, the term "yarn"",
"is employed in a general sense to indicate strand material, either textile or otherwise, and including a continuous, often plied, strand composed of fibers or filaments, or a noncontinuous strand such as staple, and the like.",
"The term "yarn"",
"also is meant to include fiber, such as continuous single filaments of a yarn, or individual strands of staple fiber before drafting and spinning into a conventional staple yarn.",
"The term "yarn product"",
"is likewise used in a general sense to indicate the end use of the yarn, and includes both fabrics used in apparel, upholstery, draperies, and similar applications, as well as carpets, either prior to or subsequent to dyeing and/or printing.",
"The phrase "synthetic organic polymer"",
"generally includes any fiber-forming thermoplastic resin, such as polypropylene, polyamide, polyester, polyacrylonitrile and blends thereof.",
"The phrase "during commercial processing of the yarn"",
"refers generally to any yarn process which utilzes a finish circulating pump in its finish circulation system.",
"DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred fluorochemical compounds which are useful in the yarn finish composition and emulsion of the present invention are trimellitates and pyromellitates.",
"They can be represented by the following formulas, wherein A and A'",
"represent the same or different radicals X(CF 2 ) m W(CONH) n Y of formula I above, and wherein each A and A'",
"radical has a main chain containing at least six carbon atoms and contains at least four perfluorinated carbon atoms in the radical.",
"In the following formulas, B is as previously defined with Formula I above and B'",
"is the same or different radical.",
"##STR2## The above fluorinated radicals A, A'",
"are likewise preferred in the various other compounds of the invention, in particular in bis(diamide)/esters of trimellitic acid and of pyromellitic acid in accordance with this invention.",
"Fluorochemical compounds which are more particularly preferred are mixtures of substituted pyromellitic acid or trimellitic acid position isomers, especially mixtures of the para and meta pyromellitate position isomers, represented by Formulas III (a) and (b) above, with A═A'",
"and B═B', and A containing at least six perfluorinated carbon atoms, and not over four other chain atoms therein;",
"especially such mixtures containing about 50:50 molar proportions of each of the two-position isomers of Formula III.",
"The attachment of the radicals in the para isomer (see Formula III (a) above) is symmetrical with respect to rotation 180 degrees about the axis through the center of the nucleus.",
"This isomer, used alone, shows relatively low repellency.",
"Nevertheless, when the para isomer is mixed in about 50:50 molar ratio with the meta isomer (which is unsymmetrical with respect to rotation about such axis), the mixture shows repellency essentially equal to the good repellency of the substantially pure meta isomer used alone in the same amount.",
"The corresponding bis(diamide)/esters of the substituted acids are likewise preferred.",
"It will be appreciated that although overall the radicals A and A'",
"will both be the same and the radicals B and B'",
"will both be the same in the preferred fluorochemical compounds, they may nevertheless vary within individual molecules because a mixture of fluorinated alcohols will generally be used to obtain the fluorinated radicals A, and because epoxides used to obtain the radicals B may react further to form dimers or higher polymers of the B radicals.",
"In especially preferred radicals A and A', the fluorinated moiety has the formula CF 3 (CF 2 ) m or (CF 3 ) 2 CFO(CF 2 ) m '",
"where m independently at each occurrence has any integral value from 5 to 9, m'",
"independently at each occurrence has any integral value from 2 to 16, and (CF 2 ) m and (CF 2 ) m '",
"are straight chains.",
"Preferred radicals B and B'",
"are CH 2 CH 2 OH, CH 2 CH(OH)CH 2 Cl, CH 2 CH(OH)CH 2 OH and CH 2 CH(OH)CH 2 Br.",
"The fluorinated radicals in the fluorochemical compounds useful in this invention are provided in general by reaction between a benzene polycarboxylic acid anhydride or carboxy chloride/anhydride, which can be additionally substituted in the benzene ring, and an appropriate fluorinated alcohol or amine.",
"The corresponding carboxylic acid/half ester containing a fluorinated esterifying radical and a carboxy group is produced from the anhydride group reacting with an alcohol;",
"or when the compound is an amide rather than an ester, the appropriate fluorinated amine is used as reactant instead of the alcohol, with production of a fluorinated amido group and a carboxy group.",
"All free carboxy groups can then be esterified by base-catalyzed reaction with the epoxide corresponding to the desired "B"",
"group in the compound.",
"The invention will now be further described in the following specific examples which are to be regarded solely as illustrative and not as restricting the scope of the invention.",
"In particular, although the examples are limited to polyamide and polyester yarns and yarn products, it will be appreciated that the yarn finish composition and emulsion of the present invention can be applied to yarn made from any synthetic organic polymer filaments and products thereof.",
"Further, although the examples are limited to sodium dinonyl sulfosuccinate, the dinonyl sulfosuccinates useful in this invention are of the salts of dinonyl sulfosuccinates, especially the ammonium salt and the alkali metal, particularly sodium and potassium, salts of a dinonyl ester of sulfosuccinic acid.",
"Likewise, while the examples are limited to dimethyl naphthalene sodium sulfonate, the dimethyl naphthalene sulfonates useful in this invention are of the salts of dimethyl naphthalene sulfonate, especially the ammonium salt and the alkali metal, particularly sodium and potassium, salts of dimethyl naphthalene sulfonate.",
"In the following examples, parts and percentages employed are by weight unless otherwise indicated.",
"EXAMPLE 1 The fluorochemical used in this example was a mixture of pyromellitates having the following structure: ##STR3## For convenience, this mixture of pyromellitates is hereinafter called Fluorochemical Composition-1.",
"About 46.3 parts of Fluorochemical Composition-1 were added to 53.7 parts of a nonhomogeneous mixture which consisted essentially of about 41.3 percent by weight of Nekal WS-25, about 17.4 percent by weight of dimethyl naphthalene sodium sulfonate and about 41.3 percent by weight of ammonium perfluoroalkyl carboxylate.",
"Nekal WS-25 is General Aniline and Film Corporation's trade name for a solution of 75 percent by weight sodium dinonyl sulfosuccinate, 10 percent by weight isopropanol, and 15 percent by weight water.",
"The ammonium perfluoroalkyl carboxylate is manufactured under the trade name of FC-143 and obtainable from the 3M Company, Chemical Division, 900 Bush Avenue, St. Paul, Minnesota.",
"The Fluorochemical Composition-1 and mixture were heated to 80° C., at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous first noncontinuous phase.",
"It is believed that the isopropanol vaporized, and is not present in the final composition.",
"This first noncontinuous phase was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for at least 30 days without signs of separation.",
"For convenience, this emulsion is called Emulsion-1.",
"It should be noted that in forming Emulsion-1 or the first noncontinuous phase above, Fluorochemical Composition-1 and the solution can be heated to a temperature of between approximately 75° C. and 90° C. The temperature of the water should correspond approximately to that of the first noncontinuous phase when it is added to the water.",
"The resultant emulsion can be cooled to a temperature between approximately 50° C. and 70° C. To Emulsion-1 was added 100 parts of a second noncontinuous phase consisting essentially of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 pecent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid.",
"The resulting emulsion was stable for at least 30 days and was suitable for use as a spin finish as described hereinafter.",
"For convenience, this emulsion is called Spin Finish-1.",
"EXAMPLE 2 The procedure of Example 1 is followed except that 46.3 parts of Fluorochemical Composition-1, 53.7 parts of the mixture, and 400 parts of water are used to form an emulsion, which is called Emulsion-2.",
"The oil particles in this emulsion have a particle size of less than one micron, and the emulsion is stable for at least 30 days without signs of separation.",
"Emulsion-2 is then blended with 500 parts of another oil in water emulsion containing 20 percent of an oil composition consisting essentially of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 percent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid.",
"The resulting emulsion is stable for at least 30 days and is suitable for use as a spin finish as described hereinafter.",
"For convenience, this emulsion is called Spin Finish-2.",
"Spin Finish-1 and Spin Finish-2 may be used in the same manner to coat yarn during or subsequent to spinning.",
"EXAMPLE 3 This example demonstrates use of Spin Finish-1 in a conventional spin-draw process for production of a polyamide yarn suitable for processing into bulked yarn that is oil repellent and resistant to soiling, especially by oily materials.",
"A typical procedure for obtaining polymer pellets for use in this example is as follows.",
"A reactor equipped with a heater and stirrer is charged with a mixture of 1,520 parts of epsilon-caprolactam and 80 parts of aminocaproic acid.",
"The mixture is then flushed with nitrogen and stirred and heated to 255° C. over a one-hour period at atmospheric pressure to produce a polymerization reaction.",
"The heating and stirring is continued at atmospheric pressure under a nitrogen sweep for an additional four hours in order to complete the polymerization.",
"Nitrogen is then admitted to the reactor and a small pressure is maintained while the polycaproamide polymer is extruded from the reactor in the form of a polymer ribbon.",
"The polymer ribbon is subsequently cooled, pelletized, washed and dried.",
"The polymer is a white solid having a relative viscosity of about 50 to 60 as determined at a concentration of 11 grams of polymer in 100 ml.",
"of 90 percent formic acid at 25° C. (ASTM D-789-62T).",
"Polyamide polymer pellets prepared in accordance, generally, with the procedure above were melted at about 285° C. and melt extruded under pressure of about 1,500 psig.",
"through a 70-orifice spinnerette to produce an undrawn yarn having about 3,600 denier.",
"Spin Finish-1 of Example 1 was applied to the yarn as a spin finish in amount to provide about 1.0 percent by weight of oil on the yarn.",
"The yarn was then drawn at about 3.2 times the extruded length and textured with a steam jet at a temperature of 140° C. to 180° C. to produce a bulked yarn that is particularly useful for production of carpets and upholstery fabrics.",
"In the finish circulation system, a finish circulating pump pumped Spin Finish-1 from a supply tank into a tray in which a kiss roll turned to pick up finish for application to the moving yarn in contact with the kiss roll.",
"Finish from the tray overflowed into the supply tank.",
"There was no separation of Spin Finish-1 in the finish circulation system.",
"The bulked yarn was visually inspected for mechanical quality after spinning and steam jet texturing.",
"The visual inspection sighting was perpendicular to the wraps of yarn on a tube forming a yarn package.",
"The rating was from 1 to 5 wherein 5 was excellent and represented no visible broken filaments, wherein 1 was poor and represented a fuzzy appearance due to a large number of broken filaments, and wherein 4 through 2 represented increasing numbers of broken filaments.",
"Bulked yarn made in accordance with this example had a mechanical quality rating of 4.",
"The bulked yarn was made into a fabric by conventional means and evaluated for oil repellency by AATCC Test No. 118-1975 which involved wetting the fabric by a selected series of liquid hydrocarbons of different surface tensions.",
"The test liquids were as follows: ______________________________________Oil RepellencyRating Number Test Liquid______________________________________1 "Nujol"2 65:35 "Nujol"",
"n-hexadecane by volume3 n-Hexadecane4 n-Tetradecane5 n-Dodecane6 n-Decane7 n-Octane8 n-Heptane______________________________________ "Nujol"",
"is the trademark of Plough, Inc. for a mineral oil having a Saybolt viscosity 360/390 at 38° C. and a specific gravity 0.880/0.900 at 15° C. In the test, one test specimen, approximately 20 ×20 cm.",
", was conditioned for a minimum of four hours at 21.",
"sup.",
"± 1° C. and 65.",
"sup.",
"± 2 percent relative humidity prior to testing.",
"The test specimen was then placed on a smooth, horizontal surface and, beginning with the lowest numbered test liquid, a small drop -- approximately 5 mm.",
"in diameter (0.05 ml.",
"volume) -- was placed with a dropping bottle pipette on the test specimen in several locations.",
"The drop was observed for 30 seconds at an angle of approximately 45 degrees.",
"If no penetration or wetting of the fabric at the liquid-fabric interface and no wicking around the drop occurred, a drop of the next higher-numbered test liquid was placed at a site adjacent on the fabric to the first drop, again observing the drop for 30 seconds.",
"This procedure was continued until one of the test liquids showed obvious wetting of the fabric under or around the drop within 30 seconds.",
"The fabric made from polyamide yarn prepared in accordance with the present example had an oil repellency of 5-6.",
"EXAMPLE 4 There are three stages at which emulsion stability was measured.",
"The first stage was after the initial oil in water emulsion was formed with Fluorochemical Composition-1.",
"The second stage was after the second emulsion, optionally aqeous, had been added to the initial oil in water emulsion.",
"And the third stage occurred during processing of the yarn when the spin finish was in a finish circulation system which utilized a finish circulating pump.",
"This example illustrates the importance of the particular emulsifier chosen with respect to the first step, i.e., the stability of the initial oil in water emulsion formed with Fluorochemical Composition-1.",
"Table I lists the formulations tested for emulsion stability, eight of which (formulations A, B, C, D, E, F, G and H) exhibited excellent emulsion stability after 72 hours.",
"As will be shown by later examples, these same formulations (A, B, C, D, E, F, G and H) showed excellent emulsion stability at the second measured stage depending on the choice of the second emulsion.",
"At the third measured stage, however, only spin finishes incorporating formulations A, F, G, and H showed excellent emulsion stability, while spin finishes incorporating formulatons B, C, D and E gradually separated.",
"Formulations F, G and H are the subject of a separate, commonly assigned patent application.",
"With the exception of formulation E, all of the formulations (A through V) had as one of their constituents a sulfosuccinate diester.",
"With respect to this group of formulations, it can be seen that the sodium dinonyl sulfosuccinate, dimethyl naphthalene sodium sulfonate and ammonium perfluoroalkyl carboxylate comprising the nonhomogeneous mixture of Example 1 and a part of formulations A, B, C and D were apparently all necessary to the stable emulsification of Fluorochemcial Composition-1.",
"This is highlighted by a comparison of formulations A and B (of the present invention) with formulation I, (necessity of sodium dinonyl sulfosuccinate), and by a comparison of formulations A and B with formulations J and S (necessity of dimethyl naphthalene sodium sulfonate and ammonium perfluoroalkyl carboxylate).",
"Especially worthy of note is the noninterchangeability of sodium dinonyl sulfosuccinate and sodium dioctyl sulfosuccinate with respect to this first stage, as evidenced by the poor stabilities of formulations I and J when compared with, respectively, formulations B and H. This is unusual in light of the first-stage stabilities of formulations A, B, C, E, F, G and H. TABLE I EMULSION STABILITY DATA Formulation (by parts) Component A B C D E F G H I J K L M N O P Q R S T U V Fluorochemical Composition-1 4.63 5.0 5.0 5.0 5.0 5.0 6.0 7.0 5.0 7.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 6.0 7.0 Nonhomogeneous Mixture-1.",
"sup[.",
"].1 5.37 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- Nonhomogeneous Mixture-2.",
"sup[.",
"].2 -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Nonhomogeneous Mixture-3.",
"sup[.",
"].3 -- -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Nonhomogeneous Mixture-4.",
"sup[.",
"].4 -- -- --5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Alkanol Amide.",
"sup[.",
"].5 -- -- -- --5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Aerosol OT-70-PG.",
"sup[.",
"].6 -- -- -- -- -- 5.0 4.0 3.0 -- -- -- -- -- -- -- -- -- 2.5 -- -- -- -- Nonhomogeneous Mixture-5.",
"sup[.",
"].7 -- -- -- -- -- -- -- -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- Solution.",
"sup[.",
"].8 -- -- -- -- -- -- -- -- --3.0 -- -- -- -- -- -- -- -- -- -- ----Aerosol OT-S.",
"sup[.",
"].9 -- -- -- -- -- -- -- -- -- --5.0 -- -- -- -- 2.5 2.5 -- -- -- -- -- Aerosol TR-70.",
"sup[.",
"].10 -- -- -- -- -- -- -- -- -- -- -- 5.0 -- -- -- 2.5 -- 2.5 -- -- -- -- Aerosol GPG.",
"sup[.",
"].11 -- -- -- -- -- -- -- -- -- -- -- -- 5.0 -- -- -- 2.5 -- -- -- -- -- Aerosol AY.",
"sup[.",
"].12 -- -- -- ---- -- -- -- -- -- -- -- -- 5.0 -- -- -- -- -- -- -- --Aerosol 1B.",
"sup[.",
"].13 -- -- -- -------- -- -- -------- -- 5.0-------- ------Nekal WS-25.",
"sup[.",
"].14-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- 5.0 -- -- -- Aerosol A-196 Extruded Modified.",
"sup[.",
"].15 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 5.0 4.0 3.0 POE(4).",
"sup.",
"POE(4(.",
"sup[.",
"].16 Lauryl Ether -- -- 5.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Tridecyl Alcohol + 5 Moles Ethylene Oxide, Phosphated, Potassium Salt -- -- -- 4.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Coconut Oil -- -- 5.0 6.0 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- Water 90.0 90.0 80.0 80.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 Emulsion Stability* After 72 Hours E E E E E E E E P P P P P P P P P P P P P P .",
"sup[.",
"].1 Consisting of 41.3 percent Nekal WS25, 17.4 percent dimethyl naphthalene sodium sulfonate, and 41.3 percent ammonium perfluoroalkyl carboxylate.",
"sup[.",
"].2 Consisting of 60 percent Nekal WS25, 20 percent dimethyl naphthalene sodium sulfonate, and 20 percent ammonium perfluoroalkyl carboxylate.",
"sup[.",
"].3 Consisting of 40 percent Nekal WS25, 20 percent dimethyl naphthalene sodium sulfonate, and 40 percent ammonium perfluoroalkyl carboxylate.",
"sup[.",
"].4 Consisting of 48 percent Nekal WS25, 20 percent dimethyl naphthalene sodium sulfonate, and 32 percent ammonium perfluoroalkyl carboxylate.",
"sup[.",
"].5 Alkanol amide resulting from reaction of coco fatty acid containin about 6 to 18 carbon atoms and diethanolamine.",
"sup[.",
"].6 American Cyanamid's trade name for solution consisting of 70 percent sodium dioctyl sulfosuccinate, 16 percent propylene glycol, and 1 percent water.",
"sup[.",
"].7 Consisting of approximately 60 percent sodium dioctyl sulfosuccinate, 20 percent dimethyl naphthalene sodium sulfonate, and 20 percent ammonium perfluoroalkyl carboxylate.",
"sup[.",
"].8 Consisting of 70 percent Nekal WS25, 16 percent propylene glycol, and 14 percent water.",
"sup[.",
"].9 American Cyanamid's trade name for solution consisting of 70 percent dioctyl sulfosuccinate and 30 percent petroleum distillate.",
"sup[.",
"].10 American Cyanamid's trade name for solution consisting of 70 percent sodium di(tridecyl(C.",
"sub[.",
"].13)) sulfosuccinate, 20 percent ethanol, and 10 percent water.",
"sup[.",
"].11 American Cyanamid's trade name for solution consisting of 70 percent sodium dioctyl sulfosuccinate, 7 percent ethanol, and 23 percent water.",
"sup[.",
"].12 American Cyanamid's trade name for waxy solid consisting of 100 percent sodium diamyl (C.",
"sub[.",
"].5) sulfosuccinate.",
"sup[.",
"].13 American Cyanamid's trade name for solution consisting of 45 percent sodium dibutyl (C.",
"sub[.",
"].4) sulfosuccinate and 55 percent water.",
"*E = Excellent no separation.",
"*P = Poor separation.",
"sup[.",
"].14 GAF's trade name for solution consisting of 75 percent sodium dinonyl sulfosuccinate, 10 percent isopropanol, and 15 percent water.",
"sup[.",
"].15 Aerosol A196 Extruded is American Cyanamid's trade name for a solid consisting of sodium di(cyclohexyl) sulfosuccinate.",
"Modified a solution is formed consisting of 70 percent sodium di(cyclohexyl)sulfosuccinate, 16 percent propylene glycol, and 14 percent water.",
"sup[.",
"].16 Four moles of ethylene oxide per mole of lauryl alcohol.",
"EXAMPLE 5 The procedure of Example 1 was followed except that the 100 parts of the second noncontinuous phase which was added to Emulsion-1 consisted essentially of about 50 percent by weight of white mineral oil (350 SUS viscosity), about 48 percent by weight of sodium salt of polyoxyethylene oleyl phosphate containing about 7 moles of ethylene oxide per mole of oleyl alcohol, and about 2 percent by weight of sodium dinonyl sulfosuccinate.",
"The resulting emulsion was stable for at least 3 days.",
"For convenience, this emulsion is called Spin Finish-3.",
"EXAMPLE 6 The procedure of Example 2 is followed except that the 500 parts of the oil in water emulsion with which Emulsion-2 is blended contains 20 percent of an oil composition consisting essentially of about 50 percent by weight of white mineral oil (350 SUS viscosity), about 48 percent by weight of sodium salt of polyoxyethylene oleyl phosphate containing about 7 moles of ethylene oxide per mole of oleyl alcohol, and about 2 percent by weight of sodium dinonyl sulfosuccinate.",
"The resulting emulsion is stable for at least 3 days.",
"For convenience, this emulsion is called Spin Finish-4.",
"Spin Finish-3 and Spin Finish-4 may be used in the same manner to coat yarn during an subsequent to spinning.",
"EXAMPLE 7 This example demonstrates use of Spin Finish-3 in a conventional spin-draw process for production of a polyamide yarn suitable for processing into bulked yarn that is oil repellent and resistant to soiling, especially by oily materials.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-3 of Example 5 for Spin Finish-1.",
"There was no separation of Spin Finish-3 in the finish circulation system.",
"Bulked yarn made in accordance with this example had a mechanical quality rating of 4.",
"Fabric made from polyamide yarn prepared in accordance with the present example had an oil repellency of 6.",
"EXAMPLE 8 (COMPARATIVE) The procedure of Example 1 was followed except that the 100 parts of the second noncontinuous phase which was added to Emulsion-1 consisted essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol.",
"(Reference U.S. Pat. No. 4,126,564 to Marshall et al.",
", hereby incorporated by reference).",
"The resulting emulsion was stable for at least 15 days.",
"For convenience, this emulsion is called Spin Finish-5.",
"EXAMPLE 9 (COMPARATIVE) The procedure of Example 2 is followed except that the 500 parts of the oil in water emulsion with which Emulsion-2 is blended contains 20 percent of an oil composition consisting essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol.",
"The resulting emulsion is stable for at least 15 days.",
"For convenience, this emulsion is called Spin Finish-6.",
"Spin Finish-6 and Spin Finish-5 may be used in the same manner to coat yarn during and subsequent to spinning.",
"EXAMPLE 10 (COMPARATIVE) This example demonstrates use of Spin Finish-5 in a conventional spin-draw process for production of a polyamide yarn suitable for processing into bulked yarn that is oil repellent and resistant to soiling, especially by oily materials.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-5 of Example 8 for Spin Finish-1.",
"There was no separation of Spin Finish-5 in the finish circulation system.",
"Bulked yarn made in accordance with this example had a mechanical quality rating of 4.",
"Fabric made from polyamide yarn prepared in accordance with the present example had an oil repellency of 1, due to the presence of hydrogenated castor oil.",
"EXAMPLE 11 (COMPARATIVE) About 50 parts of Fluorochemical Composition-1 were added to a nonhomogeneous mixture consisting essentially of about 30 parts Nekal WS-25, 10 parts dimethyl naphthalene sodium sulfonate, and 10 parts ammonium perfluoroalkyl carboxylate.",
"The mixture was heated to 80° C., at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous mixture.",
"It is believed that the isopropanol (of Nekal WS-25) vaporized.",
"The oil was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for more than 30 days without signs of separation.",
"This emulsion was then blended with 100 parts of an oil composition consisting essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol.",
"The resulting emulsion was stable for at least 30 days.",
"For convenience, this emulsion is called Spin Finish-7.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-7 for Spin Finish-1.",
"Spin Finish-7 gradually separated in the finish circulation system during commercial processing of the yarn and stopped the finish circulating pump.",
"Bulked yarn made in accordance with this example prior to stoppage of the pump had a mechanical quality rating of 3.",
"Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had an oil repellency of 1, due to the presence of hydrogenated castor oil.",
"EXAMPLE 12 (COMPARATIVE) An initial emulsion was formed according to the procedure of Example 11.",
"This emulsion was then blended with 100 parts of an oil composition (second noncontinuous phase) consisting essentially of about 59 percent by weight of coconut oil, about 15.5 percent by weight of polyoxyethlene castor oil containing about 25 moles of ethylene oxide per mole of castor oil, about 7.5 percent by weight of decaglycerol tetraoleate, about 3 percent by weight of glycerol monooleate, about 5 percent by weight of polyoxyethylene sorbitan monooleate containing about 20 moles of ethylene oxide per mole of sorbitan monooleate, and about 10 percent of weight of sulfonated petroleum product (reference U.S. Pat. No. 3,781,202 to Marshall et al.",
", hereby incorporated by reference).",
"The resulting emulsion separated and was not evaluated further.",
"EXAMPLE 13 About 50 parts of Fluorochemical Composition-1 were added to a nonhomogeneous mixture consisting essentially of about 20 parts Nekal WS-25, 10 parts dimethyl naphthalene sodium sulfonate, 20 parts ammonium perfluoralkyl carboxylate, 50 parts polyoxyethylene lauryl ether containing 4 moles of ethylene oxide per mole of lauryl alcohol, and 50 parts of coconut oil.",
"The mixture was heated to 80° C., at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous mixture.",
"It is believed that the isopropanol (of Nekal WS-25) vaporized.",
"This oil was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 28° C. The oil particles in this emulsion had a particle size of less than 3 microns and the emulsion was stable for more than seven days without signs of separation.",
"For convenience, this emulsion is called Spin Finish-8.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-8 for Spin Finish-1.",
"Spin Finish-8 separated in the finish circulation system during processing of the yarn and stopped the finish circulating pump.",
"Bulked yarn made in accordance with this example prior to stoppage of the pump had a mechanical quality rating of 3.",
"Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had an oil repellency of 5-6.",
"EXAMPLE 14 About 50 parts of Fluorochemical Composition-1 were added to a nonhomogeneous mixture consisting essentially of about 24 parts Nekal WS-25, 10 parts dimethyl naphthalene sodium sulfonate, 16 parts ammonium perfluroalkyl carboxylate, 60 parts of coconut oil, and 40 parts of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol.",
"The mixture was heated to 90° C., at which temperature the Fluorochemcial Composition-1 melted and formed a clear homogeneous mixture.",
"It is believed that the isopropanol (of Nekal WS-25) varporized.",
"This oil was then added to 800 parts of water heated to about 90° C., and the mixture was agitated to form an emulsion, which was then cooled to about 28° C. The emulsion was stable for at least three days without signs of separation.",
"For convenience, this emulsion is called Spin Finish-9.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-9 for Spin Finish-1.",
"Spin Finish-9 separated in the finish circulation system during processing of the yarn and stopped the finish circulating pump.",
"Bulked yarn made in accordance with this example prior to stoppage of the pump had a poor mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had excellent oil repellency.",
"EXAMPLE 15 (COMPARATIVE) About 50 parts of Fluorochemical Composition-1 were added to 50 parts of an alkanol amide resulting from the reaction of coco fatty acid (containing about 6 to 18 carbon atoms) and diethanolamine, and the mixture was heated to 80° C. at which temperature the Fluorochemical Composition-1 melted and formed a clear homogeneous mixture.",
"This oil was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for more than thirty days without signs of separation.",
"This emulsion was then blended with 100 parts of an oil composition consisting of about 44.5 percent by weight of butyl stearate, about 27.75 percent by weight of sorbitan monooleate, and about 27.75 percent by weight of polyoxyethylene tallow amine containing about 20 moles of ethylene oxide per mole of tallow amine.",
"(Reference U.S. Pat. No. 4,134,839 to Marshall).",
"The resulting emulsion was stable for at least 30 days.",
"For convenience, this emulsion is called Spin Finish-10.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-10 for Spin Finish-1.",
"Spin Finish-10 gradually separated in the finish circulation system during processing of the yarn and stopped the finish circulating pump.",
"Bulked yarn made in accordance with this example prior to stoppage of the pump had a mechanical quality rating of 1.",
"Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) had an oil repellency of 6.",
"EXAMPLE 16 (COMPARATIVE) About 70 parts of Fluorochemcial Composition-1 were added to 30 parts of a solution which consisted essentially of about 70 percent by weight of sodium dioctyl sulfosuccinate, about 16 percent by weight of propylene glycol and about 14 percent by weight of water.",
"This solution is manufactured under the trade name of Aerosol OT-70-PG and obtainable from the American Cyanamid Company, Industrial Chemical Division, Process Chemicals Department, Wayne, N.J 07470.",
"The Fluorochemcial Composition-1 and solution were heated to 80° C., at which temperature the Fluorochemcial Composition-1 melted and formed a clear homogeneous first noncontinuous phase.",
"This first noncontinuous phase was then added to 800 parts of water heated to about 80° C., and the mixture was agitated to form an emulsion, which was then cooled to about 60° C. The oil particles in this emulsion had a particle size of less than one micron, and the emulsion was stable for at least 30 days without signs of separation.",
"This emulsion was then blended with 100 parts of a second noncontinuous phase consisting essentially of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 percent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid.",
"The resulting emulsion was stable for at least 30 days.",
"For convenience, this emulsion is called Spin Finish-11.",
"The procedure of Example 3 was followed with the substitution of Spin Finish-11 for Spin Finish-1 There was no separation of Spin Finish-11 in the finish circulation system.",
"Bulked yarn made in accordance with this example had a mechanical quality rating of 5.",
"Fabric made from polyamide yarn prepared in accordance with this example had an oil repellency of 5-6.",
"EXAMPLE 17 (COMPARATIVE) An initial emulsion was prepared according to the procedure of Example 16.",
"This emulsion was then blended with 100 parts of the oil composition (second noncontinuous phase) of Example 12.",
"The resulting emulsion separated and was not further evaluated.",
"EXAMPLE 18 (COMPARATIVE) An initial emulsion was prepared according to the procedure of Example 16.",
"This emulsion was then blended with 100 parts of the oil composition (second noncontinuous phase) of Example 8.",
"The resulting emulsion separated and was not further evaluated.",
"EXAMPLE 19 (CONTROL-1) The procedure of Example 3 is followed except that the spin finish of U.S. Pat. No. 4,126,564 was substituted for Spin Finish-1.",
"Bulked yarn made in accordance with this example had a mechanical quality rating of 5.",
"Fabric made from polyamide yarn prepared in accordance with this example had an oil repellency of zero.",
"EXAMPLE 20 (CONTROL-2) The procedure of Example 3 is followed except that the spin finish of U.S. Pat. No. 3,781,202 is substituted for Spin Finish-1.",
"Bulked yarn made in accordance with this example has an acceptable mechanical quality rating.",
"However, fabric made from polyamide yarn prepared in accordance with this example is not oil repellent.",
"EXAMPLES 21-34 About 50 parts of Fluorochemical Composition-1 are added to 50 parts of a nonhomogeneous mixture which consists essentially of about 60 percent by weight of Nekal WS-25, about 20 percent by weight of dimethyl naphthalene sodium sulfonate and about 20 percent by weight of ammonium perfluoroalkyl carboxylate.",
"The Fluorochemical Composition-1 and nonhomogeneous mixture are heated to 80° C., at which temperature the Fluorochemical Composition-1 melts and forms a clear homogeneous noncontinuous phase.",
"It is believed that the isopropanol (of Nekal WS-25) vaporizes.",
"This noncontinuous phase is then added to 900 parts of water which has been heated to about 80° C., and the mixture is agitated to form an emulsion, which is then cooled to room temperature (about 28° C.).",
"The oil particles in this emulsion have a particle size of less than one micron, and the emulsion is stable for at least 30 days without signs of separation.",
"For convenience, this emulsion is called Emulsion-3.",
"EXAMPLE 21 (COMPARATIVE) Polyamide polymer pellets prepared in accordance, generally, with the procedure set forth in Example 3, are melted at about 285° C. and are melt extruded under pressure of about 1,500 psig.",
"through a 70-orifice spinnerette to produce an undrawn yarn having about 3,600 denier.",
"Emulsion-3 is applied to the yarn via a first kiss roll in amount to provide about 0.35 percent by weight of oil on the yarn.",
"A spin finish is applied to the yarn via a second kiss roll immediately subsequent to application of Emulsion-3, in amount to provide about 0.8 percent by weight of oil on the yarn.",
"The spin finish applied by the second kiss roll is an oil in water emulsion of about 20 percent by weight of the roll portion.",
"The oil consists essentially of about 60 percent by weight of refined coconut glyceride, about 30 percent by weight of polyoxyethylene hydrogenated castor oil containing about 16 moles of ethylene oxide per mole of hydrogenated castor oil, and about 10 percent by weight of potassium salt of polyoxyethylene tridecyl phosphate containing about 5 moles of ethylene oxide per mole of tridecyl alcohol.",
"The yarn is then drawn at about 3.2 times the extruded length and textured with a steam jet at a temperature of 140° C. to 180° C. to produce a bulked yarn that is particularly useful for production of carpets and upholstery fabrics.",
"The bulked yarn is visually inspected for mechanical quality after spinning and steam jet texturing as outlined in Example 3.",
"Bulked yarn made in accordance with this example has an acceptable mechanical quality rating.",
"The bulked yarn is made into a fabric by conventional means and is evaluated for oil repellency by AATCC Test No. 118-1975, as set forth in Example 3.",
"The fabric made from polyamide yarn prepared in accordance with the present example is not oil repellent, due to the presence of hydrogenated castor oil.",
"EXAMPLE 22 (COMPARATIVE) The procedure of Example 21 is followed except that the spin finish is applied via the first kiss roll and Emulsion-3 is applied via the second kiss roll.",
"The yarn mechanical quality rating and fabric oil repellency value are similar to Example 21.",
"EXAMPLES 23-24 The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 44.5 percent by weight of butyl stearate, about 27.75 percent by weight of sorbitan monooleate, and about 27.75 percent by weight of polyoxyethylene tallow amine containing about 20 moles of ethylene oxide per mole of tallow amine.",
"In Example 23, the spin finish is applied via the second kiss roll, and in Example 24, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 25-26 The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 55 percent by weight of mineral oil, about 11 percent by weight of a fatty acid soap, about 15 percent by weight of a sulfonated ester ethoxylate, about 12 percent by weight of polyethylene glycol ester, about 6 percent by weight of polyethylene glycol ether, and about 1 percent by weight of triethanolamine.",
"In Example 25, the spin finish is applied via the second kiss roll, and in Example 26, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 27-28 The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether contaning about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene oleate containing about 5 moles of ethylene oxide per mole of oleic acid, and about 15 percent by weight of polyoxyethylene castor oil containing about 5 moles of ethylene oxide per mole os castor oil.",
"In Example 27, the spin finish is applied via the second kiss roll, and in Example 28, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 29-30 The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 59 percent by weight of coconut oil, about 15.5 percent by weight of polyoxyethylene castor oil containing about 25 moles of ethylene oxide per mole of castor oil, about 7.5 percent by weight of decaglycerol tetraoleate, about 3 percent by weight of glycerol monooleate, about 5 percent by weight of polyoxyethylene sorbitan monooleate containing about 20 moles of ethylene oxide per mole of sorbitan monooleate and about 10 percent by weight of sulfonated petroleum product.",
"In Example 29, the spin finish is applied via the second kiss roll, and in Example 30, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 31-32 The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 55 percent by weight of coconut oil, about 25 percent by weight of polyoxyethylene oleyl ether containing about 10 moles of ethylene oxide per mole of oleyl alcohol, about 5 percent by weight of polyoxyethylene nonyl phenol containing about 9 moles of ethylene oxide per mole of nonyl phenol, and about 15 percent by weight of polyoxyethylene stearate containing about 8 moles of ethylene oxide per mole of stearic acid.",
"In Example 31, the spin finish is applied via the second kiss roll, and in Example 32, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 33-34 The procedure of Example 21 is followed except that the oil portion of the spin finish consists of about 50 percent by weight of white mineral oil (350 SUS viscosity), about 48 percent by weight of sodium salt of polyoxyethylene oleyl phosphate containing about 7 moles of ethylene oxide per mole of oleyl alcohol, and about 2 percent by weight of sodium dinonyl sulfosuccinate.",
"In Example 33, the spin finish is applied via the second kiss roll, and in Example 32, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLE 35 Polyethylene terephthalate pellets are melted at about 290° C. and are melt extruded under a pressure of about 2500 psig.",
"through a 34-orifice spinnerette to produce a partially oriented yarn having about 250 denier.",
"Spin Finish-1 of Example 1 is applied to the yarn as a spin finish via a kiss roll in amount to provide about 0.6 percent by weight of oil on the yarn.",
"The yarn is then draw-textured at about 1.3 times the extruded length and at a temperature of 150° C. to 175° C. to produce a bulked yarn having a drawn denier of about 150.",
"Yarn produced in this manner is particularly useful for production of carpets and fine apparel.",
"Bulked yarn made in accordance with this example has an acceptable mechanical quality rating.",
"In accordance with the procedure of Example 3, the bulked yarn of this example is made into fabric for evaluation of oil repellency.",
"Fabric so produced is oil repellent.",
"EXAMPLES 36-37 The procedure of Example 35 is followed except that in lieu of Spin Finish-1 are substituted Spin Finish-3 of Example 5 and Spin Finish-5 of Example 8 in each of, respectively, Examples 36 and 37.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with Example 36 is oil repellent while yarn prepared in accordance with Example 37 is not oil repellent.",
"EXAMPLE 38 (COMPARATIVE) Polyethylene terephthalate pellets are melted at about 290° C. and are melt extruded under a pressure of about 2500 psig.",
"through a 34-orifice spinnerette to produce a partially oriented yarn having about 250 denier.",
"Emulsion-3 (of Examples 21-34) is applied to the yarn via a first kiss roll, and the spin finish of Example 21 is applied to the yarn via a second kiss roll immediately subsequent to application of Emulsion-3, in amount to provide a total of about 0.6 percent by weight of oil on the yarn.",
"The yarn is then draw-textured at about 1.3 times the extruded length and at a temperature of 150° C. to 175° C. to produce a bulked yarn having a drawn denier of about 150.",
"Yarn produced in this manner is particularly useful for production of carpets and fine apparel.",
"Bulked yarn made in accordance with this example has an acceptable mechanical quality rating.",
"In accordance with the produce of Example 3, the bulked yarn of this example is made into fabric for evaluation of oil repellency.",
"Fabric so produced is not oil repellent, due to the presence of hydrogenated castor oil.",
"EXAMPLE 39 (COMPARATIVE) The procedure of Example 38 is followed except that the spin finish is applied via the first kiss roll and Emulsion-3 is applied via the second kiss roll.",
"The yarn mechanical quality rating is acceptable;",
"however, the fabric is not oil repellent.",
"EXAMPLES 40-41 The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 23-24.",
"In Example 40, the spin finish is applied via the second kiss roll, and in Example 41, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 42-43 The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 25-26.",
"In Example 42, the spin finish is applied via the second kiss roll, and in Example 43, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 44-45 The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Exmples 27-28.",
"In Example 44, the spin finish is applied via the second kiss roll, and in Example 45, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 46-47 The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 29-30.",
"In Example 46, the spin finish is applied via the second kiss roll, and in Example 47, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 48-49 The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 31-32.",
"In Example 48, the spin finish is applied via the second kiss roll, and in Example 49, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLES 50-51 The procedure of Example 38 is followed except that the oil portion of the spin finish is as set forth in Examples 33-34.",
"In Example 50, the spin finish is applied via the second kiss roll, and in Example 51, the spin finish is applied via the first kiss roll.",
"Bulked yarn made in accordance with each of these examples has an acceptable mechanical quality rating.",
"Fabric made from polyethylene terephthalate yarn prepared in accordance with each of these examples is oil repellent.",
"EXAMPLE 52 About 46.3 parts of Fluorochemical Composition-1 are added to 53.7 parts of the nonhomogeneous mixture of Example 1, and the two are heated to 80° C., at which temperature the Fluorochemical Composition melts and forms a clear homogeneous yarn finish composition.",
"This composition is sprayed onto 7-inch polyamide staple fiber, which has a denier per filament of 17 and which is produced by a conventional spinning and staple processing operation, prior to baling.",
"The yarn is subsequently heat set and made into carpet by conventional means.",
"Carpet made in accordance with this example is oil repellent.",
"EXAMPLE 53 The procedure of Example 52 is followed except that the yarn is polyethylene terephthalate staple fiber which has a denier per filament of 12.",
"Carpet made in accordance with this procedure is also oil repellent.",
"EXAMPLE 54 Polyamide woven fibric is dipped into a pad box containing Emulsion-3 of Examples 21-34 diluted to 1 percent solids.",
"The fabric is squeezed between a steel and a hard rubber roll with sufficient pressure to obtain a 50 percent wet pickup on the weight of the fabric.",
"The fabric is then cured for 1 minute at 150° C. in a circulating air oven.",
"The fluorine content of the finished fabric is 0.17 percent.",
"This is Sample Number 1.",
"This procedure is repeated, utilizing a polyethylene terephthalate fabric, which is Sample Number 2.",
"After a standard home laundering, the oil repellency of both Sample Numbers 1 and 2, as measured by AATCC Test No. 118-1975 set forth in Example 3, is 6.",
"EXAMPLE 55 The procedure of Example 1 is followed except that in forming the first noncontinuous phase, 50 parts of Fluorochemcial Composition-1 are added to 50 parts of the nonhomogeneous mixture.",
"The resulting emulsion is called Spin Finish-12.",
"The procedure of Example 3 is then followed with substitution of Spin Finish-12 for Spin Finish-1.",
"Spin Finish-12 gradually separates in the finish circulation system during commercial processing of the yarn and stops the finish circulating pump.",
"Bulked yarn made in accordance with this example prior to stoppage of the pump has an acceptable mechanical quality rating.",
"Fabric made from polyamide yarn prepared in accordance with this example (prior to pump stoppage) is oil repellent.",
"DISCUSSION As the preceding examples illustrate, the yarn finish composition of the present invention renders synthetic organic polymer yarn and/or yarn products with which it is incorporated oil repellent and resistant to soiling.",
"Further, emulsions and spin finishes which include the aforementioned yarn finish composition exhibit exceptional emulsion stability for incorporation with synthetic organic polymer yarn and/or yarn products to achieve the same beneficial results.",
"The examples which show little or no increase in soil repellency by virtue of utilizing the present invention in one of these forms, i.e., Examples 10, 11, 21, 22, 37, 38 and 39, have as a common spin finish componenet hydrogenated castor oil, the presence of which has been found to seriously diminish oil repellency.",
"In Example 4, there were defined three critical stages for emulsion stability.",
"Example 4 demonstrated the excellent emulsion stability of the initial oil in water emulsion of the present invention.",
"Examples 1, 2, 5, 6, 8, 9, 11, 13, 14, 15 and 16 demonstrate the second stage emulsion stability of, respectively, Spin Finishes -1,-2,-3,-4,-5,-6,-7,-8,-9,-10,and -11.",
"Further examination of Examples 11, 13, 14, and 15 shows that each of their respective Spin Finishes (-7,-8,-9and-10) gradually separates at the third stage, i.e., in the finish circulation system at the finish circulating pump.",
"A comparison of Spin Finishes -5 and -7 of, respectively, Examples 8 and 11, demonstrates the criticality of proportions of the Fluorochemical Composition-1 and nonhomogeneous mixture to third stage stability.",
"However, application of the yarn finish composition (consisting essentially of these components) to yarn to some method not requiring third stage stability, e.g., by tandem kiss rolls, spraying, padding, etc.",
", still effectively renders the yarn and yarn products oil repellent and resistant to soiling.",
"In this regard, it should be noted that Spin Finish-10 of Example 15 is the subject of commonly assigned U.S. Pat. No. 4,134,839, and Spin Finish-11 of Example 16 is the subject of commonly assigned U.S. Application Ser.",
"No. 974,203, filed Dec. 28, 1978."
] |
FIELD OF THE INVENTION
[0001] The invention relates to spread spectrum signal processing, and more particularly, to detecting a lock status of a GPS signal.
BACKGROUND OF THE INVENTION
[0002] Generally, a GPS receiver must first acquire GPS signals from a plurality of satellites and then track these signals. During the acquisition stage, the carrier frequency and initial phase of the pseudorandom noise code (PRN code) of a received signal are found. These two parameters are then used for tracking the signal.
[0003] Due to the motion of the satellites and the receiver, Doppler effect may occur and the carrier frequency and PRN code may vary over time. To overcome Doppler effect and maintain the availability of GPS signals, a tracking process needs to be performed based on the initial carrier frequency and initial PRN code which are acquired during the acquisition stage. When the variations of carrier frequency and PRN code are successfully tracked by the receiver, the GPS signal is referred to as “locked” by the receiver. When the receiver fails to track the variation, a GPS signal from certain satellite is referred to as “lost”. When a signal is lost, it can not be used by the receiver for further processing such as calculating the position of the receiver. The receiver may need to perform acquisition again to ensure there is enough number of signals acquired and locked for further processing.
[0004] Therefore, there is a need to detect if a GPS signal is locked or lost. When the receiver finds a signal lost, it may need to acquire the signal again or may need to acquire another signal from another satellite. The time used to detect the lock status of the signal is a critical parameter in positioning technology. The shorter the time is needed, the better the receiver performs.
[0005] Conventionally, in a GPS receiver, a bit synchronization method is employed to determine if the signal is locked or lost. More specifically, a bit synchronization module is needed to identify the bit boundaries of navigation data stream after the carrier signal and PRN code have been stripped off from the received GPS signal. The navigation data stream is formed by a sequence of navigation data bits. The lasting time of each data bit is 20 ms. The end of a data bit, which is also the beginning of another data bit, is referred to as a boundary of a navigation data bit (bit boundary). In the bit synchronization method, the lock status of the signal is detected at the same time when the bit boundaries of navigation data stream are determined. If the bit boundaries can not be determined after repeating the search process for a predetermined times, the signal is regarded as lost. The basic idea of this method is to check whether the data transitions always happen in the same position.
[0006] However, there are some drawbacks to this method. First, it is difficult to determine the bit boundaries and the lock status if there are no data transitions within a long bit sequence. In other words, this method is not efficient when there are long sequences of “0” or “1” in the navigation data stream. Second, it is time-consuming. It needs 800 ms to search 40 bits, and totally 4 seconds to confirm the result if the search process needs to be repeated 5 times. Third, the bit synchronization process needs to be performed from time to time in order to detect lock status even after the signal is acquired.
[0007] Therefore, it is to a spread spectrum receiver that is able to detect the lock status of a received signal quickly and efficiently, even if there are long sequences of “0” or “1” in the navigation data stream that the present invention is primarily directed.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method for detecting the lock status of a GPS signal at the receiver. Advantageously, the status can be detected efficiently even if there are long sequences of “0” or “1” in the navigation data stream.
[0009] In one embodiment of the invention, there is provided a method for detecting the lock status of a spread spectrum signal. The method includes producing a first and second data stream by multiplying the spread spectrum signal with an in-phase carrier signal and a quadrature carrier signal, calculating a first integration result based on the first data stream and a predetermined PRN code, calculating a second integration result based on the second data stream and the PRN code, determining a first and second evaluation values in a lock status detector based on the first and second integration results, determining a ratio by dividing the first evaluation value by the second evaluation value, and determining a lock status result in the lock status detector by comparing the ratio with a predetermined value. The method may further include determining the lock status based on multiple lock status results over a time period with a state machine.
[0010] In another embodiment of the invention there is provided an apparatus for detecting lock status of a spread spectrum signal. The apparatus includes a first accumulator, a first calculation unit, a second calculation unit, a second accumulator, a multiplier, a comparator, and a state machine. The first accumulator accumulates an in-phase integration result and a quadrature integration result over a time period respectively. The first calculation unit is coupled to the first accumulator and is capable of determining a first evaluation value based on the accumulated in-phase integration result and the accumulated quadrature integration result. The second calculation unit processes the in-phase integration result and the quadrature integration result. The second accumulator is coupled to the second calculation unit and accumulates the output of the second calculation unit over the time period. At the multiplier, the accumulated result from the second accumulator is multiplied with a predetermined value to determine a second evaluation value. The comparator is coupled to the first calculation unit and the multiplier for comparing the first and second evaluation results. The state machine monitors the output of the comparator and makes a determination indicating whether the signal is locked or lost.
[0011] In yet another embodiment of the invention there is also provided a system for processing a spread spectrum signal. The system includes an acquisition module and a tracking module. The acquisition module provides the tracking module with an initial carrier frequency and a PRN code. The tracking module tracks the spread spectrum signal. The tracking module includes a first integration unit which is capable of producing an in-phase integration result, a second integration unit which is capable of producing a quadrature integration result, a bit synchronization module for detecting boundaries of navigation data bits, a lock status detector coupled to the first and second integration unit, for detecting lock status of the spread spectrum signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Features and advantages of embodiments of the invention will become apparent as the following Detailed Description proceeds, and upon reference to the Drawings, where like numerals depict like elements, and in which:
[0013] FIG. 1 illustrates an exemplary architecture of a GPS tracking module with a lock status detector;
[0014] FIG. 2 illustrates an exemplary architecture of the lock status detector; and
[0015] FIG. 3 illustrates a flow chart of a preferred embodiment of a state machine used to improve the performance of the lock status detector.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 illustrates an exemplary architecture of a tracking module in a GPS receiver with a lock status detector for processing an intermediate frequency (IF) signal. The received GPS signal is first converted to a signal with a desired output frequency and then digitized at a predetermined sampling rate. The converted and digitized signal is known as an IF signal.
[0017] A carrier generator 102 generates two orthogonal carrier signals including an in-phase carrier signal 104 and a quadrature carrier signal 106 . The IF signal is multiplied with these two orthogonal carrier signals at multiplier 108 - 1 and multiplier 108 - 2 to generate a first data stream 110 and a second data stream 111 . A code generator 112 generates three PRN codes: an early code 114 , a late code 116 , and a prompt code 118 . The early code and the late code are both derived from the prompt code time-shifted by approximately one-half-chip more or less. The early code, late code, and prompt code are integrated with the first data stream and the second data stream respectively in a set of integrators, which are numbered consecutively form integrator 119 - 1 to integrator 119 - 6 , to generate six integration results. Integration herein refers to an operation of multiplying one of the data stream with one of the PRN code point by point and sum up the products over a time period. In a preferred embodiment, the time period of integration is 1 ms, which is the period of a PRN code. The in-phase integration result based on the prompt code and the first data stream is referred to as a first integration result Ii 120 . The quadrature integration result based on the prompt code and the second data stream is referred to as a second integration result Qi 122 . Ii and Qi are applied to a carrier tracking controller 124 which controls the carrier generator to generate the two orthogonal carrier signals. Ii and Qi are also applied to a lock status detector 126 to detect the lock status of the signal. The rest four integration results are applied to a code tracking controller 128 which controls the code generator to generate the early, late and prompt codes.
[0018] FIG. 2 illustrates architecture of the lock status detector 126 shown in FIG. 1 . The lock status detector includes a first accumulator 202 , a first calculation unit 204 , a second calculation unit 206 , a second accumulator 208 , low-pass filter (LPF) 210 - 1 , LPF 210 - 2 , a multiplier 214 , a comparator 216 and a state machine 218 . Ii and Qi are divided into two paths: an S channel including the first accumulator 202 , the first calculation unit 204 and LPF 210 - 1 , and an N channel including the second calculation unit 206 , the second accumulator 208 and LPF 210 - 2 .
[0019] In the S channel, Ii and Qi are applied to the first accumulator 202 where Ii and Qi are accumulated over a time period to produce a first accumulated result Is 211 and a second accumulated result Qs 212 , respectively. In a preferred embodiment, each Is is generated by summing up all the Ii which are generated from a navigation data bit and each Qs is generated by summing up all the Qi which are generated from the same navigation data bit. If each Ii and each Qi are the integration results of 1 ms, then, Is and Qs are the accumulated results of 20 Ii and 20 Qi because the period of a navigation data bit is 20 ms. A bit synchronization module (not shown in this figure) is employed to determine the boundaries of the navigation data bits to ensure that Is and Qs can be generated from a complete navigation data bit. According to the present invention, the lock status detector, rather than the bit synchronization module, detects whether a signal is locked or lost. Advantageously, bit synchronization only needs to be performed once after acquisition of the signal compared with the conventional way using bit synchronization module to detect the lock status of the GPS signal from time to time. After a pair of Is and Qs is generated by the first accumulator 202 , a first calculation unit 204 determines a first evaluation value SL based on Is and Qs.
[0020] In the N channel, Ii and Qi are processed in a second calculation unit 206 . The processed results are then accumulated in a second accumulator 208 by summing up multiple processed results in a predetermined time period. The predetermined time period can be multiple of 1 ms. In a preferred embodiment, the predetermined time period is 20 ms which is consistent with the time used to produce Is and Qs in the S channel. The output of the second accumulator 208 is a second evaluation value NL.
[0021] There are various available embodiments of processing Is and Qs in the first calculation unit 204 and processing Ii and Qi in the second calculation unit 206 . Three preferred embodiments are provided herein. In a first embodiment of the invention, in the S channel, the first calculation unit 204 calculates the sum of squares of Is and Qs. In the N channel the second calculation unit 206 calculates the sum of squares of Ii and Qi. The first embodiment can be expressed as the following equation, where
[0000]
∑
i
=
1
M
I
i
[0000] is referred to as Is and
[0000]
∑
i
=
1
M
Q
i
[0000] is referred to as Qs.
[0000]
{
SL
=
(
∑
i
=
1
M
I
i
)
2
+
(
∑
i
=
1
M
Q
i
)
2
NL
=
∑
i
=
1
M
(
I
i
2
+
Q
i
2
)
.
(
1
)
[0022] In a second embodiment, in the S channel, the first calculation unit 204 calculates the sum of squares of Is and Qs and then calculates the square root of the sum of squares. In the N channel, the second calculation unit 206 calculates the sum of squares of Ii and Qi and then calculates the square root of the sum of squares. The second embodiment can be expressed as the following equation.
[0000]
{
SL
=
(
∑
i
=
1
M
I
i
)
2
+
(
∑
i
=
1
M
Q
i
)
2
NL
=
∑
i
=
1
M
(
I
i
2
+
Q
i
2
)
(
2
)
[0023] In a third embodiment, in the S channel, the first calculation unit 204 calculates the sum of absolute values of Is and Qs. In the N channel, the second calculation unit 206 calculates the sum of absolute values of Ii and Qi. The third method is expressed as the following equation.
[0000]
{
SL
=
∑
i
=
1
M
I
i
+
∑
i
=
1
M
Q
i
NL
=
∑
i
=
1
M
(
I
i
+
Q
i
)
(
3
)
[0024] The first evaluation value SL and second evaluation value NL are passed through LPF 210 - 1 and LPF 210 - 2 respectively to obtain smoother filtered results. The LPF can be a first order infinite impulse response filter (IIR filter). The filtered result of the first evaluation value SL is referred to as A and the filtered result of the second evaluation value NL is referred to as C. The ratio of A to C is compared with a threshold value TH to generate a lock status result. For easy implementation, in a preferred embodiment, C is first multiplied with TH at multiplier 214 to obtain a product which is referred to as B, and then A is compared with B at comparator 216 to generate a comparison result, which is an indicator of the lock status. If A is greater than B, it is suggested that the signal may be locked. If B is greater than A, it is suggested that the signal may be lost. To determine the lock status more accurately, the state machine 218 is provided to make a determination based on multiple pairs of A and B.
[0025] FIG. 3 illustrates a flow chart of a preferred embodiment of the state machine 218 used to make the determination if the signal is locked or lost based on multiple pairs of A and B. There are some parameters of the state machine including LOCKCNT, LOSTCNT, LP, LNA, and LO. The outputs of the state machine include a LOCKOUT signal and a LOSTOUT signal. LOCKOUT and LOSTOUT always have values of either “TRUE” or “FALSE”. When the state machine begins to operate, both LOCKOUT and LOSTOUT are initially set to “FALSE”; both LOCKCNT and LOSTCNT are initially set to 0. Each one of LP, LNA and LO is set to a predetermined integer respectively. LO is always greater than LNA. LP, LNA and LO are determined by system requirement such as detection probability, false alarm probability and the time needed to generate a lock status result.
[0026] The state machine receives a pair of A and B and makes a comparison, step 302 . If A is greater than B or if A is equal with B, LOSTOUT is set to FALSE and LOSTCNT is set to 0, step 304 . Then, the state machine checks the value of LOCKCNT, step 306 . If LOCKCNT is equal with LP, LOCKOUT is set to TRUE, step 308 ; else LOCKCNT is increased by 1, step 310 .
[0027] If A is smaller than B, then LOCKCNT is set to 0, step 312 . Then the state machine checks the value of LOSTCNT, step 314 . If LOSTCNT is equal with LO, then LOSTOUT is set to TRUE, step 316 , else LOSTCNT is increased by 1, step 318 . Then the value of LOSTCNT is compared with LNA, step 320 . If LOSTCNT is greater than LNA or LOSTCNT is equal with LNA, then LOCKOUT is set to FALSE, step 322 .
[0028] The lock status is determined by the value of LOCKOUT and LOSTOUT. If LOSTOUT is equal with FALSE and LOCKOUT is equal with TRUE, a status of “locked” is detected and the receiver will further process the information obtained from the signal.
[0029] If LOSTOUT is equal with TRUE and LOCKOUT is equal with FALSE, a status of “lost” is detected. The receiver may stop further processing the signal and may need to perform the acquisition process again.
[0030] If LOSTOUT is equal with FALSE and LOCKOUT is equal with FALSE, a status of “pre-lost” is detected. The status of “pre-lost” means the signal is not locked but may become locked through tracking process. Under this condition, the signal is held and not used for further processing, but acquisition is not performed. The state machine continues running until LOSTCNT is equal with LO to determine a status of “lost”, or until LOCKCNT is equal with LP to determine a status of “locked”.
[0031] In one embodiment of the invention, the state machine can be updated each time when a pair of Is and Qs is produced. To reduce the workload, in another embodiment of the invention, the state machine is updated each time when a predetermined number of Is and Qs have been produced.
[0032] By using the state machine, detection probability can be increased and false alarm probability can be decreased because the final result is based on the signal status which is obtained from a sequence of navigation data bits rather than from only one data bit. Occasional incidental or error has little effect on the final result.
[0033] It will be appreciated by those skilled in the art that apart from the state machine described above, there are different ways to design and implement the state machine, either by hardware or software.
[0034] The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described (or portions thereof), and it is recognized that various modifications are possible within the scope of the claims. Other modifications, variations, and alternatives are also possible. Accordingly, the claims are intended to cover all such equivalents. | An apparatus for detecting lock status of a spread spectrum signal, having a first accumulator, a first calculation unit, a second calculation unit, a second accumulator, a multiplier and a comparator. The first accumulator accumulates an in-phase integration result and a quadrature integration result over a time period. The first calculation unit determines a first evaluation value based on the accumulated in-phase integration result and the accumulated quadrature integration result. The second calculation unit processes the in-phase integration result and the quadrature integration result. The second accumulator accumulates the output of the second calculation unit over the time period. The multiplier determines a second evaluation value by multiplying the accumulated result from the second accumulator with a predetermined value. The comparator compares the first and second evaluation results wherein the comparison result is an indicator of the lock status. | Summarize the key points of the given document. | [
"FIELD OF THE INVENTION [0001] The invention relates to spread spectrum signal processing, and more particularly, to detecting a lock status of a GPS signal.",
"BACKGROUND OF THE INVENTION [0002] Generally, a GPS receiver must first acquire GPS signals from a plurality of satellites and then track these signals.",
"During the acquisition stage, the carrier frequency and initial phase of the pseudorandom noise code (PRN code) of a received signal are found.",
"These two parameters are then used for tracking the signal.",
"[0003] Due to the motion of the satellites and the receiver, Doppler effect may occur and the carrier frequency and PRN code may vary over time.",
"To overcome Doppler effect and maintain the availability of GPS signals, a tracking process needs to be performed based on the initial carrier frequency and initial PRN code which are acquired during the acquisition stage.",
"When the variations of carrier frequency and PRN code are successfully tracked by the receiver, the GPS signal is referred to as “locked”",
"by the receiver.",
"When the receiver fails to track the variation, a GPS signal from certain satellite is referred to as “lost.”",
"When a signal is lost, it can not be used by the receiver for further processing such as calculating the position of the receiver.",
"The receiver may need to perform acquisition again to ensure there is enough number of signals acquired and locked for further processing.",
"[0004] Therefore, there is a need to detect if a GPS signal is locked or lost.",
"When the receiver finds a signal lost, it may need to acquire the signal again or may need to acquire another signal from another satellite.",
"The time used to detect the lock status of the signal is a critical parameter in positioning technology.",
"The shorter the time is needed, the better the receiver performs.",
"[0005] Conventionally, in a GPS receiver, a bit synchronization method is employed to determine if the signal is locked or lost.",
"More specifically, a bit synchronization module is needed to identify the bit boundaries of navigation data stream after the carrier signal and PRN code have been stripped off from the received GPS signal.",
"The navigation data stream is formed by a sequence of navigation data bits.",
"The lasting time of each data bit is 20 ms.",
"The end of a data bit, which is also the beginning of another data bit, is referred to as a boundary of a navigation data bit (bit boundary).",
"In the bit synchronization method, the lock status of the signal is detected at the same time when the bit boundaries of navigation data stream are determined.",
"If the bit boundaries can not be determined after repeating the search process for a predetermined times, the signal is regarded as lost.",
"The basic idea of this method is to check whether the data transitions always happen in the same position.",
"[0006] However, there are some drawbacks to this method.",
"First, it is difficult to determine the bit boundaries and the lock status if there are no data transitions within a long bit sequence.",
"In other words, this method is not efficient when there are long sequences of “0”",
"or “1”",
"in the navigation data stream.",
"Second, it is time-consuming.",
"It needs 800 ms to search 40 bits, and totally 4 seconds to confirm the result if the search process needs to be repeated 5 times.",
"Third, the bit synchronization process needs to be performed from time to time in order to detect lock status even after the signal is acquired.",
"[0007] Therefore, it is to a spread spectrum receiver that is able to detect the lock status of a received signal quickly and efficiently, even if there are long sequences of “0”",
"or “1”",
"in the navigation data stream that the present invention is primarily directed.",
"SUMMARY OF THE INVENTION [0008] The present invention provides a method for detecting the lock status of a GPS signal at the receiver.",
"Advantageously, the status can be detected efficiently even if there are long sequences of “0”",
"or “1”",
"in the navigation data stream.",
"[0009] In one embodiment of the invention, there is provided a method for detecting the lock status of a spread spectrum signal.",
"The method includes producing a first and second data stream by multiplying the spread spectrum signal with an in-phase carrier signal and a quadrature carrier signal, calculating a first integration result based on the first data stream and a predetermined PRN code, calculating a second integration result based on the second data stream and the PRN code, determining a first and second evaluation values in a lock status detector based on the first and second integration results, determining a ratio by dividing the first evaluation value by the second evaluation value, and determining a lock status result in the lock status detector by comparing the ratio with a predetermined value.",
"The method may further include determining the lock status based on multiple lock status results over a time period with a state machine.",
"[0010] In another embodiment of the invention there is provided an apparatus for detecting lock status of a spread spectrum signal.",
"The apparatus includes a first accumulator, a first calculation unit, a second calculation unit, a second accumulator, a multiplier, a comparator, and a state machine.",
"The first accumulator accumulates an in-phase integration result and a quadrature integration result over a time period respectively.",
"The first calculation unit is coupled to the first accumulator and is capable of determining a first evaluation value based on the accumulated in-phase integration result and the accumulated quadrature integration result.",
"The second calculation unit processes the in-phase integration result and the quadrature integration result.",
"The second accumulator is coupled to the second calculation unit and accumulates the output of the second calculation unit over the time period.",
"At the multiplier, the accumulated result from the second accumulator is multiplied with a predetermined value to determine a second evaluation value.",
"The comparator is coupled to the first calculation unit and the multiplier for comparing the first and second evaluation results.",
"The state machine monitors the output of the comparator and makes a determination indicating whether the signal is locked or lost.",
"[0011] In yet another embodiment of the invention there is also provided a system for processing a spread spectrum signal.",
"The system includes an acquisition module and a tracking module.",
"The acquisition module provides the tracking module with an initial carrier frequency and a PRN code.",
"The tracking module tracks the spread spectrum signal.",
"The tracking module includes a first integration unit which is capable of producing an in-phase integration result, a second integration unit which is capable of producing a quadrature integration result, a bit synchronization module for detecting boundaries of navigation data bits, a lock status detector coupled to the first and second integration unit, for detecting lock status of the spread spectrum signal.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0012] Features and advantages of embodiments of the invention will become apparent as the following Detailed Description proceeds, and upon reference to the Drawings, where like numerals depict like elements, and in which: [0013] FIG. 1 illustrates an exemplary architecture of a GPS tracking module with a lock status detector;",
"[0014] FIG. 2 illustrates an exemplary architecture of the lock status detector;",
"and [0015] FIG. 3 illustrates a flow chart of a preferred embodiment of a state machine used to improve the performance of the lock status detector.",
"DETAILED DESCRIPTION OF THE INVENTION [0016] FIG. 1 illustrates an exemplary architecture of a tracking module in a GPS receiver with a lock status detector for processing an intermediate frequency (IF) signal.",
"The received GPS signal is first converted to a signal with a desired output frequency and then digitized at a predetermined sampling rate.",
"The converted and digitized signal is known as an IF signal.",
"[0017] A carrier generator 102 generates two orthogonal carrier signals including an in-phase carrier signal 104 and a quadrature carrier signal 106 .",
"The IF signal is multiplied with these two orthogonal carrier signals at multiplier 108 - 1 and multiplier 108 - 2 to generate a first data stream 110 and a second data stream 111 .",
"A code generator 112 generates three PRN codes: an early code 114 , a late code 116 , and a prompt code 118 .",
"The early code and the late code are both derived from the prompt code time-shifted by approximately one-half-chip more or less.",
"The early code, late code, and prompt code are integrated with the first data stream and the second data stream respectively in a set of integrators, which are numbered consecutively form integrator 119 - 1 to integrator 119 - 6 , to generate six integration results.",
"Integration herein refers to an operation of multiplying one of the data stream with one of the PRN code point by point and sum up the products over a time period.",
"In a preferred embodiment, the time period of integration is 1 ms, which is the period of a PRN code.",
"The in-phase integration result based on the prompt code and the first data stream is referred to as a first integration result Ii 120 .",
"The quadrature integration result based on the prompt code and the second data stream is referred to as a second integration result Qi 122 .",
"Ii and Qi are applied to a carrier tracking controller 124 which controls the carrier generator to generate the two orthogonal carrier signals.",
"Ii and Qi are also applied to a lock status detector 126 to detect the lock status of the signal.",
"The rest four integration results are applied to a code tracking controller 128 which controls the code generator to generate the early, late and prompt codes.",
"[0018] FIG. 2 illustrates architecture of the lock status detector 126 shown in FIG. 1 .",
"The lock status detector includes a first accumulator 202 , a first calculation unit 204 , a second calculation unit 206 , a second accumulator 208 , low-pass filter (LPF) 210 - 1 , LPF 210 - 2 , a multiplier 214 , a comparator 216 and a state machine 218 .",
"Ii and Qi are divided into two paths: an S channel including the first accumulator 202 , the first calculation unit 204 and LPF 210 - 1 , and an N channel including the second calculation unit 206 , the second accumulator 208 and LPF 210 - 2 .",
"[0019] In the S channel, Ii and Qi are applied to the first accumulator 202 where Ii and Qi are accumulated over a time period to produce a first accumulated result Is 211 and a second accumulated result Qs 212 , respectively.",
"In a preferred embodiment, each Is is generated by summing up all the Ii which are generated from a navigation data bit and each Qs is generated by summing up all the Qi which are generated from the same navigation data bit.",
"If each Ii and each Qi are the integration results of 1 ms, then, Is and Qs are the accumulated results of 20 Ii and 20 Qi because the period of a navigation data bit is 20 ms.",
"A bit synchronization module (not shown in this figure) is employed to determine the boundaries of the navigation data bits to ensure that Is and Qs can be generated from a complete navigation data bit.",
"According to the present invention, the lock status detector, rather than the bit synchronization module, detects whether a signal is locked or lost.",
"Advantageously, bit synchronization only needs to be performed once after acquisition of the signal compared with the conventional way using bit synchronization module to detect the lock status of the GPS signal from time to time.",
"After a pair of Is and Qs is generated by the first accumulator 202 , a first calculation unit 204 determines a first evaluation value SL based on Is and Qs.",
"[0020] In the N channel, Ii and Qi are processed in a second calculation unit 206 .",
"The processed results are then accumulated in a second accumulator 208 by summing up multiple processed results in a predetermined time period.",
"The predetermined time period can be multiple of 1 ms.",
"In a preferred embodiment, the predetermined time period is 20 ms which is consistent with the time used to produce Is and Qs in the S channel.",
"The output of the second accumulator 208 is a second evaluation value NL.",
"[0021] There are various available embodiments of processing Is and Qs in the first calculation unit 204 and processing Ii and Qi in the second calculation unit 206 .",
"Three preferred embodiments are provided herein.",
"In a first embodiment of the invention, in the S channel, the first calculation unit 204 calculates the sum of squares of Is and Qs.",
"In the N channel the second calculation unit 206 calculates the sum of squares of Ii and Qi.",
"The first embodiment can be expressed as the following equation, where [0000] ∑ i = 1 M I i [0000] is referred to as Is and [0000] ∑ i = 1 M Q i [0000] is referred to as Qs.",
"[0000] { SL = ( ∑ i = 1 M I i ) 2 + ( ∑ i = 1 M Q i ) 2 NL = ∑ i = 1 M ( I i 2 + Q i 2 ) .",
"( 1 ) [0022] In a second embodiment, in the S channel, the first calculation unit 204 calculates the sum of squares of Is and Qs and then calculates the square root of the sum of squares.",
"In the N channel, the second calculation unit 206 calculates the sum of squares of Ii and Qi and then calculates the square root of the sum of squares.",
"The second embodiment can be expressed as the following equation.",
"[0000] { SL = ( ∑ i = 1 M I i ) 2 + ( ∑ i = 1 M Q i ) 2 NL = ∑ i = 1 M ( I i 2 + Q i 2 ) ( 2 ) [0023] In a third embodiment, in the S channel, the first calculation unit 204 calculates the sum of absolute values of Is and Qs.",
"In the N channel, the second calculation unit 206 calculates the sum of absolute values of Ii and Qi.",
"The third method is expressed as the following equation.",
"[0000] { SL = ∑ i = 1 M I i + ∑ i = 1 M Q i NL = ∑ i = 1 M ( I i + Q i ) ( 3 ) [0024] The first evaluation value SL and second evaluation value NL are passed through LPF 210 - 1 and LPF 210 - 2 respectively to obtain smoother filtered results.",
"The LPF can be a first order infinite impulse response filter (IIR filter).",
"The filtered result of the first evaluation value SL is referred to as A and the filtered result of the second evaluation value NL is referred to as C. The ratio of A to C is compared with a threshold value TH to generate a lock status result.",
"For easy implementation, in a preferred embodiment, C is first multiplied with TH at multiplier 214 to obtain a product which is referred to as B, and then A is compared with B at comparator 216 to generate a comparison result, which is an indicator of the lock status.",
"If A is greater than B, it is suggested that the signal may be locked.",
"If B is greater than A, it is suggested that the signal may be lost.",
"To determine the lock status more accurately, the state machine 218 is provided to make a determination based on multiple pairs of A and B. [0025] FIG. 3 illustrates a flow chart of a preferred embodiment of the state machine 218 used to make the determination if the signal is locked or lost based on multiple pairs of A and B. There are some parameters of the state machine including LOCKCNT, LOSTCNT, LP, LNA, and LO.",
"The outputs of the state machine include a LOCKOUT signal and a LOSTOUT signal.",
"LOCKOUT and LOSTOUT always have values of either “TRUE”",
"or “FALSE.”",
"When the state machine begins to operate, both LOCKOUT and LOSTOUT are initially set to “FALSE”;",
"both LOCKCNT and LOSTCNT are initially set to 0.",
"Each one of LP, LNA and LO is set to a predetermined integer respectively.",
"LO is always greater than LNA.",
"LP, LNA and LO are determined by system requirement such as detection probability, false alarm probability and the time needed to generate a lock status result.",
"[0026] The state machine receives a pair of A and B and makes a comparison, step 302 .",
"If A is greater than B or if A is equal with B, LOSTOUT is set to FALSE and LOSTCNT is set to 0, step 304 .",
"Then, the state machine checks the value of LOCKCNT, step 306 .",
"If LOCKCNT is equal with LP, LOCKOUT is set to TRUE, step 308 ;",
"else LOCKCNT is increased by 1, step 310 .",
"[0027] If A is smaller than B, then LOCKCNT is set to 0, step 312 .",
"Then the state machine checks the value of LOSTCNT, step 314 .",
"If LOSTCNT is equal with LO, then LOSTOUT is set to TRUE, step 316 , else LOSTCNT is increased by 1, step 318 .",
"Then the value of LOSTCNT is compared with LNA, step 320 .",
"If LOSTCNT is greater than LNA or LOSTCNT is equal with LNA, then LOCKOUT is set to FALSE, step 322 .",
"[0028] The lock status is determined by the value of LOCKOUT and LOSTOUT.",
"If LOSTOUT is equal with FALSE and LOCKOUT is equal with TRUE, a status of “locked”",
"is detected and the receiver will further process the information obtained from the signal.",
"[0029] If LOSTOUT is equal with TRUE and LOCKOUT is equal with FALSE, a status of “lost”",
"is detected.",
"The receiver may stop further processing the signal and may need to perform the acquisition process again.",
"[0030] If LOSTOUT is equal with FALSE and LOCKOUT is equal with FALSE, a status of “pre-lost”",
"is detected.",
"The status of “pre-lost”",
"means the signal is not locked but may become locked through tracking process.",
"Under this condition, the signal is held and not used for further processing, but acquisition is not performed.",
"The state machine continues running until LOSTCNT is equal with LO to determine a status of “lost”, or until LOCKCNT is equal with LP to determine a status of “locked.”",
"[0031] In one embodiment of the invention, the state machine can be updated each time when a pair of Is and Qs is produced.",
"To reduce the workload, in another embodiment of the invention, the state machine is updated each time when a predetermined number of Is and Qs have been produced.",
"[0032] By using the state machine, detection probability can be increased and false alarm probability can be decreased because the final result is based on the signal status which is obtained from a sequence of navigation data bits rather than from only one data bit.",
"Occasional incidental or error has little effect on the final result.",
"[0033] It will be appreciated by those skilled in the art that apart from the state machine described above, there are different ways to design and implement the state machine, either by hardware or software.",
"[0034] The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described (or portions thereof), and it is recognized that various modifications are possible within the scope of the claims.",
"Other modifications, variations, and alternatives are also possible.",
"Accordingly, the claims are intended to cover all such equivalents."
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The instant application is a continuation of U.S. patent application Ser. No. 10/181,953 filed on Feb. 5, 2001, which is a National Stage Application of International Application No. PCT/FR01/00336, filed Feb. 5, 2001. Further, the present application claims priority under 35 U.S.C. §119 of French Patent Application No. 00/01420 filed on Feb. 4, 2000. The disclosure of U.S. patent application Ser. No. 10/181,953 is hereby expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to surgical needles manufactured from hyper-elastic alloys and which are intended to be used in celioscopy or endoscopy procedures.
[0004] 2. Discussion of Background Information
[0005] Patent EP 0 529 675 of Aug. 31 1992 in the name of ETHICON INC., describes a surgical needle made of a shape memory alloy which has a low-temperature first state and a high-temperature second state.
[0006] In its low-temperature state, the needle can be configured into an elongate shape so as to allow it to be slipped into a straight tube.
[0007] In its high-temperature state, the needle forms a predetermined arc while the needle is designed to be used as a surgical needle.
[0008] The needle according to patent EP 0 529 675 is particularly well-suited to endoscopy procedures in which elements are taken to the site of surgery via a cannula or trocar which have a small-sized internal diameter.
[0009] The needle described in patent EP 0 529 675 does exhibit certain drawbacks regarding the need to bring the body of the needle arranged at the site of the operation up beside a source of heat in order to cause it to adopt a configuration which is curved into a predetermined arc.
[0010] It is also found that the tapered point of the needle runs the risk of becoming damaged inside the cannula as it is introduced to the site of the operation. What happens is that the small diameter of cannulas, approximately 5 mm, and the somewhat elongate shape of the needle, necessarily lead to its point, which is fragile, being rubbed against the interior wall of the cannula.
[0011] Damage to the tapered point of the needle is irreparable because the surgeon can no longer use it, and this forces him to introduce another needle, taking all possible skillful precautions not to damage it.
SUMMARY OF THE INVENTION
[0012] The surgical needle according to the present invention is intended to define the profile of the tapered point so that the latter does not become damaged against the interior wall of the cannula or of a special applicator of which the inside diameter housing the needle is between 1 and 2 millimeters
[0013] The surgical needle according to the present invention is made of a hyper-elastic alloy which, after treatment, has two distinct states making it possible, on the one hand, to force the needle into a roughly elongate position when it is housed in the internal bore of a cannula or of an applicator and, on the other hand, when it is extracted from the cannula or from the applicator, to adopt a curved profile in the shape of an arc of a circle because of its own characteristics of superelasticity or hyper-elasticity, and in that the needle comprises, at the opposite end to the suture crimping zone, a tapered point provided with an inclined heel which is arranged inside the curvature of the needle and which bears against the interior wall of the bore of the cannula or of the applicator to protect the profile of the tapered point as said needle slides inside the internal bore.
[0014] The surgical needle according to the present invention is made of a hyper-elastic alloy which contains about 54% to 58% of nickel and about 42% to 46% of titanium.
[0015] The surgical needle according to the present invention is made of a hyper-elastic alloy which is made up essentially of nickel, titanium and a small amount of chromium, or iron, or zirconium, modifying either the transformation temperature or the hardness of the alloy.
[0016] The surgical needle according to the present invention is made of a hyper-elastic alloy which undergoes a heat treatment under stress, the temperature of which is between 400° C. and 600° C. for 15 to 60 minutes, followed by a sudden quenching in air or water at between 0° C. and 3° C.
[0017] The surgical needle according to the present invention comprises a crimping zone which is pierced with an internal blind hole intended to house a suture.
[0018] The surgical needle according to the present invention comprises a crimping zone which may, in certain cases, undergo annealing at a temperature of 500° C., followed by slow cooling, after shaping.
[0019] The surgical needle according to the present invention comprises a heel which is inclined by an angle a which depends on the internal diameter of the cannula or of the applicator, on the diameter and on the length of the needle.
[0020] The surgical needle according to the present invention has a cross-sectional profile of triangular shape, one of the vertices of which triangle constitutes the outer edge of the arc of a circle of the needle.
[0021] The surgical needle according to the present invention comprises a heel which lies on the inside of the curvature of the needle and on the opposite side to the outer edge of the triangular profile.
[0022] The surgical needle according to the present invention comprises a crimping zone which has a cross-sectional profile of circular shape.
[0023] The surgical needle according to the present invention comprises, between the crimping zone and the tapered point, a cross-sectional profile of roughly square or rectangular shape.
[0024] The invention also provides for a surgical needle comprising a crimping zone for securing a suture to the needle. The needle is made of a hyper-elastic alloy which, after treatment, has two distinct states. One of the two distinct states allows the needle to be forced into a roughly elongated position when the needle is housed in an internal bore. Another of the two distinct states allows the needle to adopt a curved profile as a result of superelasticity or hyper-elasticity of the needle. The needle has a free end comprising a tapered point which includes an inclined heel portion. The inclined heel portion is arranged on an inside portion of the curved profile. The inclined heel portion of the needle may be adapted to bear against an interior wall of the internal bore. The internal bore may be arranged in one of a cannula and an applicator. The inclined heel portion needle may be adapted to bear against an interior wall of the internal bore of the cannula or of the applicator, whereby a profile of the tapered point is protected when the needle slides inside the internal bore. The curved profile may have the shape of an arc of a circle. The free end may be located on an opposite end to an end of the needle having the crimping zone. The hyper-elastic alloy may contain between about 54% and about 58% of nickel and between about 42% and about 46% of titanium. The hyper-elastic alloy may be essentially made up of nickel, titanium and a small amount of other material. The small amount of other material may comprise at least one of chromium, iron, and zirconium. The small amount of other material may modify at least one of a transformation temperature and a hardness of the hyper-elastic alloy.
[0025] The hyper-elastic alloy may be formed by a heat treatment under stress, a temperature of which is between 400° C. and 600° C. for 15 to 60 minutes, followed by a sudden quenching at between 0° C. and 3° C. The sudden quenching may occur in one of air and water.
[0026] The needle may comprise an internal blind hole located in the crimping zone, the internal blind hole being adapted to receive the suture. The crimping zone may be formed by annealing at a temperature of 500° C., followed by slow cooling. The crimping zone may be formed by annealing at a temperature of 500° C. and shaping, followed by slow cooling.
[0027] The inclined heel portion may be inclined by an angle α, whereby the angle a is based on a diameter of the internal bore, and on the diameter and the length of the needle. The tapered point may comprise a cross-sectional shape that is triangular. A side of the triangular cross-sectional shape may be arranged at an outside portion of the curved profile. The inside portion of the curved profile may be arranged opposite the outside portion of the curved profile. The crimping zone may comprise a cross-sectional shape that is circular. The needle may comprise, between the crimping zone and the free end, a cross-sectional shape that is one of roughly square and roughly rectangular.
[0028] The invention also provides for a surgical needle comprising a crimping end adapted to be secured to a suture. The needle is made of a treated hyper-elastic alloy that is one of superelastic and hyper-elastic, whereby the needle is capable of assuming two distinct states.
[0029] One of the two distinct states is defined by the needle's ability to be forced into a roughly elongated position. Another of the two distinct states is defined by the needle's ability to adopt a curved profile. The needle has a free end comprising a tapered point which includes an inclined heel portion. The inclined heel portion is arranged on an inside part of the curved profile.
[0030] The invention still further provides for a surgical needle having a crimping end adapted to be secured to a suture and a free end, wherein the needle comprises a treated hyper-elastic alloy material that is one of superelastic and hyper-elastic. The needle is capable of assuming first and second positions. The first position is defined by the needle being in a roughly elongated position. The second position is defined by the needle being in a curved position. The free end comprises a tapered point which includes an inclined heel portion. In the second position, the inclined heel portion is arranged on an inside curved part of the curved position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The description which will follow, with reference to the appended drawings which are given by way of non-limiting example, will allow a better understanding of the invention, wherein:
[0032] FIG. 1 is a view illustrating the needle made of hyper-elastic alloy according to the present invention;
[0033] FIG. 2 is a view showing, in detail, the tapered point of the needle according to the present invention;
[0034] FIG. 3 is a view depicting the hyper-elastic needle forced to an elongate position inside the applicator for placement at the site of the operation;
[0035] FIG. 4 is a view similar to that of FIG. 3 but illustrating the needle extracted from the applicator; and
[0036] FIG. 5 is a view showing, in detail, the position at the tapered point of the needle inside the applicator.
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIGS. 1 and 2 show a needle 1 made of a hyper-elastic alloy based on nickel (Ni) and titanium (Ti) and which, after the alloy has been treated, has two distinct states.
[0038] In the first state, the needle 1 can be forced into a roughly elongate position so as to be arranged inside a cannula or applicator 2 .
[0039] In the second state, that is to say when the stress is removed, the needle 1 is shaped into a profile in the shape of an arc of a circle for use at the site of the surgery.
[0040] The switch from the first state to the second is inherent in the characteristics of the alloy which is treated so that it has characteristics of superelasticity or hyper-elasticity.
[0041] The composition of the nickel/titanium alloy varies from 54% to 58% nickel, the remainder being titanium, that is to say from 42% to 46%. Other elements such as chromium (Cr), iron (Fe) and zirconium (Zr) may also be added in very small percentages to modify either the transformation temperature or the hardness.
[0042] The shaping of the needle is accomplished by applying a heat treatment under stress (400° C. to 600° C. for 15 to 60 minutes), followed by sudden quenching in air or water (0° C. to 3° C.).
[0043] The needle 1 comprises a crimping zone 3 which is pierced with an internal bind hole 4 intended to accommodate a suture 5 prior to crimping.
[0044] In certain cases, the crimping region 3 may undergo annealing (at 500° C. followed by slow cooling) after shaping. This heat treatment is intended to locally eliminate the elasticity of the alloy with a view to improving the retention of the suture 5 in the needle 1 .
[0045] At the opposite end to the crimping zone 3 , the needle 1 has a free end which is shaped with the profile of a tapered point 6 . The tapered point 6 of the needle 1 can be thinned or have any other shape.
[0046] The tapered point 6 comprises a heel 7 which is arranged on the inside of the curvature in the shape of an arc of a circle of the needle 1 .
[0047] The heel 7 is inclined by an angle a with respect to a horizontal tangent which depends on the internal diameter of the cannula or of the applicator 2 , on the diameter and on the length of the needle 1 .
[0048] Also, the needle 1 may be manufactured in all shapes known to the art of surgery. For example, the needle 1 may, in cross section, have a circular, square, rectangular or triangular profile.
[0049] A cross-sectional profile of triangular shape has been adopted as a preference for the tapered point 6 , one of the vertices of which triangle constitutes the outer edge of the circular arc of the needle 1 . In this case, the heel 7 is situated on the inside of the curvature of the needle 1 and on the opposite side to the outer edge of the triangular profile.
[0050] The needle 1 has, at the crimping zone 3 , a cross-sectional profile of circular shape, whereas the remainder of the body of the needle which lies between the tapered point 6 and the said crimping zone 3 has a cross-sectional profile of roughly square or rectangular shape.
[0051] The roughly square or rectangular cross-sectional profile of the body of the needle 1 allows the surgeon to grasp it with greater ease in forceps or a needle holder.
[0052] FIG. 3 depicts the applicator 2 for the placement of the needle 1 secured to its suture 3 at the site of the surgery using a trocar 8 which has already been placed through the wall 9 of a patient.
[0053] This applicator has been described and protected in a French patent No. 97 07681 (which corresponds to U.S. Pat. No. 6,179,035) of which the applicant is the owner.
[0054] The applicator 2 comprises a cylindrical sleeve 10 pierced along its entire length and parallel to its longitudinal axis with a bore 11 in which the needle 1 and its suture 5 are housed.
[0055] The sleeve 10 comprises at one of its ends a cylindrical head 12 which is given a diameter greater than that of the remainder of the body of the sleeve.
[0056] The needle 1 is arranged in the bore 11 of the sleeve 10 in such a way that its tapered point 6 faces toward the free end 13 and away from the end with the head 12 .
[0057] The applicator 2 comprises a rod 14 which is secured at one of its ends to a cylindrical stop 15 .
[0058] The rod 14 is introduced into the sleeve 10 in such a way as to bear against the needle 1 . The rod 14 passes through the bore 11 , so that the suture 5 is arranged between the rod and the wall of the bore.
[0059] Retaining mechanism 16 allows the rod 14 to be held in position with respect to the sleeve 10 , so that the free end of the rod 14 which is the opposite end to the stop 15 , always presses against the needle 1 .
[0060] The applicator 2 is arranged inside the trocar 8 which has already been placed through the wall 9 of a patient.
[0061] The trocar includes a tube 17 secured at one of its ends to a circular skirt 18 acting as a stop for the applicator when the needle 1 is placed at the site of the surgery as will be seen better later on.
[0062] The tube 17 of the trocar 8 is designed to accommodate the sleeve 10 of the applicator 2 , while the head 12 bears against the circular skirt 18 .
[0063] The surgeon then withdraws the retaining mechanism 16 in order to release the rod 14 with respect to the sleeve 10 .
[0064] FIG. 4 shows the extraction of the needle 1 from the sleeve 10 of the applicator 2 .
[0065] All the surgeon needs do is to press, in the direction of the arrow F, on the stop 15 of the rod 14 , so as, via the rod 14 , to push the needle 1 out of the sleeve 10 . The displacement of the rod 14 is limited in its travel to the point where the stop 15 makes contact with the head 12 of the sleeve 10 .
[0066] When the needle 1 is extracted from the sleeve 10 of the applicator, this needle, because of its elasticity, adopts its circular-arc shape, allowing the surgeon to suture.
[0067] FIG. 5 shows the position of the tapered point 6 of the needle 1 inside the bore 11 of the sleeve 10 of the applicator 2 .
[0068] It can be seen that the heel 7 allows the tapered point 6 of the needle to be protected as it moves or slides inside the bore 11 of the sleeve 10 .
[0069] What happens is that only the heel 7 , and more particularly, the point where it meets the curved part of the needle 1 , is in contact with the internal wall of the bore 11 of the sleeve 10 , thus protecting the tapered point 6 against any damage due to rubbing.
[0070] It goes without saying that the applicator 2 may be replaced by a cannula or a trocar which are known per se for the placement of the needle 1 inside the operating site, without that in any way changing the subject of the present invention. | A method of arranging a surgical needle in an applicator. The needle is made of a hyper-elastic alloy which, after treatment, has two distinct states and includes a crimping zone for securing a suture to the needle, a free end having a tapered point which includes an inclined heel portion arranged on an inside portion of a curved profile. The method includes forcing the needle into a roughly elongated position when the needle is housed in an internal bore of the applicator. When the needle is not housed in an internal bore of the applicator, the needle adopts a curved profile as a result of superelasticity or hyper-elasticity of the needle. | Condense the core contents of the given document. | [
"CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The instant application is a continuation of U.S. patent application Ser.",
"No. 10/181,953 filed on Feb. 5, 2001, which is a National Stage Application of International Application No. PCT/FR01/00336, filed Feb. 5, 2001.",
"Further, the present application claims priority under 35 U.S.C. §119 of French Patent Application No. 00/01420 filed on Feb. 4, 2000.",
"The disclosure of U.S. patent application Ser.",
"No. 10/181,953 is hereby expressly incorporated by reference in its entirety.",
"BACKGROUND OF THE INVENTION [0002] 1.",
"Field of the Invention [0003] The present invention relates to surgical needles manufactured from hyper-elastic alloys and which are intended to be used in celioscopy or endoscopy procedures.",
"[0004] 2.",
"Discussion of Background Information [0005] Patent EP 0 529 675 of Aug. 31 1992 in the name of ETHICON INC.",
", describes a surgical needle made of a shape memory alloy which has a low-temperature first state and a high-temperature second state.",
"[0006] In its low-temperature state, the needle can be configured into an elongate shape so as to allow it to be slipped into a straight tube.",
"[0007] In its high-temperature state, the needle forms a predetermined arc while the needle is designed to be used as a surgical needle.",
"[0008] The needle according to patent EP 0 529 675 is particularly well-suited to endoscopy procedures in which elements are taken to the site of surgery via a cannula or trocar which have a small-sized internal diameter.",
"[0009] The needle described in patent EP 0 529 675 does exhibit certain drawbacks regarding the need to bring the body of the needle arranged at the site of the operation up beside a source of heat in order to cause it to adopt a configuration which is curved into a predetermined arc.",
"[0010] It is also found that the tapered point of the needle runs the risk of becoming damaged inside the cannula as it is introduced to the site of the operation.",
"What happens is that the small diameter of cannulas, approximately 5 mm, and the somewhat elongate shape of the needle, necessarily lead to its point, which is fragile, being rubbed against the interior wall of the cannula.",
"[0011] Damage to the tapered point of the needle is irreparable because the surgeon can no longer use it, and this forces him to introduce another needle, taking all possible skillful precautions not to damage it.",
"SUMMARY OF THE INVENTION [0012] The surgical needle according to the present invention is intended to define the profile of the tapered point so that the latter does not become damaged against the interior wall of the cannula or of a special applicator of which the inside diameter housing the needle is between 1 and 2 millimeters [0013] The surgical needle according to the present invention is made of a hyper-elastic alloy which, after treatment, has two distinct states making it possible, on the one hand, to force the needle into a roughly elongate position when it is housed in the internal bore of a cannula or of an applicator and, on the other hand, when it is extracted from the cannula or from the applicator, to adopt a curved profile in the shape of an arc of a circle because of its own characteristics of superelasticity or hyper-elasticity, and in that the needle comprises, at the opposite end to the suture crimping zone, a tapered point provided with an inclined heel which is arranged inside the curvature of the needle and which bears against the interior wall of the bore of the cannula or of the applicator to protect the profile of the tapered point as said needle slides inside the internal bore.",
"[0014] The surgical needle according to the present invention is made of a hyper-elastic alloy which contains about 54% to 58% of nickel and about 42% to 46% of titanium.",
"[0015] The surgical needle according to the present invention is made of a hyper-elastic alloy which is made up essentially of nickel, titanium and a small amount of chromium, or iron, or zirconium, modifying either the transformation temperature or the hardness of the alloy.",
"[0016] The surgical needle according to the present invention is made of a hyper-elastic alloy which undergoes a heat treatment under stress, the temperature of which is between 400° C. and 600° C. for 15 to 60 minutes, followed by a sudden quenching in air or water at between 0° C. and 3° C. [0017] The surgical needle according to the present invention comprises a crimping zone which is pierced with an internal blind hole intended to house a suture.",
"[0018] The surgical needle according to the present invention comprises a crimping zone which may, in certain cases, undergo annealing at a temperature of 500° C., followed by slow cooling, after shaping.",
"[0019] The surgical needle according to the present invention comprises a heel which is inclined by an angle a which depends on the internal diameter of the cannula or of the applicator, on the diameter and on the length of the needle.",
"[0020] The surgical needle according to the present invention has a cross-sectional profile of triangular shape, one of the vertices of which triangle constitutes the outer edge of the arc of a circle of the needle.",
"[0021] The surgical needle according to the present invention comprises a heel which lies on the inside of the curvature of the needle and on the opposite side to the outer edge of the triangular profile.",
"[0022] The surgical needle according to the present invention comprises a crimping zone which has a cross-sectional profile of circular shape.",
"[0023] The surgical needle according to the present invention comprises, between the crimping zone and the tapered point, a cross-sectional profile of roughly square or rectangular shape.",
"[0024] The invention also provides for a surgical needle comprising a crimping zone for securing a suture to the needle.",
"The needle is made of a hyper-elastic alloy which, after treatment, has two distinct states.",
"One of the two distinct states allows the needle to be forced into a roughly elongated position when the needle is housed in an internal bore.",
"Another of the two distinct states allows the needle to adopt a curved profile as a result of superelasticity or hyper-elasticity of the needle.",
"The needle has a free end comprising a tapered point which includes an inclined heel portion.",
"The inclined heel portion is arranged on an inside portion of the curved profile.",
"The inclined heel portion of the needle may be adapted to bear against an interior wall of the internal bore.",
"The internal bore may be arranged in one of a cannula and an applicator.",
"The inclined heel portion needle may be adapted to bear against an interior wall of the internal bore of the cannula or of the applicator, whereby a profile of the tapered point is protected when the needle slides inside the internal bore.",
"The curved profile may have the shape of an arc of a circle.",
"The free end may be located on an opposite end to an end of the needle having the crimping zone.",
"The hyper-elastic alloy may contain between about 54% and about 58% of nickel and between about 42% and about 46% of titanium.",
"The hyper-elastic alloy may be essentially made up of nickel, titanium and a small amount of other material.",
"The small amount of other material may comprise at least one of chromium, iron, and zirconium.",
"The small amount of other material may modify at least one of a transformation temperature and a hardness of the hyper-elastic alloy.",
"[0025] The hyper-elastic alloy may be formed by a heat treatment under stress, a temperature of which is between 400° C. and 600° C. for 15 to 60 minutes, followed by a sudden quenching at between 0° C. and 3° C. The sudden quenching may occur in one of air and water.",
"[0026] The needle may comprise an internal blind hole located in the crimping zone, the internal blind hole being adapted to receive the suture.",
"The crimping zone may be formed by annealing at a temperature of 500° C., followed by slow cooling.",
"The crimping zone may be formed by annealing at a temperature of 500° C. and shaping, followed by slow cooling.",
"[0027] The inclined heel portion may be inclined by an angle α, whereby the angle a is based on a diameter of the internal bore, and on the diameter and the length of the needle.",
"The tapered point may comprise a cross-sectional shape that is triangular.",
"A side of the triangular cross-sectional shape may be arranged at an outside portion of the curved profile.",
"The inside portion of the curved profile may be arranged opposite the outside portion of the curved profile.",
"The crimping zone may comprise a cross-sectional shape that is circular.",
"The needle may comprise, between the crimping zone and the free end, a cross-sectional shape that is one of roughly square and roughly rectangular.",
"[0028] The invention also provides for a surgical needle comprising a crimping end adapted to be secured to a suture.",
"The needle is made of a treated hyper-elastic alloy that is one of superelastic and hyper-elastic, whereby the needle is capable of assuming two distinct states.",
"[0029] One of the two distinct states is defined by the needle's ability to be forced into a roughly elongated position.",
"Another of the two distinct states is defined by the needle's ability to adopt a curved profile.",
"The needle has a free end comprising a tapered point which includes an inclined heel portion.",
"The inclined heel portion is arranged on an inside part of the curved profile.",
"[0030] The invention still further provides for a surgical needle having a crimping end adapted to be secured to a suture and a free end, wherein the needle comprises a treated hyper-elastic alloy material that is one of superelastic and hyper-elastic.",
"The needle is capable of assuming first and second positions.",
"The first position is defined by the needle being in a roughly elongated position.",
"The second position is defined by the needle being in a curved position.",
"The free end comprises a tapered point which includes an inclined heel portion.",
"In the second position, the inclined heel portion is arranged on an inside curved part of the curved position.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0031] The description which will follow, with reference to the appended drawings which are given by way of non-limiting example, will allow a better understanding of the invention, wherein: [0032] FIG. 1 is a view illustrating the needle made of hyper-elastic alloy according to the present invention;",
"[0033] FIG. 2 is a view showing, in detail, the tapered point of the needle according to the present invention;",
"[0034] FIG. 3 is a view depicting the hyper-elastic needle forced to an elongate position inside the applicator for placement at the site of the operation;",
"[0035] FIG. 4 is a view similar to that of FIG. 3 but illustrating the needle extracted from the applicator;",
"and [0036] FIG. 5 is a view showing, in detail, the position at the tapered point of the needle inside the applicator.",
"DETAILED DESCRIPTION OF THE INVENTION [0037] FIGS. 1 and 2 show a needle 1 made of a hyper-elastic alloy based on nickel (Ni) and titanium (Ti) and which, after the alloy has been treated, has two distinct states.",
"[0038] In the first state, the needle 1 can be forced into a roughly elongate position so as to be arranged inside a cannula or applicator 2 .",
"[0039] In the second state, that is to say when the stress is removed, the needle 1 is shaped into a profile in the shape of an arc of a circle for use at the site of the surgery.",
"[0040] The switch from the first state to the second is inherent in the characteristics of the alloy which is treated so that it has characteristics of superelasticity or hyper-elasticity.",
"[0041] The composition of the nickel/titanium alloy varies from 54% to 58% nickel, the remainder being titanium, that is to say from 42% to 46%.",
"Other elements such as chromium (Cr), iron (Fe) and zirconium (Zr) may also be added in very small percentages to modify either the transformation temperature or the hardness.",
"[0042] The shaping of the needle is accomplished by applying a heat treatment under stress (400° C. to 600° C. for 15 to 60 minutes), followed by sudden quenching in air or water (0° C. to 3° C.).",
"[0043] The needle 1 comprises a crimping zone 3 which is pierced with an internal bind hole 4 intended to accommodate a suture 5 prior to crimping.",
"[0044] In certain cases, the crimping region 3 may undergo annealing (at 500° C. followed by slow cooling) after shaping.",
"This heat treatment is intended to locally eliminate the elasticity of the alloy with a view to improving the retention of the suture 5 in the needle 1 .",
"[0045] At the opposite end to the crimping zone 3 , the needle 1 has a free end which is shaped with the profile of a tapered point 6 .",
"The tapered point 6 of the needle 1 can be thinned or have any other shape.",
"[0046] The tapered point 6 comprises a heel 7 which is arranged on the inside of the curvature in the shape of an arc of a circle of the needle 1 .",
"[0047] The heel 7 is inclined by an angle a with respect to a horizontal tangent which depends on the internal diameter of the cannula or of the applicator 2 , on the diameter and on the length of the needle 1 .",
"[0048] Also, the needle 1 may be manufactured in all shapes known to the art of surgery.",
"For example, the needle 1 may, in cross section, have a circular, square, rectangular or triangular profile.",
"[0049] A cross-sectional profile of triangular shape has been adopted as a preference for the tapered point 6 , one of the vertices of which triangle constitutes the outer edge of the circular arc of the needle 1 .",
"In this case, the heel 7 is situated on the inside of the curvature of the needle 1 and on the opposite side to the outer edge of the triangular profile.",
"[0050] The needle 1 has, at the crimping zone 3 , a cross-sectional profile of circular shape, whereas the remainder of the body of the needle which lies between the tapered point 6 and the said crimping zone 3 has a cross-sectional profile of roughly square or rectangular shape.",
"[0051] The roughly square or rectangular cross-sectional profile of the body of the needle 1 allows the surgeon to grasp it with greater ease in forceps or a needle holder.",
"[0052] FIG. 3 depicts the applicator 2 for the placement of the needle 1 secured to its suture 3 at the site of the surgery using a trocar 8 which has already been placed through the wall 9 of a patient.",
"[0053] This applicator has been described and protected in a French patent No. 97 07681 (which corresponds to U.S. Pat. No. 6,179,035) of which the applicant is the owner.",
"[0054] The applicator 2 comprises a cylindrical sleeve 10 pierced along its entire length and parallel to its longitudinal axis with a bore 11 in which the needle 1 and its suture 5 are housed.",
"[0055] The sleeve 10 comprises at one of its ends a cylindrical head 12 which is given a diameter greater than that of the remainder of the body of the sleeve.",
"[0056] The needle 1 is arranged in the bore 11 of the sleeve 10 in such a way that its tapered point 6 faces toward the free end 13 and away from the end with the head 12 .",
"[0057] The applicator 2 comprises a rod 14 which is secured at one of its ends to a cylindrical stop 15 .",
"[0058] The rod 14 is introduced into the sleeve 10 in such a way as to bear against the needle 1 .",
"The rod 14 passes through the bore 11 , so that the suture 5 is arranged between the rod and the wall of the bore.",
"[0059] Retaining mechanism 16 allows the rod 14 to be held in position with respect to the sleeve 10 , so that the free end of the rod 14 which is the opposite end to the stop 15 , always presses against the needle 1 .",
"[0060] The applicator 2 is arranged inside the trocar 8 which has already been placed through the wall 9 of a patient.",
"[0061] The trocar includes a tube 17 secured at one of its ends to a circular skirt 18 acting as a stop for the applicator when the needle 1 is placed at the site of the surgery as will be seen better later on.",
"[0062] The tube 17 of the trocar 8 is designed to accommodate the sleeve 10 of the applicator 2 , while the head 12 bears against the circular skirt 18 .",
"[0063] The surgeon then withdraws the retaining mechanism 16 in order to release the rod 14 with respect to the sleeve 10 .",
"[0064] FIG. 4 shows the extraction of the needle 1 from the sleeve 10 of the applicator 2 .",
"[0065] All the surgeon needs do is to press, in the direction of the arrow F, on the stop 15 of the rod 14 , so as, via the rod 14 , to push the needle 1 out of the sleeve 10 .",
"The displacement of the rod 14 is limited in its travel to the point where the stop 15 makes contact with the head 12 of the sleeve 10 .",
"[0066] When the needle 1 is extracted from the sleeve 10 of the applicator, this needle, because of its elasticity, adopts its circular-arc shape, allowing the surgeon to suture.",
"[0067] FIG. 5 shows the position of the tapered point 6 of the needle 1 inside the bore 11 of the sleeve 10 of the applicator 2 .",
"[0068] It can be seen that the heel 7 allows the tapered point 6 of the needle to be protected as it moves or slides inside the bore 11 of the sleeve 10 .",
"[0069] What happens is that only the heel 7 , and more particularly, the point where it meets the curved part of the needle 1 , is in contact with the internal wall of the bore 11 of the sleeve 10 , thus protecting the tapered point 6 against any damage due to rubbing.",
"[0070] It goes without saying that the applicator 2 may be replaced by a cannula or a trocar which are known per se for the placement of the needle 1 inside the operating site, without that in any way changing the subject of the present invention."
] |
This application is a continuation of application Ser. No. 552,439, filed July, 13, 1990, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to web processing apparatus and, more particularly, to a speed control assembly for a web winder.
continuous web processing apparatus such as web printers generally include a web "unwind" or "supply" spool from which unprocessed web material is supplied and a web "rewind" or "windup" or "collection" spool upon which the processed web is collected. Each of these spools is typically mounted upon a separate, driven, winder apparatus which rotates the spool mounted thereon at a selected rate. As the diameter of the web wound about a spool changes, the rotational velocity of the spool must also change if a constant web supply or collection rate is to be maintained. The rotation rate of the web winding apparatus must also be adjusted to accommodate for speed fluctuations at various web processing operating stations which are positioned along the web between the unwind and rewind spools. The most common method for maintaining proper winder speed is through use of a dancer assembly. A dancer assembly is a device consisting of at least one idler roll which is positioned in contact with the web of material. The dancer roll is displaceable in a direction transverse to the direction of web movement and is biased in a direction which opposes the tension applied to the dancer roll by the web. The bias force is of a magnitude such that when the web processing machine is operating at its normal web tensions, the dancer is positioned near the center of its range of movement. If the speed of the web varies with respect to the speed of the associated winder in a manner which decreases web tension, the dancer is displaced by the bias force in a direction to take up the resulting "slack" in the web. If the operation of the associated winder with respect to web line speed is such that the tension in the web increases, the dancer is displaced by the web tension force in a direction which shortens the web path and reduces web tension.
Winder speed is controlled by varying the speed of the winder in response to the displacement of the associated dancer assembly.
Various methods of processing a dancer displacement signal to control winder speed are known in the prior art. One method, known as 100% proportional control, is illustrated in FIG. 1. In this method of control, the winder motor velocity is increased or decreased as a linear function of dancer displacement from a dancer position near one end of the dancer travel path. The winder velocity to dancer position relationship for a supply winder is indicated in solid lines. The winder velocity to dancer position relationship for a collection winder having a dancer assembly identical to that for the supply winder is indicated in dashed lines. In such a system, at one end of the dancer travel range the winder operates at full speed, and at the other end of the dancer travel range the winder stops. Typically, the range of dancer displacement is selected to be somewhat larger than the range of dancer displacement needed to compensate for changes in roll diameter in order to accommodate other transient fluctuations in web speed. Such 100% proportional speed control results in a system which is very responsive but difficult to stabilize. In situations where the web being processed is an extensible web such as plastic film, a 100% proportional control system becomes totally unstable and unusable.
In a variation of the 100% proportional control method illustrated in FIG. 1, the dancer displacement signal is used in the same manner to control web speed. However, it accounts for only a small portion, e.g. 10%, of the total winder velocity control signal. The remainder of the signal is a line speed reference signal produced by a web speed monitor positioned along the web at a point intermediate the unwind and rewind assemblies. In such a control scheme, the dancer is relatively unresponsive and thus the system is easy to stabilize for stead-state conditions. However, in such a scheme, the dancer typically runs off-center some amount to compensate for calibration error or web stretch. This type of system experiences trouble with major tension variations in the web and will reach a mechanical limit for correction due to the dancer's lack of responsiveness.
In another method of winder speed control, the winder is provided with a tachometer which provides a speed signal. This winder speed signal and a web line speed signal are provided to a computer and used to compute the associated winder spool web diameter. A base winder speed is then calculated by dividing line speed by winder spool web diameter. The calculated winder speed is thereafter trimmed with a velocity signal calculated as a linear function of dancer displacement such as illustrated in FIG. 1. Such systems are quite expensive and require factory technicians for accurate calibration and setup.
Another method of winder speed control is known in the art as 100% integrated dancer centering speed control. According to this method, an analog integrator receives an input representative of linear dancer displacement and a winder acceleration (as opposed to velocity) signal is calculated which is linearly proportional to the dancer displacement signal. In such a system, the dancer under normal operating conditions remains at the center of its displacement range. However, it is generally difficult to find a balance between stability and responsiveness for such a control system. A graph indicative of winder motor acceleration response to dancer displacement for such a system is illustrated in FIG. 2.
In a variation on the 100% integrated dancer centering control system illustrated in FIG. 2, a signal identical to that illustrated in FIG. 2 is initially provided. However, the control system rather than using this signal as a motor acceleration signal instead uses it as a spool diameter signal and the winder velocity signal is provided by dividing web line speed by this diameter signal. Such systems generally require a factory technical for setup. Such systems are subject to failure due to calibration shifts and also experience stability problems.
SUMMARY OF THE INVENTION
The present invention may comprise a speed control assembly for a rotatable web winding apparatus comprising: dancer means engaged with a web of material wound about said winder apparatus for displaceably responding within a predetermined range of dancer positions to tension variations in said web; first control signal generating means for generating a first control signal in response to dancer means displacement from a predetermined centered position, the ratio of dancer displacement to said first control signal being variable over said range of dancer displacement positions; and dancer response rotation control means for rotationally accelerating said winding apparatus in response to said first control signal.
The invention may also comprise a speed control assembly for a rotatable web winding apparatus comprising dancer means engaging with a web of material wound about said winder apparatus for displaceably responding within a predetermined range of dancer positions to tension variations in said web; first control signal generating means for generating a first control signal in response to dancer means displacement from a predetermined centered position, the ratio of dancer displacement to said first control signal being variable over said range of dancer displacement positions; dancer response rotation control means for rotationally accelerating said winding apparatus in response to said first control signal; wherein said dancer means comprises a dancer signal generating means for generating a dancer signal which is proportionate to the amount of displacement of said dancer means from said predetermined centered position and wherein said first control signal generating means processes said dancer signal to generate said first control signal; wherein said first control signal changes relatively slowly in response to dancer displacement within a first range of dancer positions which includes said predetermined centered position and wherein said first control signal changes relatively more rapidly in response to dancer displacement within a second range of dancer positions lying outside of said first range of positions; wherein said first control signal changes relatively most quickly in response to dancer displacement in a third range of dancer positions lying outside of said second range of positions; wherein the ratio of said first control signal to said dancer signal is a first constant value when said dancer mean is positioned within said first range of dancer positions; wherein the ratio of said first control signal to said dancer signal is a second constant value greater than said first constant value when said dancer means is positioned within said second range of dancer positions; wherein the ratio of said first control signal to said dancer signal is a third constant value greater than said second constant value when said dancer means is positioned within said third range of dancer positions; wherein said dancer response rotation control means comprises: motor means drivingly linked to said winding apparatus for rotating said winding apparatus; motor control means for controlling the speed of said motor means in response to a motor speed control signal; and speed control signal generating for receiving said first control signal and for generating said motor speed control signal in response thereto; web speed monitoring means for measuring web speed at a position on the web which is more remote from said web winding apparatus than the position of said dancer means and for generating a web speed signal indicative of said measurement; web speed response rotation control mean for receiving said web speed signal and for rotationally accelerating said winding apparatus by an amount dependent upon said web speed signal; whereby total winding apparatus acceleration is dependent upon web tension at said dancer means and web speed at said web speed monitoring means.
The invention may also comprise a method of controlling the rotational speed of a web winding apparatus comprising: monitoring the displacement of a web dancer from a predetermined dancer position; generating a first control signal which is a predetermined nonlinear function of dancer displacement over a predetermined range of dancer displacement position; accelerating said web winding apparatus in response to said first control signal.
BRIEF DESCRIPTION OF THE DRAWINGS
An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which:
FIG. 1 is a graph illustrating the relationship between dancer position and winder motor velocity in one prior art method of winder control.
FIG. 2 is a graph illustrating the relationship between dancer position and winder motor acceleration in a second prior art method of web winder control.
FIG. 3 is a schematic elevation view of a web processing system.
FIG. 4 is a graph illustrating the relationship between dancer position and winder motor acceleration for web winders used in the web processing assembly of FIG. 3.
FIG. 5 is a circuit diagram of a circuit used for generating a web winder motor velocity signal from a dancer displacement signal.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 is a schematic illustration of a web processing apparatus 10 such as a web printer. A continuous web of material 12 is unwound from a supply roll 14 (also referred to as an unwind spool), processed at one or more processing stations 16 located downstream from the supply roll 14, and collected on a web rewind spool 18 (also referred to as a collection spool or a windup spool).
The unwind spool 14 is rotated about an axis AA by a direct current (DC) drive motor 22 which rotates spool 14 at a rotation rate which is directly proportional to the drive motor rotation rate. The drive motor 22 operates at a velocity which is directly proportional to a velocity command signal 24 which it receives from speed control assembly 26.
Speed control assembly 26 generates velocity control signal 24 by integrating a motor acceleration signal 28 which it receives from nonlinear dancer response circuit 30.
Nonlinear dancer response circuit 30 calculates control signal 28 from a dancer signal 32 generated by dancer displacement sensing device 34. Dancer signal 32 is directly proportional to the displacement of dancer 36.
Dancer 36 includes an idler roll 38, engaged by web 12, which is displaceable between a lowermost position 40 and an uppermost position 42. The dancer roll is biased toward position 40 by a conventional biasing device (not shown) of the type adapted to provide a biasing force which is constant over the displacement of the dancer from position 40 to 42. The biasing force is selected which corresponds to the normal tension setting of the web processing apparatus. Thus, if web velocity downstream of dancer assembly 36 becomes greater than the surface velocity of the web on spool 14, dancer roll 38 is displaced downwardly, and if web downstream velocity falls below that of the surface velocity of the web on spool 14, dancer 38 is displaced upwardly.
Web processing stations illustrated generally at 16 may comprise a pair of nip rolls 50, 52, which are driven at a relatively constant rate by a nip motor 54. In a typical processing operation, continuous web 12 is provided with a repeating set of web graphics at a printing nip 56 provided by rolls 50, 52.
Downstream of the web processing station 16, rewind spool 18 collects the processed web. Rewind spool 18 is rotated about axis BB by a DC drive motor 62 which drives spool 18 at a rate proportional to the drive motor rotation rate. Drive motor 62 rotates spool 18 at a rate which is linear proportionate to its own rotation rate. DC motor 62 receives a speed control command 64 from a control circuit 66 which integrates an acceleration command 68 which is generated by nonlinear dancer response circuit 70. Dancer response circuit 70 receives a dancer displacement command 72 from a dancer displacement signal generating device 74 which generates a signal that is linearly proportionate to the displacement of dancer 76. Dancer 76 comprises an idler roll 78 which is displaceable between positions 80, 82 and which as a centered position 84. Dancers 36, 76 may be of identical construction and may be of a type which are commercially available and well-known in the art such as, for example, Model No. L10075966 of Winder Assembly Model 192, Se. No. 27087-02 manufactured by Gloucester Engineering Company having a business mailing address of P.O. Box 900, Gloucester, Mass. 01930. Dancer displacement signal generating means 34, 74 may also be of a type well-known in the art such as those sold as a unit with the above-referenced commercially available dancers.
A graph showing the value of signal 28 and 68 as the vertical axis and showing the relative dancer displacement from a center position as the horizontal axis in a typical dancer winder configuration is illustrated in FIG. 4. The graph of signal 68 is indicated in solid lines, and the graph of signal 28 is illustrated in dashed lines. As shown by FIG. 4, motor acceleration signal 68 comprises a relatively flat response in a central portion 82 of the dancer range of motion, a relatively larger response in an intermediate portion 84, and a relatively highest response in an exterior portion 86. In the illustrated embodiment, in the central region 82 of dancer motion acceleration signal 68 comprises a straight line 82A. In intermediate region 84, signal 68 may comprise straight lines 84A, 84B of the same or slightly different slope steeper than the slope of 82A. In the exterior response region 86, signal 68 may also comprises two straight lines 86A, 86B of the same of slightly different slope steeper than the slopes of 84A of 84B. A response characteristic such as that illustrated in FIG. 4 provides a system which is extremely stable and yet also capable of providing relatively high-rate response when necessary.
The circuitry used to produce motor acceleration signal 68 is illustrated in FIG. 5. The circuit comprises a first resistance pot P 1 which may be a 1 MΩ-resistance pot; a second resistance pot P 2 which may be a 100 Ω-resistance pot; and a third resistance pot P 3 which may be a 10 kΩ-resistance pot. The circuit may also comprise a first diode pair D 3 , D 4 , a second diode pair D 5 , D 6 , a third diode pair D 7 , D 8 , and a fourth diode pair D 9 , D 10 . In one exemplary embodiment, the first diode in each diode pair is a zener diode which conducts at 2 volts, and the second diode in each diode pair is a rectifier diode which conducts at 1/2 volt and the linear dancer input voltage is equal to the dancer displacement from a centered position as measured in inches, e.g. a dancer displacement of +7.5 inches from a centered position produces a dancer signal 70 voltage of +7.5 volts, and a dancer displacement of -2.5 inches from center produces a dancer signal voltage of -2.5 volts. In this arrangement, the value "A" of signal 68 produced by the nonlinear dancer response circuitry 70 may be represented by the algorithms
A=x/p.sub.1, for -2.5<x<+2.5;
A=x/p.sub.1 +(x-2.5)/p.sub.2, for -7.5<x<-2.5<x<7.5;
and
A=x/p.sub.1 +(x-2.5)/p.sub.2 +(x-7.5)/P.sub.3, for -10<x<-7.5 and 7.5<x<10
where x is the dancer displacement in inches from a centered position and where p 1 , p 2 , and p 3 are the resistance in ohms of resistance pots p 1 , p 2 , and p 3 , respectively.
The signal 68 produced by nonlinear dancer response circuitry 70 is thereafter integrated with respect to time by integrator circuit 66. Integrator circuit 66 comprises a zenor diode D 11 which in the exemplary embodiment conducts current at a voltage value about 10 volts. The circuit further comprises a resistor pot P 4 which may have a resistance of 100 KΩ, a capacitor C 1 which may have a capacitance of 10 μfd, and an operational amplifier OA 1 which may be a general purpose op amp such as the LM741C, produced by National Semiconductor Corp., 2900 Semiconductor Drive, Santa Clara, Calif. This circuit integrates signal 68 over time producing integrated signal 64 which is the velocity command signal to DC motor 62, i.e. DC motor 62 responds to signal 64 by operating at a velocity which is directly proportional to signal 64. Although DC drive motor 62 takes a short period of time to accelerate, the power of the motor is such that the motor response with respect to the speed signal may be considered to be instantaneous. In one preferred embodiment of the invention, the DC motor 62 comprises a model 40 hp, 289 AT2 frame 1750 rpm, manufactured by Emerson Electric Company having a business address of 3036 Alt Boulevard, Grand Island, N.Y., 14072. The typical range of speed control of such a motor over a range of 500 volts is between 0 and 1750 rpm. The construction of nonlinear dancer response circuitry 30 and integrator circuit 26 may be identical to that shown at 70 and 66, respectively, in FIG. 5 with the difference that the linear dancer input signal is inverted by a signal inverter (not shown) prior to being received by nonlinear dancer response circuitry 30 or, alternatively, the signal output 24 of the integrator circuitry 26 may be inverted prior to being applied as a velocity command signal to drive motor 22.
In an alternative embodiment of the invention as illustrated in phantom in FIG. 3, a web speed monitoring device 90 monitors web speed at a position downstream from dancer 36 and generates a web speed voltage signal 92 which is linearly proportionate to web speed. Web speed signal 92 is provided as an input to a divider chip 94 which also receives signal 24 as an input thereto. The divider chip 94 divides the speed signal 92 by signal 24. Signal 24 is proportionate to the web diameter which is wound about spool 14.
While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | A speed control assembly for a rotatable web winding apparatus comprising a dancer engaged with a web of material wound about the winder apparatus for displaceably responding within a predetermined range of dancer positions to tension variations in the web; a first control signal generating device for generating a first control signal in response to dancer displacement from a predetermined centered position, the ratio of dancer displacement to the first control signal being variable over the range of dancer displacement positions; and a dancer response rotation control device for rotationally accelerating the winding apparatus in response to the first control signal. | Identify the most important claim in the given context and summarize it | [
"This application is a continuation of application Ser.",
"No. 552,439, filed July, 13, 1990, now abandoned.",
"BACKGROUND OF THE INVENTION The present invention relates generally to web processing apparatus and, more particularly, to a speed control assembly for a web winder.",
"continuous web processing apparatus such as web printers generally include a web "unwind"",
"or "supply"",
"spool from which unprocessed web material is supplied and a web "rewind"",
"or "windup"",
"or "collection"",
"spool upon which the processed web is collected.",
"Each of these spools is typically mounted upon a separate, driven, winder apparatus which rotates the spool mounted thereon at a selected rate.",
"As the diameter of the web wound about a spool changes, the rotational velocity of the spool must also change if a constant web supply or collection rate is to be maintained.",
"The rotation rate of the web winding apparatus must also be adjusted to accommodate for speed fluctuations at various web processing operating stations which are positioned along the web between the unwind and rewind spools.",
"The most common method for maintaining proper winder speed is through use of a dancer assembly.",
"A dancer assembly is a device consisting of at least one idler roll which is positioned in contact with the web of material.",
"The dancer roll is displaceable in a direction transverse to the direction of web movement and is biased in a direction which opposes the tension applied to the dancer roll by the web.",
"The bias force is of a magnitude such that when the web processing machine is operating at its normal web tensions, the dancer is positioned near the center of its range of movement.",
"If the speed of the web varies with respect to the speed of the associated winder in a manner which decreases web tension, the dancer is displaced by the bias force in a direction to take up the resulting "slack"",
"in the web.",
"If the operation of the associated winder with respect to web line speed is such that the tension in the web increases, the dancer is displaced by the web tension force in a direction which shortens the web path and reduces web tension.",
"Winder speed is controlled by varying the speed of the winder in response to the displacement of the associated dancer assembly.",
"Various methods of processing a dancer displacement signal to control winder speed are known in the prior art.",
"One method, known as 100% proportional control, is illustrated in FIG. 1. In this method of control, the winder motor velocity is increased or decreased as a linear function of dancer displacement from a dancer position near one end of the dancer travel path.",
"The winder velocity to dancer position relationship for a supply winder is indicated in solid lines.",
"The winder velocity to dancer position relationship for a collection winder having a dancer assembly identical to that for the supply winder is indicated in dashed lines.",
"In such a system, at one end of the dancer travel range the winder operates at full speed, and at the other end of the dancer travel range the winder stops.",
"Typically, the range of dancer displacement is selected to be somewhat larger than the range of dancer displacement needed to compensate for changes in roll diameter in order to accommodate other transient fluctuations in web speed.",
"Such 100% proportional speed control results in a system which is very responsive but difficult to stabilize.",
"In situations where the web being processed is an extensible web such as plastic film, a 100% proportional control system becomes totally unstable and unusable.",
"In a variation of the 100% proportional control method illustrated in FIG. 1, the dancer displacement signal is used in the same manner to control web speed.",
"However, it accounts for only a small portion, e.g. 10%, of the total winder velocity control signal.",
"The remainder of the signal is a line speed reference signal produced by a web speed monitor positioned along the web at a point intermediate the unwind and rewind assemblies.",
"In such a control scheme, the dancer is relatively unresponsive and thus the system is easy to stabilize for stead-state conditions.",
"However, in such a scheme, the dancer typically runs off-center some amount to compensate for calibration error or web stretch.",
"This type of system experiences trouble with major tension variations in the web and will reach a mechanical limit for correction due to the dancer's lack of responsiveness.",
"In another method of winder speed control, the winder is provided with a tachometer which provides a speed signal.",
"This winder speed signal and a web line speed signal are provided to a computer and used to compute the associated winder spool web diameter.",
"A base winder speed is then calculated by dividing line speed by winder spool web diameter.",
"The calculated winder speed is thereafter trimmed with a velocity signal calculated as a linear function of dancer displacement such as illustrated in FIG. 1. Such systems are quite expensive and require factory technicians for accurate calibration and setup.",
"Another method of winder speed control is known in the art as 100% integrated dancer centering speed control.",
"According to this method, an analog integrator receives an input representative of linear dancer displacement and a winder acceleration (as opposed to velocity) signal is calculated which is linearly proportional to the dancer displacement signal.",
"In such a system, the dancer under normal operating conditions remains at the center of its displacement range.",
"However, it is generally difficult to find a balance between stability and responsiveness for such a control system.",
"A graph indicative of winder motor acceleration response to dancer displacement for such a system is illustrated in FIG. 2. In a variation on the 100% integrated dancer centering control system illustrated in FIG. 2, a signal identical to that illustrated in FIG. 2 is initially provided.",
"However, the control system rather than using this signal as a motor acceleration signal instead uses it as a spool diameter signal and the winder velocity signal is provided by dividing web line speed by this diameter signal.",
"Such systems generally require a factory technical for setup.",
"Such systems are subject to failure due to calibration shifts and also experience stability problems.",
"SUMMARY OF THE INVENTION The present invention may comprise a speed control assembly for a rotatable web winding apparatus comprising: dancer means engaged with a web of material wound about said winder apparatus for displaceably responding within a predetermined range of dancer positions to tension variations in said web;",
"first control signal generating means for generating a first control signal in response to dancer means displacement from a predetermined centered position, the ratio of dancer displacement to said first control signal being variable over said range of dancer displacement positions;",
"and dancer response rotation control means for rotationally accelerating said winding apparatus in response to said first control signal.",
"The invention may also comprise a speed control assembly for a rotatable web winding apparatus comprising dancer means engaging with a web of material wound about said winder apparatus for displaceably responding within a predetermined range of dancer positions to tension variations in said web;",
"first control signal generating means for generating a first control signal in response to dancer means displacement from a predetermined centered position, the ratio of dancer displacement to said first control signal being variable over said range of dancer displacement positions;",
"dancer response rotation control means for rotationally accelerating said winding apparatus in response to said first control signal;",
"wherein said dancer means comprises a dancer signal generating means for generating a dancer signal which is proportionate to the amount of displacement of said dancer means from said predetermined centered position and wherein said first control signal generating means processes said dancer signal to generate said first control signal;",
"wherein said first control signal changes relatively slowly in response to dancer displacement within a first range of dancer positions which includes said predetermined centered position and wherein said first control signal changes relatively more rapidly in response to dancer displacement within a second range of dancer positions lying outside of said first range of positions;",
"wherein said first control signal changes relatively most quickly in response to dancer displacement in a third range of dancer positions lying outside of said second range of positions;",
"wherein the ratio of said first control signal to said dancer signal is a first constant value when said dancer mean is positioned within said first range of dancer positions;",
"wherein the ratio of said first control signal to said dancer signal is a second constant value greater than said first constant value when said dancer means is positioned within said second range of dancer positions;",
"wherein the ratio of said first control signal to said dancer signal is a third constant value greater than said second constant value when said dancer means is positioned within said third range of dancer positions;",
"wherein said dancer response rotation control means comprises: motor means drivingly linked to said winding apparatus for rotating said winding apparatus;",
"motor control means for controlling the speed of said motor means in response to a motor speed control signal;",
"and speed control signal generating for receiving said first control signal and for generating said motor speed control signal in response thereto;",
"web speed monitoring means for measuring web speed at a position on the web which is more remote from said web winding apparatus than the position of said dancer means and for generating a web speed signal indicative of said measurement;",
"web speed response rotation control mean for receiving said web speed signal and for rotationally accelerating said winding apparatus by an amount dependent upon said web speed signal;",
"whereby total winding apparatus acceleration is dependent upon web tension at said dancer means and web speed at said web speed monitoring means.",
"The invention may also comprise a method of controlling the rotational speed of a web winding apparatus comprising: monitoring the displacement of a web dancer from a predetermined dancer position;",
"generating a first control signal which is a predetermined nonlinear function of dancer displacement over a predetermined range of dancer displacement position;",
"accelerating said web winding apparatus in response to said first control signal.",
"BRIEF DESCRIPTION OF THE DRAWINGS An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which: FIG. 1 is a graph illustrating the relationship between dancer position and winder motor velocity in one prior art method of winder control.",
"FIG. 2 is a graph illustrating the relationship between dancer position and winder motor acceleration in a second prior art method of web winder control.",
"FIG. 3 is a schematic elevation view of a web processing system.",
"FIG. 4 is a graph illustrating the relationship between dancer position and winder motor acceleration for web winders used in the web processing assembly of FIG. 3. FIG. 5 is a circuit diagram of a circuit used for generating a web winder motor velocity signal from a dancer displacement signal.",
"DETAILED DESCRIPTION OF THE INVENTION FIG. 3 is a schematic illustration of a web processing apparatus 10 such as a web printer.",
"A continuous web of material 12 is unwound from a supply roll 14 (also referred to as an unwind spool), processed at one or more processing stations 16 located downstream from the supply roll 14, and collected on a web rewind spool 18 (also referred to as a collection spool or a windup spool).",
"The unwind spool 14 is rotated about an axis AA by a direct current (DC) drive motor 22 which rotates spool 14 at a rotation rate which is directly proportional to the drive motor rotation rate.",
"The drive motor 22 operates at a velocity which is directly proportional to a velocity command signal 24 which it receives from speed control assembly 26.",
"Speed control assembly 26 generates velocity control signal 24 by integrating a motor acceleration signal 28 which it receives from nonlinear dancer response circuit 30.",
"Nonlinear dancer response circuit 30 calculates control signal 28 from a dancer signal 32 generated by dancer displacement sensing device 34.",
"Dancer signal 32 is directly proportional to the displacement of dancer 36.",
"Dancer 36 includes an idler roll 38, engaged by web 12, which is displaceable between a lowermost position 40 and an uppermost position 42.",
"The dancer roll is biased toward position 40 by a conventional biasing device (not shown) of the type adapted to provide a biasing force which is constant over the displacement of the dancer from position 40 to 42.",
"The biasing force is selected which corresponds to the normal tension setting of the web processing apparatus.",
"Thus, if web velocity downstream of dancer assembly 36 becomes greater than the surface velocity of the web on spool 14, dancer roll 38 is displaced downwardly, and if web downstream velocity falls below that of the surface velocity of the web on spool 14, dancer 38 is displaced upwardly.",
"Web processing stations illustrated generally at 16 may comprise a pair of nip rolls 50, 52, which are driven at a relatively constant rate by a nip motor 54.",
"In a typical processing operation, continuous web 12 is provided with a repeating set of web graphics at a printing nip 56 provided by rolls 50, 52.",
"Downstream of the web processing station 16, rewind spool 18 collects the processed web.",
"Rewind spool 18 is rotated about axis BB by a DC drive motor 62 which drives spool 18 at a rate proportional to the drive motor rotation rate.",
"Drive motor 62 rotates spool 18 at a rate which is linear proportionate to its own rotation rate.",
"DC motor 62 receives a speed control command 64 from a control circuit 66 which integrates an acceleration command 68 which is generated by nonlinear dancer response circuit 70.",
"Dancer response circuit 70 receives a dancer displacement command 72 from a dancer displacement signal generating device 74 which generates a signal that is linearly proportionate to the displacement of dancer 76.",
"Dancer 76 comprises an idler roll 78 which is displaceable between positions 80, 82 and which as a centered position 84.",
"Dancers 36, 76 may be of identical construction and may be of a type which are commercially available and well-known in the art such as, for example, Model No. L10075966 of Winder Assembly Model 192, Se.",
"No. 27087-02 manufactured by Gloucester Engineering Company having a business mailing address of P.O. Box 900, Gloucester, Mass.",
"01930.",
"Dancer displacement signal generating means 34, 74 may also be of a type well-known in the art such as those sold as a unit with the above-referenced commercially available dancers.",
"A graph showing the value of signal 28 and 68 as the vertical axis and showing the relative dancer displacement from a center position as the horizontal axis in a typical dancer winder configuration is illustrated in FIG. 4. The graph of signal 68 is indicated in solid lines, and the graph of signal 28 is illustrated in dashed lines.",
"As shown by FIG. 4, motor acceleration signal 68 comprises a relatively flat response in a central portion 82 of the dancer range of motion, a relatively larger response in an intermediate portion 84, and a relatively highest response in an exterior portion 86.",
"In the illustrated embodiment, in the central region 82 of dancer motion acceleration signal 68 comprises a straight line 82A.",
"In intermediate region 84, signal 68 may comprise straight lines 84A, 84B of the same or slightly different slope steeper than the slope of 82A.",
"In the exterior response region 86, signal 68 may also comprises two straight lines 86A, 86B of the same of slightly different slope steeper than the slopes of 84A of 84B.",
"A response characteristic such as that illustrated in FIG. 4 provides a system which is extremely stable and yet also capable of providing relatively high-rate response when necessary.",
"The circuitry used to produce motor acceleration signal 68 is illustrated in FIG. 5. The circuit comprises a first resistance pot P 1 which may be a 1 MΩ-resistance pot;",
"a second resistance pot P 2 which may be a 100 Ω-resistance pot;",
"and a third resistance pot P 3 which may be a 10 kΩ-resistance pot.",
"The circuit may also comprise a first diode pair D 3 , D 4 , a second diode pair D 5 , D 6 , a third diode pair D 7 , D 8 , and a fourth diode pair D 9 , D 10 .",
"In one exemplary embodiment, the first diode in each diode pair is a zener diode which conducts at 2 volts, and the second diode in each diode pair is a rectifier diode which conducts at 1/2 volt and the linear dancer input voltage is equal to the dancer displacement from a centered position as measured in inches, e.g. a dancer displacement of +7.5 inches from a centered position produces a dancer signal 70 voltage of +7.5 volts, and a dancer displacement of -2.5 inches from center produces a dancer signal voltage of -2.5 volts.",
"In this arrangement, the value "A"",
"of signal 68 produced by the nonlinear dancer response circuitry 70 may be represented by the algorithms A=x/p.",
"sub[.",
"].1, for -2.5<x<+2.5;",
"A=x/p.",
"sub[.",
"].1 +(x-2.5)/p.",
"sub[.",
"].2, for -7.5<x<-2.5<x<7.5;",
"and A=x/p.",
"sub[.",
"].1 +(x-2.5)/p.",
"sub[.",
"].2 +(x-7.5)/P.",
"sub[.",
"].3, for -10<x<-7.5 and 7.5<x<10 where x is the dancer displacement in inches from a centered position and where p 1 , p 2 , and p 3 are the resistance in ohms of resistance pots p 1 , p 2 , and p 3 , respectively.",
"The signal 68 produced by nonlinear dancer response circuitry 70 is thereafter integrated with respect to time by integrator circuit 66.",
"Integrator circuit 66 comprises a zenor diode D 11 which in the exemplary embodiment conducts current at a voltage value about 10 volts.",
"The circuit further comprises a resistor pot P 4 which may have a resistance of 100 KΩ, a capacitor C 1 which may have a capacitance of 10 μfd, and an operational amplifier OA 1 which may be a general purpose op amp such as the LM741C, produced by National Semiconductor Corp.",
", 2900 Semiconductor Drive, Santa Clara, Calif.",
"This circuit integrates signal 68 over time producing integrated signal 64 which is the velocity command signal to DC motor 62, i.e. DC motor 62 responds to signal 64 by operating at a velocity which is directly proportional to signal 64.",
"Although DC drive motor 62 takes a short period of time to accelerate, the power of the motor is such that the motor response with respect to the speed signal may be considered to be instantaneous.",
"In one preferred embodiment of the invention, the DC motor 62 comprises a model 40 hp, 289 AT2 frame 1750 rpm, manufactured by Emerson Electric Company having a business address of 3036 Alt Boulevard, Grand Island, N.Y., 14072.",
"The typical range of speed control of such a motor over a range of 500 volts is between 0 and 1750 rpm.",
"The construction of nonlinear dancer response circuitry 30 and integrator circuit 26 may be identical to that shown at 70 and 66, respectively, in FIG. 5 with the difference that the linear dancer input signal is inverted by a signal inverter (not shown) prior to being received by nonlinear dancer response circuitry 30 or, alternatively, the signal output 24 of the integrator circuitry 26 may be inverted prior to being applied as a velocity command signal to drive motor 22.",
"In an alternative embodiment of the invention as illustrated in phantom in FIG. 3, a web speed monitoring device 90 monitors web speed at a position downstream from dancer 36 and generates a web speed voltage signal 92 which is linearly proportionate to web speed.",
"Web speed signal 92 is provided as an input to a divider chip 94 which also receives signal 24 as an input thereto.",
"The divider chip 94 divides the speed signal 92 by signal 24.",
"Signal 24 is proportionate to the web diameter which is wound about spool 14.",
"While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art."
] |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 13/089,340, filed on Apr. 19, 2011, now U.S. Pat. No. 8,262,620 which is a continuation of U.S. patent application Ser. No. 12/468,363, filed on May 19, 2009, now U.S. Pat. No. 7,951,117 which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/075,542, filed Jun. 25, 2008, the entire contents of which are incorporated herein by reference.
BACKGROUND
1. Technical Field
The present disclosure relates to access devices and, more particularly, to a multi-lumen access port.
2. Background of Related Art
During laparoscopic surgery, a surgeon performs surgical procedures through small incisions. Typically, these incisions measure about half an inch. The surgeon also places small ports through the incisions to gain access into the abdominal cavity of the patient. These parts have a number of uses. For example, a surgeon may use a port for insufflating the abdominal cavity to create space, another port for introducing a laparoscope for viewing, and a number of other ports for introducing surgical instruments for operating on tissue. Generally, laparoscopic surgery costs less than open surgery. In addition, patients typically recover faster from a laparoscopic surgery than from an open surgery.
In open surgery, surgeons use their hands, together with surgical instruments, to manipulate tissue. Surgeons performing open surgery may decide to perform particular steps of the procedure with their hands and other steps with surgical instruments. For instance, open surgery allows surgeons to obtain tactile feedback through their fingertips. Surgeons may also use their hands to remove relatively large portions of tissue from a body cavity. Moreover, open surgery facilitates the use of relatively large surgical instruments within the human body.
SUMMARY
The present disclosure relates to an access device. The access device includes a body, a first tube, a second tube, and a mechanism. The first and the second tubes extend through the body of the access device. The mechanism operably couples the first and second tubes such that at least one tube is pivotable about an axis with respect to the other. The proximal ends of the first and second tubes are located within the body. At least one of the tubes extends distally from a surface of the body. The body may be adapted for placement in an opening in body tissue. During use, body may form a substantially fluid-tight seal at the opening or incision. The access device may further include a third tube extending through the body. In this embodiment, the mechanism operably couples the tubes together such that at least two tubes are pivotable about the axis with respect to the remaining tube.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the presently disclosed multi-lumen access port are described herein with reference to the accompanying drawings, wherein:
FIG. 1 is side view of an embodiment of the presently disclosed multi-lumen access port;
FIG. 2 is a side view of an alternate embodiment of the presently disclosed multi-lumen access port;
FIG. 3 is a top view of the embodiments of FIGS. 1 and 2 ;
FIG. 4 is a cross-sectional side view of an access tube and a portion of a support body according to an embodiment of the present disclosure; and
FIG. 5 is a cross-sectional side view of an access tube and a portion of a support body according to another embodiment of the present disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiments of the presently disclosed multi-lumen access port will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. In the drawings and in the description which follows, the term “proximal”, as is traditional, will refer to the end of the multi-lumen access port which is closest to the operator while the term “distal” will refer to the end of the device which is farthest from the operator.
Referring initially to FIG. 1 , the presently disclosed multi-lumen access port is shown generally as access port 100 . Access port 100 includes a plurality of access tubes 10 , 20 , 30 . One or more of the access tubes 10 , 20 , 30 may contain a fluid-tight seal. Each access tube 10 , 20 , 30 has an open proximal end 14 , 24 , 34 and an open distal end 16 , 26 , 36 . A passageway 12 , 22 , 32 is defined between open proximal ends 14 , 24 , 34 and open distal ends 16 , 26 , 36 . Each access tube 10 , 20 , 30 is generally an elongate tubular structure that is adapted for receiving at least a portion of an endoscopic surgical instrument (not shown) therethrough. In one embodiment, the configuration of at least one passageway 12 , 22 , 33 allows passage of a surgical instrument having an outside diameter ranging between about 5 mm and about 12 mm through access tubes 10 , 20 , 30 . Access tubes 10 , 20 , 30 may be configured, however, to receive surgical instruments having other suitable sizes. The present disclosure envisions access tubes 10 , 20 , 30 having a variety of sizes and shapes. Access tubes 10 , 20 , 30 may have circular cross-sections, oval cross-sections, or any other suitable shape so long as they are capable of receiving a surgical instrument. In addition to their ability to receive a surgical instrument, access tubes 10 , 20 , 30 are able to move axially with respect to one another.
Access port 100 includes a mechanism 56 adapted to facilitate relative movement of access tubes 10 , 20 , 30 . Mechanism 56 operably connects access tubes 10 , 20 , 30 at a pivot point P. Consequently, a portion of each access tube 10 , 20 , 30 overlaps at pivot point P. The location of pivot pin P allows users to employ mechanism 56 to pivot access tubes 10 , 20 , 30 with respect to one another. In the depicted embodiment, mechanism 56 includes a pivot pin 58 or any other suitable fastening member adapted to interconnect access tubes 10 , 20 , 30 . Pivot pin 58 facilitates pivotal movement of access tubes 10 , 20 , 30 about an axis. Alternatively, pivot pin 58 operably couples only two access tubes 10 , 20 . In any case, the location of pivot pin 58 coincides with the location of pivot point P. Accordingly, access tubes 10 , 20 , 30 rotate about pivot point P upon manipulation by a user during operation.
FIG. 2 illustrates an alternate embodiment of the present disclosure. This embodiment is generally designated as access port 200 . Access port 200 is substantially similar to access port 100 . The presently disclosed access port 200 includes a plurality of access tubes 210 , 220 , 230 . At least one access tube 210 , 220 , 230 may include a fluid-tight seal. Each access tube 210 , 220 , 230 has an open proximal ends 214 , 224 , 234 and an open distal end 216 , 226 , 236 . Open proximal ends 214 , 224 , 234 and open distal ends 216 , 226 , 236 each defines a passageway 212 , 222 , 232 therebetween. Each passageway 212 , 222 , 232 has a cross-section adapted to receive an endoscopic surgical instrument. In one embodiment, the cross-section of at least one passageway 212 , 222 , 232 is capable of receiving therethrough a surgical instrument having an outside diameter ranging between about 5 mm and about 12 mm. During use, a surgeon may introduce a surgical instrument through open proximal end 214 , 224 , 234 until it reaches a location beyond open distal ends 216 , 226 , 236 .
The open distal ends 216 , 226 , 236 of access port 200 form a juncture 256 , as illustrated in FIG. 2 . Juncture 256 operatively connects open distal ends 216 , 226 , 236 with one another. During operation, juncture 256 facilitates relative movement of access tubes 210 , 220 , 230 upon manipulation by a user. Therefore, juncture 264 is sufficiently strong to maintain open distal ends 216 , 226 , 236 joined, but sufficiently flexible to allow relative movement of access tubes 210 , 220 , 230 .
As seen in FIGS. 1 and 2 , the embodiments of the present disclosure include a support body 50 . Support body 50 supports access tubes 10 , 20 , 30 . In use, support access 50 serves as a standalone component for providing access to a working space in the patient's body. Alternatively, a user may use support body 50 in conjunction with other access devices (i.e. access ports). In any case, support body 50 has a flexible outer wall 54 . The resiliency of flexible outer wall 54 permits temporarily deformation of support body 50 during its installation. After installation, support body 50 along with its flexible outer wall 54 reverts to its original configuration and provides a fluid-tight seal in conjunction with the patient's skin (i.e. standalone mode) or the access device. In either mode, support body 50 conforms to the skin at an opening in the patient's body or the interior wall of the access device, thereby providing a fluid-tight seal for inhibiting leakage of insufflation fluids from the working space or the introduction of external contaminants into the working space.
The structural relationships between support body 50 and access tubes 10 , 20 , 30 is substantially similar to the structural relationship between support body 50 and access tubes 210 , 220 , 230 . Therefore, the mechanical cooperation and operation of support body 50 and access tubes 210 , 220 , 230 will not be described herein in detail.
Referring to FIGS. 3 and 4 , an embodiment of support body 50 has a circular cross-section. The present disclosure nevertheless envisions support bodies with other configurations. In the depicted embodiment, support body 50 includes a plurality of bores 52 . Bores 52 are laterally and longitudinally spaced apart from one another. Each bore 52 is adapted to receive an access tube 10 , 20 , 30 and extends through support body 50 . The cross-section of each bore 55 is larger than the cross-section of access tubes 10 , 20 , 30 , as seen in FIGS. 3 and 4 . This configuration provides access tubes 10 , 20 , 30 certain freedom of movement within bores 52 .
In an alternative embodiment, support body 50 includes at least one slit 60 extending along at least a portion of the length of support body 50 , as illustrated in FIG. 5 . Slit 60 enhances the flexibility of support body 50 . The presence of slit 60 allows user to move access tubes 10 , 20 , 30 beyond the boundaries of bores 52 .
In use, a surgeon may employ access port 100 or 200 to create and maintain access into a working space inside a patient's body during a surgical procedure. In particular, physicians may employ either access port 100 , 200 during a laparoscopy or a HALS procedure. Initially, the surgeon may first incise a body wall with scalpel or any other suitable instrument. Alternatively, the surgeon may penetrate the body wall with a sharp tip. Once the body wall has an opening, the surgeon may place support body 50 in the desired site.
The physician may employ support body 50 by itself or in conjunction with other access device. Before placing access port 100 inside a patient's body, the surgeon may deform support body 50 . Thereafter, the surgeon places access port 100 inside the patient's body.
Immediately after its installation, support body 50 reverts to its original configuration and creates a fluid-tight seal in conjunction with the patient's skin (in the standalone mode) or an access device. After the establishing the fluid-tight seal, the surgeon inserts one or more surgical instruments though access tubes 10 , 20 , 30 . In particular, the surgeon may initially insert an insufflation device through any access tube 10 , 20 , 30 . Before activating the insufflation device, the user may move access tubes 10 , 20 , 20 to direct the delivery of insufflation gas. Once in position, the insufflation device delivers gas to a body cavity upon activation by the surgeon. This gas expands the body cavity and prepares the surgical site. Subsequently, the physician may insert a laparoscope or any other suitable viewing apparatus through another access tube 10 , 20 , 30 . The laparoscope facilitates visual observation of the surgical site. Again, the operator may move access tubes 10 , 20 , 30 to observe several areas of the body cavity. After visually inspection the body cavity, the physician may insert a surgical instrument through any of the open proximal ends 14 , 24 , 34 . The surgeon should advance the surgical instrument through the corresponding passageway 12 , 22 , 32 until it reaches a location beyond corresponding open distal end 16 , 26 , 36 . The surgeon may then move access tubes 10 , 20 , 30 to reach the desired surgical site.
Access tubes 10 , 20 , 30 may move upon manual manipulation by the operator. The operator, however, may use any suitable means to move access tubes 10 , 20 , 30 . During operation, access tubes 10 , 20 , 30 of access port 100 move relative to one another about pivot point “P.” The boundaries of bores 52 may slightly restrict the movement of access tubes 10 , 20 , 30 , as shown in FIG. 4 . Nonetheless, access tubes disposed in a support body 50 having a slit 60 may easily move beyond the boundaries of bores 52 .
The method of using access port 100 is substantially similar to the method of using access port 200 . During the operation of access port 200 , however, a surgeon may move access tubes 210 , 220 , 230 with respect to one another, but their distal open ends 216 , 226 , 236 are fixed in relation to each other.
It will be understood that various modifications may be made to the embodiments of the presently disclosed surgical stapling instruments. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. | An access device includes a body, a first tube, a second tube, and a mechanism. The first and second tubes extend through the body. The mechanism operably couples the first and second tubes such that at least one tube is pivotable about an axis with respect to the other tube. The body may form a substantially fluid-tight seal at the incision. In another embodiment, the access device further includes a third tube extending through the body and the mechanism operably couples the tubes together such that at least two tubes are pivotable about the axis with respect to the remaining tube. | Briefly summarize the invention's components and working principles as described in the document. | [
"CROSS REFERENCE TO RELATED APPLICATION This application is a continuation of U.S. patent application Ser.",
"No. 13/089,340, filed on Apr. 19, 2011, now U.S. Pat. No. 8,262,620 which is a continuation of U.S. patent application Ser.",
"No. 12/468,363, filed on May 19, 2009, now U.S. Pat. No. 7,951,117 which claims the benefit of and priority to U.S. Provisional Patent Application Ser.",
"No. 61/075,542, filed Jun. 25, 2008, the entire contents of which are incorporated herein by reference.",
"BACKGROUND 1.",
"Technical Field The present disclosure relates to access devices and, more particularly, to a multi-lumen access port.",
"Background of Related Art During laparoscopic surgery, a surgeon performs surgical procedures through small incisions.",
"Typically, these incisions measure about half an inch.",
"The surgeon also places small ports through the incisions to gain access into the abdominal cavity of the patient.",
"These parts have a number of uses.",
"For example, a surgeon may use a port for insufflating the abdominal cavity to create space, another port for introducing a laparoscope for viewing, and a number of other ports for introducing surgical instruments for operating on tissue.",
"Generally, laparoscopic surgery costs less than open surgery.",
"In addition, patients typically recover faster from a laparoscopic surgery than from an open surgery.",
"In open surgery, surgeons use their hands, together with surgical instruments, to manipulate tissue.",
"Surgeons performing open surgery may decide to perform particular steps of the procedure with their hands and other steps with surgical instruments.",
"For instance, open surgery allows surgeons to obtain tactile feedback through their fingertips.",
"Surgeons may also use their hands to remove relatively large portions of tissue from a body cavity.",
"Moreover, open surgery facilitates the use of relatively large surgical instruments within the human body.",
"SUMMARY The present disclosure relates to an access device.",
"The access device includes a body, a first tube, a second tube, and a mechanism.",
"The first and the second tubes extend through the body of the access device.",
"The mechanism operably couples the first and second tubes such that at least one tube is pivotable about an axis with respect to the other.",
"The proximal ends of the first and second tubes are located within the body.",
"At least one of the tubes extends distally from a surface of the body.",
"The body may be adapted for placement in an opening in body tissue.",
"During use, body may form a substantially fluid-tight seal at the opening or incision.",
"The access device may further include a third tube extending through the body.",
"In this embodiment, the mechanism operably couples the tubes together such that at least two tubes are pivotable about the axis with respect to the remaining tube.",
"BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the presently disclosed multi-lumen access port are described herein with reference to the accompanying drawings, wherein: FIG. 1 is side view of an embodiment of the presently disclosed multi-lumen access port;",
"FIG. 2 is a side view of an alternate embodiment of the presently disclosed multi-lumen access port;",
"FIG. 3 is a top view of the embodiments of FIGS. 1 and 2 ;",
"FIG. 4 is a cross-sectional side view of an access tube and a portion of a support body according to an embodiment of the present disclosure;",
"and FIG. 5 is a cross-sectional side view of an access tube and a portion of a support body according to another embodiment of the present disclosure.",
"DETAILED DESCRIPTION OF EMBODIMENTS Embodiments of the presently disclosed multi-lumen access port will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements.",
"In the drawings and in the description which follows, the term “proximal”, as is traditional, will refer to the end of the multi-lumen access port which is closest to the operator while the term “distal”",
"will refer to the end of the device which is farthest from the operator.",
"Referring initially to FIG. 1 , the presently disclosed multi-lumen access port is shown generally as access port 100 .",
"Access port 100 includes a plurality of access tubes 10 , 20 , 30 .",
"One or more of the access tubes 10 , 20 , 30 may contain a fluid-tight seal.",
"Each access tube 10 , 20 , 30 has an open proximal end 14 , 24 , 34 and an open distal end 16 , 26 , 36 .",
"A passageway 12 , 22 , 32 is defined between open proximal ends 14 , 24 , 34 and open distal ends 16 , 26 , 36 .",
"Each access tube 10 , 20 , 30 is generally an elongate tubular structure that is adapted for receiving at least a portion of an endoscopic surgical instrument (not shown) therethrough.",
"In one embodiment, the configuration of at least one passageway 12 , 22 , 33 allows passage of a surgical instrument having an outside diameter ranging between about 5 mm and about 12 mm through access tubes 10 , 20 , 30 .",
"Access tubes 10 , 20 , 30 may be configured, however, to receive surgical instruments having other suitable sizes.",
"The present disclosure envisions access tubes 10 , 20 , 30 having a variety of sizes and shapes.",
"Access tubes 10 , 20 , 30 may have circular cross-sections, oval cross-sections, or any other suitable shape so long as they are capable of receiving a surgical instrument.",
"In addition to their ability to receive a surgical instrument, access tubes 10 , 20 , 30 are able to move axially with respect to one another.",
"Access port 100 includes a mechanism 56 adapted to facilitate relative movement of access tubes 10 , 20 , 30 .",
"Mechanism 56 operably connects access tubes 10 , 20 , 30 at a pivot point P. Consequently, a portion of each access tube 10 , 20 , 30 overlaps at pivot point P. The location of pivot pin P allows users to employ mechanism 56 to pivot access tubes 10 , 20 , 30 with respect to one another.",
"In the depicted embodiment, mechanism 56 includes a pivot pin 58 or any other suitable fastening member adapted to interconnect access tubes 10 , 20 , 30 .",
"Pivot pin 58 facilitates pivotal movement of access tubes 10 , 20 , 30 about an axis.",
"Alternatively, pivot pin 58 operably couples only two access tubes 10 , 20 .",
"In any case, the location of pivot pin 58 coincides with the location of pivot point P. Accordingly, access tubes 10 , 20 , 30 rotate about pivot point P upon manipulation by a user during operation.",
"FIG. 2 illustrates an alternate embodiment of the present disclosure.",
"This embodiment is generally designated as access port 200 .",
"Access port 200 is substantially similar to access port 100 .",
"The presently disclosed access port 200 includes a plurality of access tubes 210 , 220 , 230 .",
"At least one access tube 210 , 220 , 230 may include a fluid-tight seal.",
"Each access tube 210 , 220 , 230 has an open proximal ends 214 , 224 , 234 and an open distal end 216 , 226 , 236 .",
"Open proximal ends 214 , 224 , 234 and open distal ends 216 , 226 , 236 each defines a passageway 212 , 222 , 232 therebetween.",
"Each passageway 212 , 222 , 232 has a cross-section adapted to receive an endoscopic surgical instrument.",
"In one embodiment, the cross-section of at least one passageway 212 , 222 , 232 is capable of receiving therethrough a surgical instrument having an outside diameter ranging between about 5 mm and about 12 mm.",
"During use, a surgeon may introduce a surgical instrument through open proximal end 214 , 224 , 234 until it reaches a location beyond open distal ends 216 , 226 , 236 .",
"The open distal ends 216 , 226 , 236 of access port 200 form a juncture 256 , as illustrated in FIG. 2 .",
"Juncture 256 operatively connects open distal ends 216 , 226 , 236 with one another.",
"During operation, juncture 256 facilitates relative movement of access tubes 210 , 220 , 230 upon manipulation by a user.",
"Therefore, juncture 264 is sufficiently strong to maintain open distal ends 216 , 226 , 236 joined, but sufficiently flexible to allow relative movement of access tubes 210 , 220 , 230 .",
"As seen in FIGS. 1 and 2 , the embodiments of the present disclosure include a support body 50 .",
"Support body 50 supports access tubes 10 , 20 , 30 .",
"In use, support access 50 serves as a standalone component for providing access to a working space in the patient's body.",
"Alternatively, a user may use support body 50 in conjunction with other access devices (i.e. access ports).",
"In any case, support body 50 has a flexible outer wall 54 .",
"The resiliency of flexible outer wall 54 permits temporarily deformation of support body 50 during its installation.",
"After installation, support body 50 along with its flexible outer wall 54 reverts to its original configuration and provides a fluid-tight seal in conjunction with the patient's skin (i.e. standalone mode) or the access device.",
"In either mode, support body 50 conforms to the skin at an opening in the patient's body or the interior wall of the access device, thereby providing a fluid-tight seal for inhibiting leakage of insufflation fluids from the working space or the introduction of external contaminants into the working space.",
"The structural relationships between support body 50 and access tubes 10 , 20 , 30 is substantially similar to the structural relationship between support body 50 and access tubes 210 , 220 , 230 .",
"Therefore, the mechanical cooperation and operation of support body 50 and access tubes 210 , 220 , 230 will not be described herein in detail.",
"Referring to FIGS. 3 and 4 , an embodiment of support body 50 has a circular cross-section.",
"The present disclosure nevertheless envisions support bodies with other configurations.",
"In the depicted embodiment, support body 50 includes a plurality of bores 52 .",
"Bores 52 are laterally and longitudinally spaced apart from one another.",
"Each bore 52 is adapted to receive an access tube 10 , 20 , 30 and extends through support body 50 .",
"The cross-section of each bore 55 is larger than the cross-section of access tubes 10 , 20 , 30 , as seen in FIGS. 3 and 4 .",
"This configuration provides access tubes 10 , 20 , 30 certain freedom of movement within bores 52 .",
"In an alternative embodiment, support body 50 includes at least one slit 60 extending along at least a portion of the length of support body 50 , as illustrated in FIG. 5 .",
"Slit 60 enhances the flexibility of support body 50 .",
"The presence of slit 60 allows user to move access tubes 10 , 20 , 30 beyond the boundaries of bores 52 .",
"In use, a surgeon may employ access port 100 or 200 to create and maintain access into a working space inside a patient's body during a surgical procedure.",
"In particular, physicians may employ either access port 100 , 200 during a laparoscopy or a HALS procedure.",
"Initially, the surgeon may first incise a body wall with scalpel or any other suitable instrument.",
"Alternatively, the surgeon may penetrate the body wall with a sharp tip.",
"Once the body wall has an opening, the surgeon may place support body 50 in the desired site.",
"The physician may employ support body 50 by itself or in conjunction with other access device.",
"Before placing access port 100 inside a patient's body, the surgeon may deform support body 50 .",
"Thereafter, the surgeon places access port 100 inside the patient's body.",
"Immediately after its installation, support body 50 reverts to its original configuration and creates a fluid-tight seal in conjunction with the patient's skin (in the standalone mode) or an access device.",
"After the establishing the fluid-tight seal, the surgeon inserts one or more surgical instruments though access tubes 10 , 20 , 30 .",
"In particular, the surgeon may initially insert an insufflation device through any access tube 10 , 20 , 30 .",
"Before activating the insufflation device, the user may move access tubes 10 , 20 , 20 to direct the delivery of insufflation gas.",
"Once in position, the insufflation device delivers gas to a body cavity upon activation by the surgeon.",
"This gas expands the body cavity and prepares the surgical site.",
"Subsequently, the physician may insert a laparoscope or any other suitable viewing apparatus through another access tube 10 , 20 , 30 .",
"The laparoscope facilitates visual observation of the surgical site.",
"Again, the operator may move access tubes 10 , 20 , 30 to observe several areas of the body cavity.",
"After visually inspection the body cavity, the physician may insert a surgical instrument through any of the open proximal ends 14 , 24 , 34 .",
"The surgeon should advance the surgical instrument through the corresponding passageway 12 , 22 , 32 until it reaches a location beyond corresponding open distal end 16 , 26 , 36 .",
"The surgeon may then move access tubes 10 , 20 , 30 to reach the desired surgical site.",
"Access tubes 10 , 20 , 30 may move upon manual manipulation by the operator.",
"The operator, however, may use any suitable means to move access tubes 10 , 20 , 30 .",
"During operation, access tubes 10 , 20 , 30 of access port 100 move relative to one another about pivot point “P.”",
"The boundaries of bores 52 may slightly restrict the movement of access tubes 10 , 20 , 30 , as shown in FIG. 4 .",
"Nonetheless, access tubes disposed in a support body 50 having a slit 60 may easily move beyond the boundaries of bores 52 .",
"The method of using access port 100 is substantially similar to the method of using access port 200 .",
"During the operation of access port 200 , however, a surgeon may move access tubes 210 , 220 , 230 with respect to one another, but their distal open ends 216 , 226 , 236 are fixed in relation to each other.",
"It will be understood that various modifications may be made to the embodiments of the presently disclosed surgical stapling instruments.",
"Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments.",
"Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure."
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Divisional of application Ser. No. 10/570,156 filed Mar. 27, 2006, which in turn is a National Phase Application of PCT/JP2004/013791 filed Sep. 22, 2004. This application claims the benefit of Japanese Patent Application No. JP 2003-333664, filed Sep. 25, 2003. The entire disclosures of the prior applications are hereby incorporated by reference herein in its entirety.
BACKGROUND
The invention relates to substrate treatment equipment for treating a substrate of a semiconductor device or the like, and a manufacturing method of the substrate.
As is generally known, there is equipment as this type of substrate treatment equipment, which has a substrate holder for holding substrates in a multistage manner and a transfer unit for transferring the substrates into the substrate holder, and treats the substrates in a treatment furnace while holding a number of substrates in the substrate holder.
SUMMARY
When the substrates are heated in the treatment furnace, or removed from the treatment furnace and then cooled, abnormal phenomena such as cracks or warps may occur in the substrates due to thermal stress. When the cracks or warps are in such a level that they result in disabling automatic carrying of the substrates by an automatic substrate carrying mechanism, tweezers for taking in and out the substrates may collide with the substrates, and push down the substrate holder, leading to a serious accident such as damage of a quartz component.
To solve this, a mechanism for sensing a condition of the substrates can be considered to be provided. For example, the sensing mechanism has a photo-sensor provided on the transfer unit, and senses the substrates in the substrate holder by moving the photo-sensor using a vertical shaft of the transfer unit.
Portions where light is intercepted by the substrates and portions where light is transmitted between the substrates are recorded, and a shift level of the vertical shaft and sensing data of the photo-sensor are used to find whether a substrate pitch is normal with respect to a pitch of the substrate holder which has been known.
When a substrate drops from a support slot on the support holder due to cracking of the substrate or transfer errors, discrepancy may occur between interception/transmission data of light by the photo-sensor and the recorded data, and a substrate on a support slot at which the discrepancy appeared is determined to be in an abnormal transfer condition.
Moreover, when the substrate completely drops from a support slot and consequently the substrate does not lie on the support slot on which the substrate is essentially to be held, since light is not intercepted, the substrate can be sensed as a lost substrate.
After a substrate condition is sensed by the substrate sensing mechanism, a substrate that has been transferred onto the support slot at which an error occurred is manually collected by an operator who has entered the equipment.
Furthermore, after the substrate has been visually confirmed to be safe, it is automatically transferred by the automatic substrate carrying mechanism.
Currently, it is an issue to realize a mini-environment by using an L/L device (load/lock device), a N 2 purge device, and an organic filter and the like in order to avoid entering of moisture or particles contained in the air and thus reduce contamination of the substrate in substrate treatment equipment. When an abnormal substrate is manually collected after an abnormal phenomenon is sensed by the substrate condition sensing mechanism as describe above, particles generated from a human body may have adverse effects on a substrate in a normal condition at high possibility. In substrate treatment equipment using the N 2 purge device, an atmosphere within the equipment must be returned to the air to reset the environment such that the operator can enter the equipment. In such a situation, a natural oxidation film on a surface of the substrate can not be reduced, consequently a substrate that has been normally transferred also has a problem in process.
An object of the invention is to provide substrate treatment equipment that can automatically collect a substrate in a normal condition without needing manual operation.
To solve the problem, a first feature of the invention is substrate treatment equipment having a substrate treatment chamber, a substrate holder that can be inserted into the substrate treatment chamber and holds substrates in a multistage manner in a substantially vertical direction, a substrate transfer unit for transferring the substrates onto the substrate holder, and a sensing device for sensing a holding condition of the substrate held in the substrate holder; which includes a control device that, in transfer of the substrates, senses the holding condition of the substrates using the sensing device, and controls the substrate transfer unit such that substrates other than a substrate which was determined to be in an abnormal substrate holding condition are transferred by the substrate transfer unit.
A second feature of the invention is substrate treatment equipment having a substrate treatment chamber, a substrate holder that can be inserted into the substrate treatment chamber and holds substrates in a multistage manner in a substantially vertical direction, a substrate transfer unit for transferring the substrates onto the substrate holder, and a sensing device for sensing a holding condition of the substrate held in the substrate holder; which includes a control device that, in transfer of the substrates, senses the holding condition of the substrates using the sensing device, and controls the substrate transfer unit such that substrates other than a substrate which was determined to be in an abnormal substrate holding condition are transferred by the substrate transfer unit; wherein the control device controls the substrate transfer unit such that substrates other than the substrate determined to be abnormal and at least one of substrates held on and under the substrate determined to be abnormal are transferred by the substrate transfer unit.
A third feature of the invention is a manufacturing method of a substrate having a step of inserting a substrate holder in which substrates are held in a multistage manner in a substantially vertical direction into a substrate treatment chamber, a step of performing heat treatment to the substrates in the substrate treatment chamber, a step of sensing a holding condition of the substrates held in the substrate holder, and a step of transferring substrates other than a substrate that was determined to be in an abnormal substrate holding condition by a substrate transfer unit.
A fourth feature of the invention is a manufacturing method of a substrate having a step of inserting a substrate holder in which substrates are held in a multistage manner in a substantially vertical direction into a substrate treatment chamber, a step of performing heat treatment to the substrates in the substrate treatment chamber, a step of sensing a holding condition of the substrates held in the substrate holder, and a step of transferring substrates other than a substrate that was determined to be in an abnormal substrate holding condition by a substrate transfer unit; wherein the substrates are transferred in such a manner that substrates are carried for each of several predetermined number of substrates, and when all the predetermined number of substrates to be carried are determined to be in a normal substrate holding condition, all the predetermined number of substrates are carried together, and when at least one of the substrates is determined to be in an abnormal substrate holding condition, substrates other than the substrate that was determined to be abnormal in the predetermined number of substrates are carried one at a time.
While control means may control the transfer unit such that all the substrates other than the substrate that was determined to be abnormal are transferred by the transfer unit, it preferably controls the transfer unit such that substrates other than the substrate that was determined to be abnormal and at least one of substrates on and under the substrate are transferred by the transfer unit.
According to the substrate treatment equipment of the invention, in transfer of substrates, the holding condition of the substrates is sensed, and the transfer unit is controlled such that substrates other than at least a substrate that was determined to be abnormal are transferred by the transfer unit, therefore substrates in a normal condition can be automatically collected, and entering of particles into the equipment or oxidation on the substrates can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view generally showing substrate treatment equipment according to an embodiment of the invention;
FIG. 2 is a cross section view generally showing the substrate treatment equipment according to the embodiment of the invention;
FIG. 3 is a cross section view showing a treatment furnace used in the substrate treatment equipment according to the embodiment of the invention and the periphery of the furnace;
FIG. 4 is a side view showing a substrate transfer unit used in the substrate treatment equipment according to the embodiment of the invention;
FIG. 5 is a side view showing a substrate holder used in the substrate treatment equipment according to the embodiment of the invention;
FIG. 6 is views for illustrating an abnormal condition of substrate holding in the substrate treatment equipment according to the embodiment of the invention, wherein (a) is a plane view showing a normal condition, (b) is a front view showing a condition of cracking in a substrate, (c) is a front view showing the substrate holder, and (d) is a side view of the substrate holder;
FIG. 7 is views for illustrating a sensing method when an abnormal condition of substrate holding is found in the substrate treatment equipment according to the embodiment of the invention, wherein (a) is an illustrative view showing a relation between the abnormal condition of substrate holding and a sensing waveform, and (b) is a plane view of the substrate transfer unit; and
FIG. 8 is a flowchart showing operation of substrate sensing in the substrate treatment equipment according to the embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Next, an embodiment of the invention is described according to drawings.
FIG. 1 and FIG. 2 show substrate treatment equipment 10 according to the embodiment of the invention. The substrate treatment equipment 10 is vertical-type one for performing diffusion treatment or CVD treatment to a substrate. In the substrate treatment equipment 10 , a load/unload stage 18 for inserting a pod 14 accommodating substrates 12 formed from silicon and the like from the outside into a housing 16 is fixed on a front face of the housing 16 . A cassette shelf 22 for storing the inserted pod 14 is provided within the housing 16 . Moreover, an N 2 purge chamber 24 is provided within the housing 16 . The N 2 purge chamber 24 acts as a carrying area of the substrates 12 , or a space for carrying in and out a substrate holder (boat) 26 . When treatment of the substrate 12 is performed, the N 2 purge chamber 24 is filled with inert gas such as N 2 gas to prevent a natural oxidation film from being formed on the substrate 12 .
FOUP is used for the pod 14 , and the substrate 12 can be carried while being isolated from the air by covering an opening provided in a side face of the pod 14 by a cap (not shown), and the substrate 12 can be taken in and out into/from the pod 14 by removing the cap. For example, 25 substrates 12 are stored in the pod 14 . A pod opener 28 is provided in a front face of the N 2 purge chamber 24 so that the cap of the pod 14 is removed to communicate the atmosphere within the pod 14 with the atmosphere within the N 2 purge chamber 24 . The pod 14 is carried among the pod opener 28 , cassette shelf 22 and load/unload stage 18 by the cassette transfer unit 30 . Air cleaned by a clean unit (not shown) provided on the housing 16 is flowed through a space for carrying the pod 14 by the cassette transfer unit 30 .
Within the N 2 purge chamber 24 , a substrate holder 26 for loading a plurality of substrates 12 in a multistage manner, a substrate alignment device 32 for aligning a notch (or an orientation flat) of the substrate 12 to an optional position, and a substrate transfer unit 34 for carrying the substrate 12 between the pod 14 on the pod opener 28 and the substrate alignment device 32 are provided. A treatment furnace 36 for treating the substrates 12 is provided in an upper part of the N 2 purge chamber 24 , and the substrate holder 26 is loaded into the treatment furnace 36 by a boat elevator 38 as elevating means, or unloaded from the treatment furnace 36 by it. The treatment furnace 36 has a furnace port which is closed by a furnace port shutter 40 during except for a period during treating the substrate 12 .
Next, operation of the substrate processing equipment 10 according to the embodiment is described.
First, the pod 14 carried from the outside of the housing 16 by AGV or OHT is set on the load/unload stage 18 . The pod 14 set on the load/unload stage 18 is directly carried onto the pod opener 28 , or stocked temporarily on the cassette shelf 22 and then carried onto the pod opener 28 by the cassette transfer unit 30 . When the pod 14 is carried onto the pod opener 28 , the cap of the pod 14 is removed by the pod opener 28 , and thereby the atmosphere within the pod 14 is communicated with the atmosphere within the N 2 purge chamber 24 .
Then, a substrate 12 is removed from the pod 14 in a condition of being communicated with the atmosphere within the N 2 purge chamber 24 by the substrate transfer unit 34 . The removed substrate 12 is aligned by the substrate alignment device 32 such that the notch or the orientation flat is fixed in an optional position, and after that carried onto the substrate holder 26 .
When the substrates 12 have been carried into the substrate holder 26 , the furnace port shutter 40 of the treatment furnace 36 is opened, and then the substrate holder 26 having the substrates 12 mounted therein is loaded into the treatment furnace 36 by the boat elevator 38 .
After loading, predetermined treatment is performed to the substrates 12 in the treatment furnace 36 , and after the treatment, the substrates 12 and the pod 14 are ejected to the outside of the housing 16 in the reverse order of the above procedure.
FIG. 3 shows a peripheral configuration of the treatment furnace 36 . The treatment furnace 36 has an outer tube 42 formed from a heat resistant material such as quartz (SiO 2 ). The outer tube 42 is in a cylindrical shape that is closed at an upper end and has an opening at a lower end. An inner tube 44 is disposed concentrically within the outer tube 42 . A heater 46 as heating means is disposed concentrically on the outer circumference of the outer tube 42 . The heater 46 is held on the housing 16 via a heater base 48 .
As shown in FIG. 4 and FIG. 5 , in the substrate holder 26 , for example, three poles 50 formed from, quartz, silicon carbide and the like are disposed parallel in a vertical direction, and the substrates 12 are held by support slots 52 formed on the poles 50 . The substrate transfer unit 34 has a transfer unit body 54 that moves vertically and rotates, and a main tweezers body 56 that moves reciprocally on the transfer unit body 54 . For example, four tweezers 58 a , 58 b , 58 c and 58 d are fixed to the main tweezers body 56 in a manner of extending parallel to one another. Moreover, sub tweezers body 57 is provided on the transfer unit body 54 such that it can reciprocally move either along with or independently of the main tweezers body 56 . Tweezers 58 e are fixed to the sub tweezers body 57 at a position below the four tweezers 58 a to 58 d and parallel to them. Therefore, as shown in FIG. 4 , the substrate transfer unit 34 can collectively transfer five substrates 12 using the five tweezers 58 a to 58 e , and can transfer one monitor substrate (sheet transfer) using the tweezers 58 e at the lowermost stage. When the monitor substrate is transferred, as shown in FIG. 5 , a space corresponding to one slot is opened between sets of collectively transferred, five substrates 12 , and a monitor substrate 59 is extracted from a pod different from a pod for typical substrates 12 , and inserted between the sets of the five substrates.
For example, 25 substrates 12 are accommodated in the pod 14 , and in the case that the substrates 12 are transferred into or collected from the substrate holder 26 by the substrate transfer unit 34 , when there is no abnormal substrate in five slots (slot group), five substrates 12 are collectively transferred or collected using the five tweezers 58 a to 58 e , and when there is an abnormal substrate in the slot group, only normal substrates are collected using the tweezers 58 e at the lowermost stage. The monitor substrate may be collected one at a time as in insertion.
A sensing section 60 as sensing means is provided on the transfer unit body 54 . The sensing section 60 has parallel, two arms 62 a , 62 b , and is provided such that the arms 62 a , 62 b can be turned on a side face of the transfer body 54 . Near front ends of the arms 62 a , 62 b , transmission-type photo-sensors 64 a , 64 b are provided, and one of the photo-sensors is a light emitting element, and the other is a light receiving element. When a holding condition of the substrates 12 transferred into the substrate holder 26 is sensed, the arms 62 a , 62 b are turned and fixed to a side of the substrate holder 26 so that light axes of the photo-sensors 64 a , 64 b run through the substrates 12 , and then sensing output of the photo-sensors 64 a , 64 b is monitored while the substrate transfer unit 34 is moved from a lower end to an upper end of the substrate holder 26 . On the other hand, when the substrates 12 are transferred into the substrate holder 26 by the substrate transfer unit 34 , the arms 62 a , 62 b are turned to a side opposite to the substrate holder side to prevent the arms 62 a , 62 b from being interfered with the substrates 12 or the substrate holder 26 .
As shown in FIG. 3 , analog signals outputted from the photo-sensors 64 a , 64 b are outputted to a control section 66 including a computer. The control section 66 controls the substrate transfer unit 34 via a driver section 68 such as a motor.
Next, sensing of the abnormal condition of the substrates 12 is described.
As shown in FIG. 6( a ), it is assumed that the light emitting element 64 a is situated at the right side, and the light receiving element 64 b is situated at the left side in a view from a top of the substrate holder 26 , and the light emitting element 64 a and the light receiving element 64 b are disposed at a front face side of the substrate holder 26 . As shown in FIG. 6( b ), the substrate 12 may crack while being held in the substrate holder 26 or drop from the support slot 52 of the substrate holder 26 , resulting in falling into abnormal condition. As shown in FIG. 6( c ) and FIG. 6( d ), the abnormal conditions of the substrate 12 are given as follows.
A. drop/in pairs
B. drop/light-emitting side drop (left face drop)
C. drop/light-receiving side drop (right face drop)
D. drop/rear drop (back face drop)
E. drop/front drop (front face drop)
F. cracking/center cracking
G. cracking/front cracking
H. cracking/rear cracking
J. no substrate
A substrate 12 , which is in the normal condition, is supported parallel to a support slot 52 .
FIG. 7( a ) shows a relation of signal output from the photo-sensors 64 a , 64 b to the abnormal condition. A positional relation between the substrate holder 26 and the photo-sensors 64 a , 64 b is assumed that the photo-sensors 64 a , 64 b are at a front side, and a side opposed to the photo-sensors is a back side as shown in FIG. 7( b ).
When the holding condition of the substrates 12 is normal, waveforms outputted from the photo-sensors 64 a , 64 b are regular. For example, when a left or right surface of the substrate 12 drops, sensing waveforms of the photo-sensors 64 a , 64 b are gradually spread at left and right of a peak compared with a normal waveform, consequently width at a reference line is increased. When the substrate 12 completely drops from the support slot 52 , sensing output of the photo-sensors 64 a , 64 b disappears at that support slot 52 from which the substrate has dropped. When the substrate 12 drops from the support slot 52 at the back, the peak is shifted to the upper side compared with the normal waveform. When the substrate 12 drops from the support slot 52 at the front, the peak is shifted to the lower side compared with the normal waveform. The case that the substrate 12 has cracked can be also sensed.
FIG. 8 shows an example of substrate sensing operation by the control section in a flowchart.
First, in step S 10 , drive of the substrate transfer unit and the photo-sensors is started. That is, as previously shown in FIG. 3 , the arms 62 a , 62 b are rotationally fixed to the side of the substrate holder 26 , and then a transfer condition of the substrates 12 is sensed by the photo-sensors 64 a , 64 b while the substrate transfer unit 34 is raised from the lowermost end of the substrate holder 26 at a constant speed. The quantity of light of light emitting/receiving of the photo-sensors 64 a , 64 b is inputted into the control section 66 as analog signals.
In next step S 12 , the analog signals inputted from the photo-sensors 64 a , 64 b are converted into digital signals to analyze detection output from the photo-sensors 64 a , 64 b . In this analysis of output from the photo-sensors 64 a , 64 b , the sensing waveforms from the photo-sensors 64 a , 64 b are recorded and then compared with the normal waveform so that an abnormal slot is specified and thus an abnormal slot list is prepared.
In next step S 14 , whether before or after heat treatment is determined. When determination is made as before heat treatment, the operation is advanced to step 16 to determine whether an abnormal slot is found or not, and when it is determined that the abnormal slot is not found, the operation is advanced to step S 18 in which the substrate supporter 26 is carried into the treatment furnace 36 , and then heat treatment is carried out. On the other hand, when determination is made as after heat treatment in the step S 14 , or when it is determined in the step S 16 that the abnormal slot is found, the operation is advanced to step S 20 in which collection of the substrates 12 is started. As described before, the collection of the substrates 12 is performed for each of slot groups, and it is begun at a first slot group and ended at a fifth slot group that is a final slot group. In next step S 22 , whether all the five substrates in the slot group to be collected are transferred in the normal condition (not found in the abnormal slot list) is determined. When all the five substrates are determined to be in the normal condition in the step S 22 , the operation is advanced to step S 24 in which all the five substrates are collected together. On the other hand, when it is determined that there is a substrate in the abnormal condition in the five substrates 12 in an objective slot group (found in the abnormal slot list) in the step S 22 , the operation is advanced to step S 26 in which only the substrates in the normal condition are collected in a manner of sheet transfer. When collection is not completed for all the slot groups in the step S 28 , the operation is returned to processing for a next slot group, and when collection is completed for all the slot groups, the operation is finished.
In the embodiment, when a substrate in the abnormal condition is found, the substrate in the abnormal condition is remained in the substrate holder, and all the substrates in the normal condition are returned into the pod, however, the invention is not necessarily limited to this. When the substrate in the abnormal condition is found, a substrate on or under the substrate may receive a kind of damage. Thus, it is also acceptable that at least one of substrates on and under the substrate in the abnormal condition is also remained in the substrate holder, and other substrates in the normal condition are returned into the pod.
INDUSTRIAL APPLICABILITY
The invention can be used for substrate treatment equipment that automatically collects substrates. | The invention aims to provide substrate treatment equipment that can automatically collect a substrate in a normal condition without needing manual operation. The equipment includes a substrate holder 26 for holding substrates 12 in a multistage manner and a substrate transfer unit 34 for transferring the substrates 12 into the substrate holder 26 , wherein a substrate holding condition of the substrate holder 26 is sensed by a sensing section 60 . The sensing section 60 has photo-sensors 64 a, 64 b , and sensing waveforms sensed by the photo-sensors 64 a, 64 b are compared with a normal waveform. A control section 66 is provided, which controls a substrate transfer unit 34 such that substrates 12 other than at least a substrate 12 that was determined to be abnormal are transferred by the unit. | Summarize the key points of the given document. | [
"CROSS-REFERENCE TO RELATED APPLICATIONS This is a Divisional of application Ser.",
"No. 10/570,156 filed Mar. 27, 2006, which in turn is a National Phase Application of PCT/JP2004/013791 filed Sep. 22, 2004.",
"This application claims the benefit of Japanese Patent Application No. JP 2003-333664, filed Sep. 25, 2003.",
"The entire disclosures of the prior applications are hereby incorporated by reference herein in its entirety.",
"BACKGROUND The invention relates to substrate treatment equipment for treating a substrate of a semiconductor device or the like, and a manufacturing method of the substrate.",
"As is generally known, there is equipment as this type of substrate treatment equipment, which has a substrate holder for holding substrates in a multistage manner and a transfer unit for transferring the substrates into the substrate holder, and treats the substrates in a treatment furnace while holding a number of substrates in the substrate holder.",
"SUMMARY When the substrates are heated in the treatment furnace, or removed from the treatment furnace and then cooled, abnormal phenomena such as cracks or warps may occur in the substrates due to thermal stress.",
"When the cracks or warps are in such a level that they result in disabling automatic carrying of the substrates by an automatic substrate carrying mechanism, tweezers for taking in and out the substrates may collide with the substrates, and push down the substrate holder, leading to a serious accident such as damage of a quartz component.",
"To solve this, a mechanism for sensing a condition of the substrates can be considered to be provided.",
"For example, the sensing mechanism has a photo-sensor provided on the transfer unit, and senses the substrates in the substrate holder by moving the photo-sensor using a vertical shaft of the transfer unit.",
"Portions where light is intercepted by the substrates and portions where light is transmitted between the substrates are recorded, and a shift level of the vertical shaft and sensing data of the photo-sensor are used to find whether a substrate pitch is normal with respect to a pitch of the substrate holder which has been known.",
"When a substrate drops from a support slot on the support holder due to cracking of the substrate or transfer errors, discrepancy may occur between interception/transmission data of light by the photo-sensor and the recorded data, and a substrate on a support slot at which the discrepancy appeared is determined to be in an abnormal transfer condition.",
"Moreover, when the substrate completely drops from a support slot and consequently the substrate does not lie on the support slot on which the substrate is essentially to be held, since light is not intercepted, the substrate can be sensed as a lost substrate.",
"After a substrate condition is sensed by the substrate sensing mechanism, a substrate that has been transferred onto the support slot at which an error occurred is manually collected by an operator who has entered the equipment.",
"Furthermore, after the substrate has been visually confirmed to be safe, it is automatically transferred by the automatic substrate carrying mechanism.",
"Currently, it is an issue to realize a mini-environment by using an L/L device (load/lock device), a N 2 purge device, and an organic filter and the like in order to avoid entering of moisture or particles contained in the air and thus reduce contamination of the substrate in substrate treatment equipment.",
"When an abnormal substrate is manually collected after an abnormal phenomenon is sensed by the substrate condition sensing mechanism as describe above, particles generated from a human body may have adverse effects on a substrate in a normal condition at high possibility.",
"In substrate treatment equipment using the N 2 purge device, an atmosphere within the equipment must be returned to the air to reset the environment such that the operator can enter the equipment.",
"In such a situation, a natural oxidation film on a surface of the substrate can not be reduced, consequently a substrate that has been normally transferred also has a problem in process.",
"An object of the invention is to provide substrate treatment equipment that can automatically collect a substrate in a normal condition without needing manual operation.",
"To solve the problem, a first feature of the invention is substrate treatment equipment having a substrate treatment chamber, a substrate holder that can be inserted into the substrate treatment chamber and holds substrates in a multistage manner in a substantially vertical direction, a substrate transfer unit for transferring the substrates onto the substrate holder, and a sensing device for sensing a holding condition of the substrate held in the substrate holder;",
"which includes a control device that, in transfer of the substrates, senses the holding condition of the substrates using the sensing device, and controls the substrate transfer unit such that substrates other than a substrate which was determined to be in an abnormal substrate holding condition are transferred by the substrate transfer unit.",
"A second feature of the invention is substrate treatment equipment having a substrate treatment chamber, a substrate holder that can be inserted into the substrate treatment chamber and holds substrates in a multistage manner in a substantially vertical direction, a substrate transfer unit for transferring the substrates onto the substrate holder, and a sensing device for sensing a holding condition of the substrate held in the substrate holder;",
"which includes a control device that, in transfer of the substrates, senses the holding condition of the substrates using the sensing device, and controls the substrate transfer unit such that substrates other than a substrate which was determined to be in an abnormal substrate holding condition are transferred by the substrate transfer unit;",
"wherein the control device controls the substrate transfer unit such that substrates other than the substrate determined to be abnormal and at least one of substrates held on and under the substrate determined to be abnormal are transferred by the substrate transfer unit.",
"A third feature of the invention is a manufacturing method of a substrate having a step of inserting a substrate holder in which substrates are held in a multistage manner in a substantially vertical direction into a substrate treatment chamber, a step of performing heat treatment to the substrates in the substrate treatment chamber, a step of sensing a holding condition of the substrates held in the substrate holder, and a step of transferring substrates other than a substrate that was determined to be in an abnormal substrate holding condition by a substrate transfer unit.",
"A fourth feature of the invention is a manufacturing method of a substrate having a step of inserting a substrate holder in which substrates are held in a multistage manner in a substantially vertical direction into a substrate treatment chamber, a step of performing heat treatment to the substrates in the substrate treatment chamber, a step of sensing a holding condition of the substrates held in the substrate holder, and a step of transferring substrates other than a substrate that was determined to be in an abnormal substrate holding condition by a substrate transfer unit;",
"wherein the substrates are transferred in such a manner that substrates are carried for each of several predetermined number of substrates, and when all the predetermined number of substrates to be carried are determined to be in a normal substrate holding condition, all the predetermined number of substrates are carried together, and when at least one of the substrates is determined to be in an abnormal substrate holding condition, substrates other than the substrate that was determined to be abnormal in the predetermined number of substrates are carried one at a time.",
"While control means may control the transfer unit such that all the substrates other than the substrate that was determined to be abnormal are transferred by the transfer unit, it preferably controls the transfer unit such that substrates other than the substrate that was determined to be abnormal and at least one of substrates on and under the substrate are transferred by the transfer unit.",
"According to the substrate treatment equipment of the invention, in transfer of substrates, the holding condition of the substrates is sensed, and the transfer unit is controlled such that substrates other than at least a substrate that was determined to be abnormal are transferred by the transfer unit, therefore substrates in a normal condition can be automatically collected, and entering of particles into the equipment or oxidation on the substrates can be prevented.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view generally showing substrate treatment equipment according to an embodiment of the invention;",
"FIG. 2 is a cross section view generally showing the substrate treatment equipment according to the embodiment of the invention;",
"FIG. 3 is a cross section view showing a treatment furnace used in the substrate treatment equipment according to the embodiment of the invention and the periphery of the furnace;",
"FIG. 4 is a side view showing a substrate transfer unit used in the substrate treatment equipment according to the embodiment of the invention;",
"FIG. 5 is a side view showing a substrate holder used in the substrate treatment equipment according to the embodiment of the invention;",
"FIG. 6 is views for illustrating an abnormal condition of substrate holding in the substrate treatment equipment according to the embodiment of the invention, wherein (a) is a plane view showing a normal condition, (b) is a front view showing a condition of cracking in a substrate, (c) is a front view showing the substrate holder, and (d) is a side view of the substrate holder;",
"FIG. 7 is views for illustrating a sensing method when an abnormal condition of substrate holding is found in the substrate treatment equipment according to the embodiment of the invention, wherein (a) is an illustrative view showing a relation between the abnormal condition of substrate holding and a sensing waveform, and (b) is a plane view of the substrate transfer unit;",
"and FIG. 8 is a flowchart showing operation of substrate sensing in the substrate treatment equipment according to the embodiment of the invention.",
"DETAILED DESCRIPTION OF EMBODIMENTS Next, an embodiment of the invention is described according to drawings.",
"FIG. 1 and FIG. 2 show substrate treatment equipment 10 according to the embodiment of the invention.",
"The substrate treatment equipment 10 is vertical-type one for performing diffusion treatment or CVD treatment to a substrate.",
"In the substrate treatment equipment 10 , a load/unload stage 18 for inserting a pod 14 accommodating substrates 12 formed from silicon and the like from the outside into a housing 16 is fixed on a front face of the housing 16 .",
"A cassette shelf 22 for storing the inserted pod 14 is provided within the housing 16 .",
"Moreover, an N 2 purge chamber 24 is provided within the housing 16 .",
"The N 2 purge chamber 24 acts as a carrying area of the substrates 12 , or a space for carrying in and out a substrate holder (boat) 26 .",
"When treatment of the substrate 12 is performed, the N 2 purge chamber 24 is filled with inert gas such as N 2 gas to prevent a natural oxidation film from being formed on the substrate 12 .",
"FOUP is used for the pod 14 , and the substrate 12 can be carried while being isolated from the air by covering an opening provided in a side face of the pod 14 by a cap (not shown), and the substrate 12 can be taken in and out into/from the pod 14 by removing the cap.",
"For example, 25 substrates 12 are stored in the pod 14 .",
"A pod opener 28 is provided in a front face of the N 2 purge chamber 24 so that the cap of the pod 14 is removed to communicate the atmosphere within the pod 14 with the atmosphere within the N 2 purge chamber 24 .",
"The pod 14 is carried among the pod opener 28 , cassette shelf 22 and load/unload stage 18 by the cassette transfer unit 30 .",
"Air cleaned by a clean unit (not shown) provided on the housing 16 is flowed through a space for carrying the pod 14 by the cassette transfer unit 30 .",
"Within the N 2 purge chamber 24 , a substrate holder 26 for loading a plurality of substrates 12 in a multistage manner, a substrate alignment device 32 for aligning a notch (or an orientation flat) of the substrate 12 to an optional position, and a substrate transfer unit 34 for carrying the substrate 12 between the pod 14 on the pod opener 28 and the substrate alignment device 32 are provided.",
"A treatment furnace 36 for treating the substrates 12 is provided in an upper part of the N 2 purge chamber 24 , and the substrate holder 26 is loaded into the treatment furnace 36 by a boat elevator 38 as elevating means, or unloaded from the treatment furnace 36 by it.",
"The treatment furnace 36 has a furnace port which is closed by a furnace port shutter 40 during except for a period during treating the substrate 12 .",
"Next, operation of the substrate processing equipment 10 according to the embodiment is described.",
"First, the pod 14 carried from the outside of the housing 16 by AGV or OHT is set on the load/unload stage 18 .",
"The pod 14 set on the load/unload stage 18 is directly carried onto the pod opener 28 , or stocked temporarily on the cassette shelf 22 and then carried onto the pod opener 28 by the cassette transfer unit 30 .",
"When the pod 14 is carried onto the pod opener 28 , the cap of the pod 14 is removed by the pod opener 28 , and thereby the atmosphere within the pod 14 is communicated with the atmosphere within the N 2 purge chamber 24 .",
"Then, a substrate 12 is removed from the pod 14 in a condition of being communicated with the atmosphere within the N 2 purge chamber 24 by the substrate transfer unit 34 .",
"The removed substrate 12 is aligned by the substrate alignment device 32 such that the notch or the orientation flat is fixed in an optional position, and after that carried onto the substrate holder 26 .",
"When the substrates 12 have been carried into the substrate holder 26 , the furnace port shutter 40 of the treatment furnace 36 is opened, and then the substrate holder 26 having the substrates 12 mounted therein is loaded into the treatment furnace 36 by the boat elevator 38 .",
"After loading, predetermined treatment is performed to the substrates 12 in the treatment furnace 36 , and after the treatment, the substrates 12 and the pod 14 are ejected to the outside of the housing 16 in the reverse order of the above procedure.",
"FIG. 3 shows a peripheral configuration of the treatment furnace 36 .",
"The treatment furnace 36 has an outer tube 42 formed from a heat resistant material such as quartz (SiO 2 ).",
"The outer tube 42 is in a cylindrical shape that is closed at an upper end and has an opening at a lower end.",
"An inner tube 44 is disposed concentrically within the outer tube 42 .",
"A heater 46 as heating means is disposed concentrically on the outer circumference of the outer tube 42 .",
"The heater 46 is held on the housing 16 via a heater base 48 .",
"As shown in FIG. 4 and FIG. 5 , in the substrate holder 26 , for example, three poles 50 formed from, quartz, silicon carbide and the like are disposed parallel in a vertical direction, and the substrates 12 are held by support slots 52 formed on the poles 50 .",
"The substrate transfer unit 34 has a transfer unit body 54 that moves vertically and rotates, and a main tweezers body 56 that moves reciprocally on the transfer unit body 54 .",
"For example, four tweezers 58 a , 58 b , 58 c and 58 d are fixed to the main tweezers body 56 in a manner of extending parallel to one another.",
"Moreover, sub tweezers body 57 is provided on the transfer unit body 54 such that it can reciprocally move either along with or independently of the main tweezers body 56 .",
"Tweezers 58 e are fixed to the sub tweezers body 57 at a position below the four tweezers 58 a to 58 d and parallel to them.",
"Therefore, as shown in FIG. 4 , the substrate transfer unit 34 can collectively transfer five substrates 12 using the five tweezers 58 a to 58 e , and can transfer one monitor substrate (sheet transfer) using the tweezers 58 e at the lowermost stage.",
"When the monitor substrate is transferred, as shown in FIG. 5 , a space corresponding to one slot is opened between sets of collectively transferred, five substrates 12 , and a monitor substrate 59 is extracted from a pod different from a pod for typical substrates 12 , and inserted between the sets of the five substrates.",
"For example, 25 substrates 12 are accommodated in the pod 14 , and in the case that the substrates 12 are transferred into or collected from the substrate holder 26 by the substrate transfer unit 34 , when there is no abnormal substrate in five slots (slot group), five substrates 12 are collectively transferred or collected using the five tweezers 58 a to 58 e , and when there is an abnormal substrate in the slot group, only normal substrates are collected using the tweezers 58 e at the lowermost stage.",
"The monitor substrate may be collected one at a time as in insertion.",
"A sensing section 60 as sensing means is provided on the transfer unit body 54 .",
"The sensing section 60 has parallel, two arms 62 a , 62 b , and is provided such that the arms 62 a , 62 b can be turned on a side face of the transfer body 54 .",
"Near front ends of the arms 62 a , 62 b , transmission-type photo-sensors 64 a , 64 b are provided, and one of the photo-sensors is a light emitting element, and the other is a light receiving element.",
"When a holding condition of the substrates 12 transferred into the substrate holder 26 is sensed, the arms 62 a , 62 b are turned and fixed to a side of the substrate holder 26 so that light axes of the photo-sensors 64 a , 64 b run through the substrates 12 , and then sensing output of the photo-sensors 64 a , 64 b is monitored while the substrate transfer unit 34 is moved from a lower end to an upper end of the substrate holder 26 .",
"On the other hand, when the substrates 12 are transferred into the substrate holder 26 by the substrate transfer unit 34 , the arms 62 a , 62 b are turned to a side opposite to the substrate holder side to prevent the arms 62 a , 62 b from being interfered with the substrates 12 or the substrate holder 26 .",
"As shown in FIG. 3 , analog signals outputted from the photo-sensors 64 a , 64 b are outputted to a control section 66 including a computer.",
"The control section 66 controls the substrate transfer unit 34 via a driver section 68 such as a motor.",
"Next, sensing of the abnormal condition of the substrates 12 is described.",
"As shown in FIG. 6( a ), it is assumed that the light emitting element 64 a is situated at the right side, and the light receiving element 64 b is situated at the left side in a view from a top of the substrate holder 26 , and the light emitting element 64 a and the light receiving element 64 b are disposed at a front face side of the substrate holder 26 .",
"As shown in FIG. 6( b ), the substrate 12 may crack while being held in the substrate holder 26 or drop from the support slot 52 of the substrate holder 26 , resulting in falling into abnormal condition.",
"As shown in FIG. 6( c ) and FIG. 6( d ), the abnormal conditions of the substrate 12 are given as follows.",
"A. drop/in pairs B. drop/light-emitting side drop (left face drop) C. drop/light-receiving side drop (right face drop) D. drop/rear drop (back face drop) E. drop/front drop (front face drop) F. cracking/center cracking G. cracking/front cracking H. cracking/rear cracking J. no substrate A substrate 12 , which is in the normal condition, is supported parallel to a support slot 52 .",
"FIG. 7( a ) shows a relation of signal output from the photo-sensors 64 a , 64 b to the abnormal condition.",
"A positional relation between the substrate holder 26 and the photo-sensors 64 a , 64 b is assumed that the photo-sensors 64 a , 64 b are at a front side, and a side opposed to the photo-sensors is a back side as shown in FIG. 7( b ).",
"When the holding condition of the substrates 12 is normal, waveforms outputted from the photo-sensors 64 a , 64 b are regular.",
"For example, when a left or right surface of the substrate 12 drops, sensing waveforms of the photo-sensors 64 a , 64 b are gradually spread at left and right of a peak compared with a normal waveform, consequently width at a reference line is increased.",
"When the substrate 12 completely drops from the support slot 52 , sensing output of the photo-sensors 64 a , 64 b disappears at that support slot 52 from which the substrate has dropped.",
"When the substrate 12 drops from the support slot 52 at the back, the peak is shifted to the upper side compared with the normal waveform.",
"When the substrate 12 drops from the support slot 52 at the front, the peak is shifted to the lower side compared with the normal waveform.",
"The case that the substrate 12 has cracked can be also sensed.",
"FIG. 8 shows an example of substrate sensing operation by the control section in a flowchart.",
"First, in step S 10 , drive of the substrate transfer unit and the photo-sensors is started.",
"That is, as previously shown in FIG. 3 , the arms 62 a , 62 b are rotationally fixed to the side of the substrate holder 26 , and then a transfer condition of the substrates 12 is sensed by the photo-sensors 64 a , 64 b while the substrate transfer unit 34 is raised from the lowermost end of the substrate holder 26 at a constant speed.",
"The quantity of light of light emitting/receiving of the photo-sensors 64 a , 64 b is inputted into the control section 66 as analog signals.",
"In next step S 12 , the analog signals inputted from the photo-sensors 64 a , 64 b are converted into digital signals to analyze detection output from the photo-sensors 64 a , 64 b .",
"In this analysis of output from the photo-sensors 64 a , 64 b , the sensing waveforms from the photo-sensors 64 a , 64 b are recorded and then compared with the normal waveform so that an abnormal slot is specified and thus an abnormal slot list is prepared.",
"In next step S 14 , whether before or after heat treatment is determined.",
"When determination is made as before heat treatment, the operation is advanced to step 16 to determine whether an abnormal slot is found or not, and when it is determined that the abnormal slot is not found, the operation is advanced to step S 18 in which the substrate supporter 26 is carried into the treatment furnace 36 , and then heat treatment is carried out.",
"On the other hand, when determination is made as after heat treatment in the step S 14 , or when it is determined in the step S 16 that the abnormal slot is found, the operation is advanced to step S 20 in which collection of the substrates 12 is started.",
"As described before, the collection of the substrates 12 is performed for each of slot groups, and it is begun at a first slot group and ended at a fifth slot group that is a final slot group.",
"In next step S 22 , whether all the five substrates in the slot group to be collected are transferred in the normal condition (not found in the abnormal slot list) is determined.",
"When all the five substrates are determined to be in the normal condition in the step S 22 , the operation is advanced to step S 24 in which all the five substrates are collected together.",
"On the other hand, when it is determined that there is a substrate in the abnormal condition in the five substrates 12 in an objective slot group (found in the abnormal slot list) in the step S 22 , the operation is advanced to step S 26 in which only the substrates in the normal condition are collected in a manner of sheet transfer.",
"When collection is not completed for all the slot groups in the step S 28 , the operation is returned to processing for a next slot group, and when collection is completed for all the slot groups, the operation is finished.",
"In the embodiment, when a substrate in the abnormal condition is found, the substrate in the abnormal condition is remained in the substrate holder, and all the substrates in the normal condition are returned into the pod, however, the invention is not necessarily limited to this.",
"When the substrate in the abnormal condition is found, a substrate on or under the substrate may receive a kind of damage.",
"Thus, it is also acceptable that at least one of substrates on and under the substrate in the abnormal condition is also remained in the substrate holder, and other substrates in the normal condition are returned into the pod.",
"INDUSTRIAL APPLICABILITY The invention can be used for substrate treatment equipment that automatically collects substrates."
] |
CROSS REFERENCE TO PRIOR APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/409,720, filed Mar. 1, 2012, now U.S. Pat. No. 8,660,533, which claims the benefit of U.S. Provisional Application No. 61/448,002 filed on Mar. 1, 2011, which is hereby incorporated by reference in its entirety for all purposes as if fully set forth herein.
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
This disclosure relates generally to a system, method and apparatus for pairing postpaid SIM or UICC cards with authorized wireless devices. More specifically, this disclosure relates to a system, method and apparatus for pairing postpaid SIM or UICC cards with authorized wireless devices in order to restrict usage of the postpaid SIM or UICC cards to certain devices.
2. Related Art
Certain companies that provide postpaid wireless services, such as mobile phone service, can be wireless carriers that maintain and control their own wireless networks, where carriers rely heavily on backend systems to address any provisional, billing, security and data issues that might threaten the health of their networks. Wireless carriers also typically offer multi-tiered postpaid offerings which allow their subscriber's unrestricted access to their network by progressively charging or taxing them based on their network usage based on data usage and airtime usage.
A Mobile Virtual Network Operator (MVNO) is a mobile operator that typically does not own its own frequency spectrum and typically does not have its own network infrastructure. Instead, MVNOs have business arrangements and contracts with wireless carriers to purchase usage of their networks (e.g., minutes of use, volume of data transfer, number of SMS messages, etc.) that the MVNOs in turn sell to their own subscribers. Based on these business arrangements and contracts, carriers and MVNOs have established detailed Terms of Service (TOS) and conditions for their subscribers. As such, if a subscriber is found in violation of these conditions they are typically given a warning, they have their subscription/service terminated or the like.
In today's MVNO prepaid marketplace, the prepaid phones that implement identification devices such as a subscriber identity module or a subscriber identification module (SIM) cards or Universal Integrated Circuit Cards (UICC) are strictly regulated in order to keep costs low and prepaid phone/rate offerings attractive. In an effort to diversify their revenue portfolio, MVNOs are now looking towards the postpaid market as a means to diversify their revenue portfolio but face a number of challenges based on the fact that: (1) MVNOs do not operate and control their own wireless networks and thus do not have the same ability as the carriers to implement provisional, billing, security and data controls on the backend to control network usage; and (2) MVNOs and, in turn, their subscribers are bound by the terms of services and conditions of the MVNO's business arrangements and contracts with the carriers associated with purchased network usage. In order for MVNOs to provide a comparable postpaid experience for its customers as provided for by the carriers, there is a need for MVNOs to provide customers with enough freedom of choice while still regulating the customers' usage of the network. To be competitive with carriers, MVNOs further need to provide attractive postpaid offerings to its customers while still keeping costs low enough to turn a profit based on the contractual obligations the MVNOs have with the carriers. For example, if MVNO customers exceed the collective network usage that has been contracted for by a MVNO, the MVNO is typically heavily charged or penalized.
The solutions for controlling and charging customers typically implemented by carriers do not mitigate the risks enough from the perspective of MVNOs whose business model is quite different of that of network carriers. Furthermore, the network solution implemented by carriers is extensive and complex, thus making it a slow solution to integrate. Additionally, it is also expensive in its implementation and expansive in its affects since this encompasses everyone on the network. Yet another shortcoming of the existing network solution is that it is easier for a carrier to absorb the cost of network traffic generated by its subscribers (violators of TOS) as they own the network versus MVNOs who have to pay exorbitant out of pocket fees for violations of its TOS with the carrier. Moreover, to date, MVNOs have no meaningful way to prevent TOS violators which can have a significant impact on their rate/phone offerings. For example, conventional postpaid SIM and UICC cards on the Global System for Mobile Communication (GSM) network are now unlocked (or can be unlocked) and can be moved between mobile phones without restriction, which can be particularly troublesome for MVNOs that only want their subscribers to use certain devices that have certain offerings.
Accordingly, there is a need for a Mobile Virtual Network Operator to be able to provide subscribers with the ability to have greater choice of services and devices while allowing the Mobile Virtual Network Operator the ability to limit the choice of services and devices.
SUMMARY OF THE INVENTION
Aspects of the invention advantageously provide a process of authorizing a wireless device including storing a list of authorized terminals within a memory accessible by a wireless device, comparing the list of authorized terminals in the memory to at least one of terminal profile data and an IMEI of the wireless device, and allowing network access if at least one of the terminal profile data and the IMEI are found on the list of authorized terminals and limiting network access if the terminal profile data and the IMEI are not found on the list of authorized terminals.
The memory may include a removable memory associated with the wireless device. The removable memory may include at least one of a Subscriber Identity Module (SIM) and Universal Integrated Circuit Card (UICC). The list of authorized terminals may include at least one of a previously stored International Mobile Equipment Identity (IMEI) and a listing of authorized terminal profile data values. The process may include sending a report comprising at least one of a current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), a current IMEI, and an Universal Integrated Circuit Card (UICC) Integrated Circuit Card ID (ICC-ID) to a backend server. The process may include storing securely in the removable memory at least one of a current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), a current IMEI, and an UICC Integrated Circuit Card ID (ICC-ID). The process may include at least one of provisioning and updating Over The Air (OTA) at least one of switches of an authorizing application and the list of authorized terminals. The network may include at least one of a Global System for Mobile Communication (GSM) network and a UMTS/LTE telecommunication network. The process may include functioning in at least one of a Global System for Mobile Communication (GSM) network and a UMTS/LTE telecommunication network as a Mobile Virtual Network Operator (MVNO) comprising using the process of authorizing a wireless device above.
Further aspects of the invention advantageously provide a wireless device configured to control network authorization including a removable memory storing a list of authorized terminals within the wireless device, a comparator to compare the list of authorized terminals in the removable memory to at least one of terminal profile data and an IMEI of the wireless device, and the wireless device being configured to allow network access if at least one the terminal profile data and the IMEI of the wireless device is found on the list of authorized terminals and the wireless device being further configured to limit network access if the terminal profile data and the IMEI of the wireless device is not found on the list of authorized terminals.
The removable memory may include at least one of a Subscriber Identity Module (SIM) and Universal Integrated Circuit Card (UICC). The list of authorized terminals may include at least one of a previously stored International Mobile Equipment Identity (IMEI) and a listing of authorized terminal profiles. The wireless device may be configured to send a report comprising at least one of the current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), the current IMEI, and an Universal Integrated Circuit Card (UICC) Integrated Circuit Card ID (ICC-ID) to a backend server. The wireless device may include storing securely in the memory at least one of the current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), the current IMEI, and a Universal Integrated Circuit Card (UICC) Integrated Circuit Card ID (ICC-ID). The wireless device may be configured to provision an application authorizing a wireless device using one of an Over The Air (OTA) process and a non-OTA process.
In one or more aspects, a system, apparatus and method are provided for pairing postpaid SIM or UICC cards with authorized wireless devices in order to restrict usage of the postpaid SIM or UICC cards to certain authorized wireless devices.
In one or more aspects, a SIM or UICC pairing software application installed on or associated with a SIM or UICC card is provided that only allows usage of the SIM or UICC card with certain authorized wireless devices in order to restrict usage of the SIM or UICC card to such authorized wireless devices. This allows the MVNO (or a wireless carrier) to control the particular wireless devices that are able to connect to a wireless network without fundamentally requiring any modifications to the wireless devices themselves, where such network access controls are implemented by the SIM or UICC pairing application that only pairs or marries the SIM or UICC card with certain authorized wireless devices. The SIM or UICC pairing application also prevents a user or subscriber of wireless service from accessing the network by removing their SIM or UICC card from an authorized wireless device and inserting the SIM or UICC card into another device that is not authorized, since the SIM or UICC pairing application would cause wireless service to be limited when the SIM or UICC card is inserted into an unauthorized device in this manner. This limits users or subscribers to accessing the wireless network from only authorized wireless devices.
In one or more aspects, postpaid SIM or UICC cards (e.g., GSM/UMTS/LTE SIM cards and UICC cards) are paired to wireless handsets appearing on an approved or authorized list of wireless devices in a new and creative way, where the wireless devices appearing on the approved list can be chosen by the MVNO, carrier or another trusted source. This way of securing the SIM or UICC card will ensure to the best of its ability that only those wireless devices offered (approved) by a particular MVNO/carrier will be able to access a wireless network. This solution is advantageous in that it does not require any fundamental modification of the wireless device in order to restrict their access to particular networks, thereby making the solution forwards and backwards compatible with all compatible wireless devices.
In one or more aspects, the postpaid SIM or UICC cards can be configured to possess a reporting feature that will transmit critical information about the SIM or UICC card/wireless device over the network to a backend server, system, or component operated by the carrier/MVNO for appropriate action, if deemed necessary, in a real-time manner. One benefit of this solution is that it helps carriers and MVNOs keep unauthorized, rogue wireless handsets and devices from accessing limited network resources, thereby helping in reducing unwanted traffic and associated costs. Another benefit of this solution is that MVNOs will have more control over what equipment (i.e., wireless handset) is used on a carrier's network without needing to have the same level of access to network and backend resources as the carrier themselves. For instance, this solution can help in differentiating between those subscribers that violate the terms of service (TOS) versus those that are simply using unapproved devices. For example, a subscriber may have TOS that prevent the subscriber from performing certain actions (e.g., tethering, Internet browsing, etc.), where the subscriber may have been provided a wireless device that is configured consistent with such TOS (e.g., it may not have the capability to perform tethering, Internet browsing, etc.). If the subscriber were to remove the SIM or UICC card and reinstall it into another authorized wireless device that possessed different capabilities and use thereof would violate the subscriber's TOS, the reporting feature of the SIM or UICC card can allow the MVNO (or carrier) to monitor whether a particular subscriber is performing actions that are inconsistent with their TOS and allow the MVNO (or carrier) to disable or otherwise restrict functionality of the SIM or UICC card and, in turn, restrict access to the network.
As a specific example, a MVNO may have a basic metric that identifies a user violation of terms of service (TOS) for some plans as whether such users exceed a particular data usage. Once the user hits that level, the MVNO will typically shutdown the device, whether through the system or by making such requests to the carriers. While the particular data usage does offer a metric, there are costs with data usage. While an MVNO has typically controlled such usage with device selection, the invention has become additionally applicable and more critical with unlocked SIMs or UICCs to be used with third-party devices.
Yet another benefit of this solution is that it can operate in 2G, 3G, 3.5G, 4G and subsequent generations of environments. It is backwards and forwards compatible with appropriate enhancements. In addition, this solution offers enhanced flexibility where the SIM or UICC card itself would also have the capability of being preloaded with the SIM or UICC pairing application or having the SIM or UICC pairing application updated OTA (over the air) if required with various possible rules and policies. Lastly, this solution is simple, cost effective and flexible to the needs of both carriers and MVNOs which will inevitability lead to more competitive post-paid offerings. It is important to note that this solution could also have other practical applications for small businesses, government entities, private organizations, parents, etc. who would want to take advantage of managing and tracking a subscriber in various ways.
There has thus been outlined, rather broadly, certain aspects of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional aspects of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one aspect of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of aspects in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows wireless device and a GSM network in accordance with aspects of the invention.
FIG. 2 shows a terminal profile validation process in accordance with aspects of the invention.
FIG. 3 shows a wireless identification validation process in accordance with aspects of the invention.
FIG. 4 shows Table I that includes exemplary variations of a configuration and logic possible in accordance with aspects of the invention.
DETAILED DESCRIPTION
In the description that follows, the inventions may be described in reference to one or more aspects for the authorized use of SIM or UICC cards in verified wireless devices. The inventions, however, are not limited to any particular application nor is it limited by the examples described below. Various modifications to the disclosed aspects may be apparent to those skilled in the art and the general principles defined herein may be applied to other aspects and applications without departing from the spirit and scope of the inventions. Therefore, the description of the aspects that follow are for purposes of illustration and not limitation. In particular, the invention may be implemented with SIM cards, UICC cards, and any equivalent. However, the description will describe an implementation for a SIM card only for brevity.
Reference in this specification to “one aspect,” “an aspect,” “other aspects,” “one or more aspects” or the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect of the disclosure. The appearances of, for example, the phrase “in one aspect” in various places in the specification are not necessarily all referring to the same aspect, nor are separate or alternative aspects mutually exclusive of other aspects. Moreover, various features are described which may be exhibited by some aspects and not by others. Similarly, various requirements are described which may be requirements for some aspects but not other aspects.
Reference in this specification to a “wireless device” is intended to encompass any compatible mobile technology computing device that connects to a wireless communication network and utilizes a UICC, SIM card, or the like, such as mobile phones, mobile equipment, mobile stations, user equipment, cellular phones, smartphones or the like (e.g., Apple iPhone, iPad, Google Android based devices, BlackBerry based devices, other types of PDAs or smartphones), wireless dongles, or other mobile computing devices. The term “wireless device” may be interchangeably used and referred to herein as “wireless handset,” “handset,” “mobile device,” “device,” “mobile phones,” “mobile equipment,” “mobile station,” “user equipment,” “cellular phone,” “smartphones,” or “phone.” Further, reference in this specification to a “wireless network” or “network” is intended to encompass any type of wireless network from which a MVNO contracts with a wireless carrier to provide mobile phone services through the use of a wireless device having a SIM card installed therein, such as the Global System for Mobile Communication (GSM) network. However, other cellular wireless communication protocols, such as CDMA or the like, may utilize the teachings of the present application to the extent such other cellular wireless communication protocols are modified to utilize a replaceable memory or the like that can be installed in a wireless device to allow a wireless device to connect to a wireless network.
In one or more aspects, a system, apparatus and method are provided for pairing postpaid SIM cards with authorized wireless devices in order to track and/or restrict usage of the postpaid SIM cards to certain authorized wireless devices. In one or more aspects, a postpaid SIM pairing application (PSP) is installed on, operates on, and/or is associated with a postpaid SIM card to provide the functionality of the various aspects described herein. Of course, the PSP application may be installed on, operate on, and/or associated with other aspects of the invention.
The following acronyms used herein will be defined as follows:
APPD—Authorized PostPaid Device (as authorized by the MVNO)
BSC—Base Station Controller
BTS—Base Transceiver Station
GSM—Global System for Mobile Communication
HLR—Home Location Register
ICCID—Integrated Circuit Card ID
IMEI—International Mobile Equipment Identity
IMSI—International Mobile Subscriber Identity
Ki—Authentication Key
LAI—Local Area Identity
LTE—Long Term Evolution
MSC—Mobile services Switching Center
MVNO—Mobile Virtual Network Operator
NACC—Network ACCess (allowing 2G/3G/3.5G network authentication, reading from and writing to EF-Kc and EF-LOCI, EF-KcGPRS, EF-LOCI GPRS (EF_PSLOCI), EF-Keys, EFPSKeys and reading from EF-IMSI)
OTA—Over-The-Air
PLMN—Public Land Mobile Network
PP—PostPaid
PSP—PostPaid SIM Pairing (Application)
SIM—Subscriber Identity Module or UICC
SMS—Short Message Service
TOS—Terms Of Service
TPD—Terminal Profile Data
UICC—Universal Integrated Circuit Card or SIM
UMTS—Universal Mobile Telecommunications Service
VLR—Visitor Location Register
FIG. 1 shows a wireless device and a GSM network in accordance with aspects of the invention. In particular, FIG. 1 shows a user handset or wireless device 104 . The wireless device 104 provides the radio and signal processing needed to access a GSM network 102 for services. The wireless device 104 includes a processor 114 , memory 116 , display 118 , transceiver 120 , user interface 122 , and the like as is known in the art. The processor is configured to process call functions, provide other services to the user, and may also execute any programs including the PSP application. It should be noted that the PSP application may also execute on a subscriber identification module (SIM) or on dedicated hardware including semiconductors, application specific integrated circuits (ASIC), programmable logic arrays, and other hardware devices. The PSP application may also execute partially or completely on the network 102 and/or any other network including any form of cloud computing and the like.
A subscriber identity module or subscriber identification module (SIM) 112 is associated with the wireless device 104 . The SIM 112 is an integrated circuit that stores an International Mobile Subscriber Identity (IMSI) and also stores a key used to identify and authenticate subscribers on the wireless device 104 and other devices. The SIM 112 may be configured to be transferred between different wireless devices. SIM 112 may also store network-specific information used to authenticate and identify subscribers on the network 102 . The network-specific information may include the ICCID, Authentication Key (Ki), Local Area Identity (LAI), Operator-Specific Emergency Number, and so on.
The SIM 112 (or UICC) may allow full/limited Network ACCess (NACC) by default. In one aspect, Network ACCess may include allowing 2G/3G/3.5G/4G LTE network authentication, reading from and writing to one or more of the following elementary files: EF-Kc, EF-LOCI, EF-KcGPRS, EF-LOCI GPRS, EF_PSLOCI, EF-Keys, and EFPSKeys and reading from EF-IMSI. The PSP application is configured to ensure to the best extent possible that the MVNO (or carrier) subscription is used in only APPD devices. Also, the PSP application may also be configured to track and report device changes occurring with GSM subscriptions.
FIG. 1 further shows that the GSM network 102 may include a Mobile services Switching Center (MSC) 106 that may perform the switching of calls and that may include a Visitor Location Register (VLR). The GSM network 102 may also include a Base Transceiver Station (BTS) 108 and a Base Station Controller (BSC) 110 . The Base Transceiver Station 108 houses the radio transceivers that define a cell and handle the radio-link protocols with the wireless device 104 . The Base Station Controller 110 manages the radio resources for one or more BTSs 108 . The BSC 110 is the connection between the wireless device 104 and the Mobile service Switching Center (MSC) 106 .
A Home Location Register (HLR (not shown)) and the VLR together with the MSC 106 , provide the call-routing and roaming capabilities. The HLR contains all the administrative information of each subscriber registered in the corresponding GSM network 102 , along with the current location of the wireless device 104 .
Detailed Description of PSP Application
In one or more aspects, the PSP application may have four secure switches. As referred to herein, the term “switch” can refer to configurable, logical flags internally stored within the SIM application domain. Of course the PSP application may have more or less switches as needed. The switches may include one switch for terminal profile validation, one switch for IMEI locking, one switch for OTA provisioning, and one switch for sending SMS reporting messages to a backend server, system, or component and to toggle between a specific validation/reporting to process and not to process.
During a power-up on the wireless device 104 , the PSP application may perform validation and/or a reporting process based on the switch settings. The switches may be updated via a secure non-OTA programming method or may be updated using an OTA programming method. In one or more aspects, the PSP application may include any combination of these secure switches activated at any given time, may include only a portion of these secure switches or may include further switches for validation, reporting, and the like. Additionally, the invention contemplates any aspect that provides similar functionality of the switches.
In one or more aspects, the PSP application may include OTA programming functionality in case the PSP application needs to be updated via OTA programming. Furthermore, when provided, OTA based provisioning and updating may be secure with a specific access domain created for the MVNO based on the PSP application.
In one or more aspects, the PSP Application may include the following switches:
First Switch—Terminal Profile Validation
The first switch may analyze terminal profile data (TPD) in the wireless device 104 and match it against a listing stored on the SIM 112 for validation. Upon power-up, the PSP application may receive the identifying information about the wireless device 104 , such as its TPD, from the wireless device 104 and compare this identifying information partially or completely against a listing of authorized terminal profile listings. The terminal profile listings may be stored on the SIM 112 . If the terminal profile listing matches the TPD, the wireless device 104 may be authorized for continued use of the wireless network 102 . In one or more aspects, the TPD may include the International Mobile Equipment Identity (IMEI) or other identifying information of the wireless device 104 .
Second Switch—Pairing to Specific Wireless Device
The SIM 112 may be originally paired or married to a specific wireless device 104 . In this regard, the original IMEI of the wireless device 104 may be stored securely in the SIM 112 or in the PSP application upon initial power-up. Upon subsequent power-ups of the wireless device 104 , the PSP application may verify that it is still installed in an authorized wireless device 104 by checking the IMEI presently retrieved with the originally paired IMEI for continued use of the wireless network.
Third Switch—SIM Reports Activity to Backend Server
The PSP application may also be configured to send activity reports, such as by SMS messages (e.g., text SMS, binary SMS, or the like), to a backend server, system, or component controlled by the MVNO or wireless carrier for additional validation or monitoring by the backend server, system, or component. For example, whenever there has been a detected IMEI change when a SIM 112 has been installed into a new wireless device 104 associated with the new IMEI, this information may be transmitted by the PSP application to the backend server, system, or component for validation and/or monitoring. These reports can also include activity of the wireless device 104 to ensure that a particular subscriber is only using those services that are allowed under their Terms of Service (TOS).
Fourth Switch—Over-the-Air (OTA) Provisioning
The PSP application may also be configured to receive OTA updates to refresh its programming and procedures. For example, the OTA updates may include initial PSP application setup, new listings of authorized parameters, revised methods for sending activity reports, updated switch settings, connectivity with the BTS, handoff between BTSs, bandwidth/frequency control etc.
Terminal Profile Validation
FIG. 2 shows a terminal profile validation process in accordance with aspects of the invention. In one or more aspects, a Terminal Profile Validation process may be performed responsive to the first switch and may include one or more of the following processes:
1. The TPD may be received by the wireless device 104 to the PSP application or requested by the PSP application during step 202 . Subsequently, the TPD of the wireless device 104 may be checked against a listing of multiple Terminal Profile values during step 204 . The listing of multiple Terminal Profile values may be configurable based on a secure non-OTA configuration method and/or an OTA configuration method. The Terminal Profile values may be stored on the SIM 112 and may correspond to authorized wireless devices. In one or more aspects, the listing of multiple Terminal Profile values may be kept in a proprietary and secure file on the SIM 112 . The listing may be securely modifiable before/after production of the SIM 112 . The listing may take into account any future additions, modifications or deletions of authorized wireless devices. If the TPD does not match one of the values in the listing of multiple Terminal Profile values, then the Terminal Profile Verification fails as shown in step 206 .
2. In one or more aspects, either the entire TPD or parts of the TPD of variable length (e.g., up to 32 bytes or an adjustable length) may be checked against the authorized terminal profile listings on the SIM 112 during step 204 . Each entry in the Terminal Profile listing may have a length, a value, and/or a mask. The mask may serve the purpose of determining which bits of the Terminal Profile listing must be checked against the entry's value during step 204 .
3. At each SIM 112 power cycle, the PSP application may verify that the Terminal Profile value for the wireless device 104 in which the SIM 112 is installed matches at least one entry of the Terminal Profile listing of an authorized wireless device 104 if the Terminal Profile Verification flag is set. If the Terminal Profile Verification flag is set and the wireless device's TPD is not received within a certain period of time, then the Terminal Profile Verification may also fail as shown in step 206 .
4. The TPD listing of authorized wireless devices can be provided to a SIM manufacturer to be included on the SIM 112 at the time of card personalization and the TPD listing of authorized wireless devices can be updated via a secure non-OTA programming method or an OTA programming method.
Wireless Device Acceptance/Rejection
In one or more aspects, at each SIM 112 power cycle, the PSP application may accept the wireless device 104 if all required wireless device verifications are successful (e.g., the device TPD or other verifications). Otherwise, the PSP may limit the capabilities of the wireless device 104 in which the SIM 112 has been installed as shown in step 206 .
In one or more aspects, the valid IMSI value must be present by default in the elementary file of the IMSI (EF IMSI) in the SIM 112 at production of the SIM card. If the PSP application rejects the wireless device 104 and/or the elementary file of the IMSI (EF IMSI) or the SIM 112 already contains an invalid value, the PSP application may display an error message, such as “Handset rejected. Insert SIM in proper handset.” In one or more aspects, the PSP application may restore the original, valid IMSI in the elementary file of the IMSI if the application accepts the wireless device 104 and EF-IMSI had contained an invalid IMSI value.
In a specific GSM implementation of the invention, the following procedures may be performed when dealing with an IMSI value. When setting a valid IMSI, the PSP application may perform the following operations in this order:
Reset the elementary files of: EF-FPLMN, EF-LOCI and EF-LOCIGPRS (EF_PSLOCI in 2G & 3G).
Refresh the wireless device using the Full File Change Notification and SIM Init option. The PSP application may display a message, such as “Please power cycle the handset,” if the Refresh operation returns an error while in an accepted wireless device.
In one or more aspects, the PSP application may store an invalid IMSI in EF-IMSI if the PSP application rejects the wireless device and EF-IMSI contains a valid IMSI value. When setting an invalid IMSI, in one or more aspects, the PSP application may perform the following operations in this order:
Reset the elementary files of: EF-FPLMN, EF-LOCI and EF-LOCIGPRS (EF_PSLOCI in 2G & 3G).
Refresh using the Reset option. The PSP application may retry a Refresh on a subsequent Status if Refresh returns a temporary error code while in a rejected wireless device.
Resetting the elementary files of: EF-FPLMN, EF-LOCI, and EF-LOCIGPRS (EF_PSLOCI in 2G & 3G) may ensure that the handset is not confused by the information stored in those files when using a different IMSI.
IMEI Locking (Second Switch)
FIG. 3 shows a wireless identification validation process in accordance with aspects of the invention. In one or more aspects, an IMEI locking procedure may be performed by the second switch of the PSP application. This procedure may include marrying or pairing the SIM 112 to the current IMEI of the wireless device 104 that is being used. The IMEI of the wireless device 104 to which the SIM 112 may be locked to may be stored in a secure location on the SIM 112 . The location of the IMEI of the wireless device 104 on the SIM 112 may be updated or cleared based on a secure non-OTA programming method and/or updated or cleared based on an OTA programming configuration method.
At each subsequent power-up of the wireless device 104 , the PSP application may accept the wireless device 104 if all required wireless device verifications are successful. In particular, the PSP application may conduct IMEI verification when the second switch has been activated. In this regard, the PSP application may request or receive the IMEI of the wireless device as shown in step 302 . The PSP application may then compare the IMEI of the wireless device with the IMEI that was locked and/or stored in the secure location on the SIM 112 as shown in step 304 . If the IMEI provided/requested does not match the stored IMEI, then the PSP application may limit network access by the wireless device 104 in which the SIM card has been installed as shown in step 306 .
SIM Reporting Activities
In one or more aspects, the third switch of the PSP application may be configured to send activity reports, such as by SMS messages or the like, to a backend server, system, or component controlled by the MVNO, wireless carrier, or the like for additional validation or monitoring by the backend server, system, or component.
The PSP application may report any one or more of the current Terminal Profile Data (TPD), last accepted (previous) IMEI, the current IMEI, a UICC ICC-ID along with other possible parameters via the SMS messages to the backend server, system, or component. The reporting activity may be transparent to the end user. The listing of parameters that may be reported may be stored securely on the SIM 112 .
In one or more aspects, for such SMS reporting messages, the PSP application may be configured to possess a destination address for the messages and a detail format (e.g., as provided by the MVNO or carrier) of the messages. In one aspect, the wireless device 104 change SMS fields may be coded as a clear text ASCII comma separated value. In one or more aspects, the PSP application may use a secure nonvolatile variable called Last Accepted IMEI, where the Last Accepted IMEI is initially blank when the SIM card is manufactured.
Upon request, SMS reporting parameters, including the destination address and other parameters, can be modified at the time of SIM card 112 personalization via a secure non-OTA programming method and they can be updated via OTA programming or non-OTA programming procedures.
In one or more aspects, the PSP application may send a SMS reporting message whenever there is an IMEI change detected and the wireless device 104 obtains network service (including reporting of the originally-installed wireless device 104 ). This may be checked via the execution of various commands including the PLI (LOCI) command (the execution of which indicates the wireless device currently has normal service on a valid public land mobile network (PLMN) (different than 000000 or FFFFFF)) and if the PLI (LOCI) command is not supported the PSP application may still attempt to send a SMS reporting message.
In one or more aspects, all of the following conditions should be met before sending of a SMS reporting message:
1. Reporting SMS switch (i.e., third switch) is enabled for sending SMS messages. 2. Wireless device is accepted, i.e. passes TPD validation if enabled and/or device IMEI verification if enabled. 3. An IMEI change is detected (including original installation). 4. The wireless device reports not supporting the PLI (LOCI) command in its Terminal Profile and 10 Status command has been received since power-up OR if the wireless device reports supporting the PLI (LOCI) command, the execution of the command indicates the wireless device currently has normal service on a valid PLMN (different than 000000 or FFFFFF).
If all of the SMS reporting conditions are met, except the last (fourth) condition, the PSP application may retry the PLI (LOCI) command if supported by the wireless device at each subsequent Status command should all conditions be finally met. When all the conditions are met, the PSP application may attempt to send a wireless device change reporting SMS.
In one or more aspects, if the sending of the wireless device change reporting SMS fails, the PSP application may retry to send the wireless device Change reporting SMS only on the next SIM power cycle.
In one or more aspects, the PSP application may update the Last Accepted IMEI with the wireless device's current IMEI, if one of the following conditions is met:
The wireless device 104 reports that Device Change SMS has been successfully sent, or
A certain number of reporting SMS message attempts have failed (e.g., 3 attempts).
In one or more aspects, the reporting SMS message may be sent with the following information: the current TPD (such as its entire value up to 32 bytes, up to 64 hexadecimal digits), the Last Accepted IMEI (e.g., 16 decimal digits), the Current IMEI (e.g., 16 decimal digits), and the UICC ICC-ID (e.g., 20 decimal digits).
OTA Provisioning
The PSP application can also be configured to self-initiate a request for OTA programming updates to refresh its programming and procedures as necessary based on backend rules and procedures (e.g., initial PSP application setup, new listings of authorized parameters, revised methods for sending activity reports, updated switch settings, etc.). The OTA Provisioning switch may work independently of standard OTA platform functionality for the wireless device 104 and SIM 112 . For example, standard wireless carrier based OTA updates or standard backend initiated OTA updates to PSP application, may work independent of and regardless of OTA Provisioning switch status.
SIM Variants
In one or more aspects, the PSP application may include any combination of the secure switches described in various aspects described herein or otherwise, which may be activated at any given time, which may include only a portion of these secure switches or which may include even further switches for validation and/or reporting. In one or more aspects, several exemplary variations of the SIM 112 configuration and logic are possible, for example, as represented in Table I shown in FIG. 4 .
For UICC configuration Variant 1 in Table I shown in FIG. 4 , if a wireless device 104 passes the terminal profile validation test of the first switch, only then may the SIM 112 be paired or married to that specific wireless device's IMEI which would then be stored securely in the SIM 112 . Once a SIM 112 has been successfully paired or married to a wireless device 104 with a valid IMEI stored on the SIM 112 , then the IMEI lock, i.e. verifying that the SIM 112 is being placed into the wireless device 104 with correct corresponding IMEI, may take precedence and the PSP application may skip TPD verification for subsequent SIM 112 power-ups. This should be done without turning off TPD verification switch so that, for example, if the IMEI stored on the UICC is possibly cleared in the future (e.g., via OTA) then the PSP application may resort to TPD verification described above.
For SIM 112 configuration Variant 2 in Table I shown in FIG. 4 , the IMEI Locking switch may be disabled such that the PSP application relies on the TPD Verification and Reporting SMS switches for wireless device verification.
For SIM 112 configuration Variant 3 in Table I shown in FIG. 4 , the TPD Verification switch may be turned off and the PSP application may give precedence to the IMEI Locking switch, which locks the SIM 112 to the first wireless device 104 IMEI that the PSP application encounters upon power-up.
For SIM 112 configuration Variant 4 in Table I shown in FIG. 4 , the TPD Verification and IMEI Locking switches are turned off, where the PSP application relies solely on the Reporting SMS switch for wireless device 104 verification, such that the condition #2 for sending a Reporting SMS would be ignored (i.e., the conditions for acceptance of the wireless device by passing TPD validation if enabled and/or device IMEI verification if enabled would be ignored).
For SIM 112 configuration Variant 5 in Table I shown in FIG. 4 , since all switches are set to OFF, the SIM 112 may behave in a standard manner similar to a post-paid SIM.
For SIM 112 configuration Variant 6 in Table I shown in FIG. 4 , when the OTA Provisioning switch is set to ON, then this may trigger the PSP application to initiate OTA provisioning via a TPD (Terminal Profile Data) update request to the OTA platform. The OTA platform may handle the TPD update request based on backend rules and communicate appropriate updates as necessary. Once the PSP application receives the necessary OTA updates, it may subsequently send a Proof of receipt to the OTA platform confirming the update was successful. The initial state of the PSP application for OTA Provisioning may include the following configuration:
The OTA Provisioning switch may be set to ON, the TPD Verification and IMEI Locking switches may be set to OFF, while the Reporting SMS switch may remain ON; and
SMS Service may be activated. (e.g., the GSM line may be fully provisioned before OTA provisioning request or other SMS message is sent to OTA platform or SMSC).
The workflow of the OTA Provisioning switch may include:
When wireless device 104 is powered up, the PSP application may send the current TPD, IMEI and UICC ICC-ID as part of wireless device change reporting for backend records. In addition, the PSP application may request that the OTA platform update the TPD listing of authorized wireless devices. The PSP application may continue to retry sending out the OTA request(s) until it receives appropriate OTA response(s).
The PSP application may display a message on the wireless device 104 , such as “Activation in Progress,” during this process for the end user.
The OTA platform may then push the necessary responses such as but not limited to setting the TPD verification and IMEI Locking switches ON as well as pushing the most current TPD(s), if needed, for updating the TPD listing of authorized wireless devices.
A refresh command may be sent upon backend discretion. For example, if the backend determines from available data that the UICC is in a legitimate wireless device, then it may not send a refresh command to avoid possible customer impact.
If a refresh command is sent due to the backend determining the UICC is in an unintended wireless device or for any reason such as the backend logic not being implemented, then upon encountering a full refresh (reset) command the PSP application may attempt to display a warning message to the end user before committing the refresh (i.e., “The phone may be rebooting shortly”). The PSP Application may then reboot the wireless device and complete the TPD verification and IMEI pairing operations associated with their respective switches described herein.
Upon accepting the OTA responses, the PSP application may send a POR (proof of receipt) to the OTA platform as well as remove any activation prompts being displayed for the end user.
Complete account activation (e.g., SMS+voice+data) may be completed by the account provider (e.g., MVNO or carrier), if not already done.
In one or more aspects, on wireless devices that are verified or accepted, the following Card Application Toolkit (CAT) commands (otherwise known as STK or SIM Toolkit commands or other similar commands) should be provided, where additional CAT support may be required as needed:
Terminal Profile—this command is mandatory to accept a device.
Refresh (Full File Change Notification and SIM Init)—if not supported, the user would be required to manually power cycle the handset when swapping the UICC from a rejected handset to an accepted handset.
PLI (IMEI)—if not supported, the device change notification reporting SMS may miss some information.
PLI (MCC, MNC, LAC and Cell ID)—if not supported, the applet may assume there is coverage after 10 Status command has been received.
Send SMS—if not supported, the device change notification SMS cannot be sent.
Display Text (high priority, user defined)—if not supported, the user may not be informed to power cycle the handset if Refresh is not supported as well.
In one or more aspects, on wireless devices that are rejected, the following CAT support should be provided, where additional CAT support may be required as needed:
Refresh (Reset)—if not supported, the device would still be usable until the next power cycle.
Display Text (high priority, user defined)—if not supported, the user may not be informed that the device is not supported.
In one or more aspects, for an identical use case and PSP application configuration, the user experience may vary depend on the wireless device 104 , on the wireless network and possibly on the UICC profile.
In one or more aspects, the PSP application installed on and operating on the UICC (i.e., SIM card) and its associated functionality described herein may be implemented in software, stored on a computer readable medium or computer readable storage medium, such as a memory of the UICC, where the memory may store computer readable instructions, e.g., program code, that can be executed by a processor or controller in a device (e.g., on the UICC or mobile device) to carry out one or more of the techniques described herein. Additionally, it should be noted that if needed, the invention and/or PSP application may also use other areas of memory to implement the invention including memory in the wireless device, network based memory, or the like.
As described above, the invention provides a Mobile Virtual Network Operator the ability to provide subscribers with greater choice of services and devices. Moreover, the invention allows the Mobile Virtual Network Operator the ability to limit the choice of services and devices.
For the purposes of this disclosure a computer readable medium stores computer data, which data can include computer program code that is executable by a processor of the SIM or mobile device, in machine readable form. By way of example, and not limitation, a computer readable medium may comprise computer readable storage media, for tangible or fixed storage of data, or communication media for transient interpretation of code-containing signals. Computer readable storage media, as used herein, refers to physical or tangible storage (as opposed to signals) and includes without limitation volatile and non-volatile, removable and nonremovable storage media implemented in any method or technology for the tangible storage of information such as computer-readable instructions, data structures, program modules or other data. Computer readable storage media includes, but is not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other solid state memory technology, optical storage media, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other physical or material medium which can be used to tangibly store the desired information or data or instructions and which can be accessed by a processor or computing device. In one or more aspects, the actions and/or events of a method, algorithm or module may reside as one or any combination or set of codes and/or instructions on a computer readable medium or machine readable medium, which may be incorporated into a computer program product.
The invention may include communication channels that may be any type of wired or wireless electronic communications network, such as, e.g., a wired/wireless local area network (LAN), a wired/wireless personal area network (PAN), a wired/wireless home area network (HAN), a wired/wireless wide area network (WAN), a campus network, a metropolitan network, an enterprise private network, a virtual private network (VPN), an internetwork, a backbone network (BBN), a global area network (GAN), the Internet, an intranet, an extranet, an overlay network, a cellular telephone network, a Personal Communications Service (PCS), using known protocols such as the Global System for Mobile Communications (GSM), CDMA (Code-Division Multiple Access), W-CDMA (Wideband Code-Division Multiple Access), Wireless Fidelity (Wi-Fi), Bluetooth, and/or the like, and/or a combination of two or more thereof.
In an embodiment, the invention may be implemented in any type of mobile smartphones that are operated by any type of advanced mobile data processing and communication operating system, such as, e.g., an Apple™ iOS™ operating system, a Google™ Android™ operating system, a RIM™ Blackberry™ operating system, a Nokia™ Symbian™ operating system, a Microsoft™ Windows Mobile™ operating system, a Microsoft™ Windows Phone™ operating system, a Linux™ operating system or the like.
Further in accordance with various embodiments of the invention, the methods described herein are intended for operation with dedicated hardware implementations including, but not limited to, PCs, PDAs, SIM cards, semiconductors, application specific integrated circuits (ASIC), programmable logic arrays, cloud computing devices, and other hardware devices constructed to implement the methods described herein.
While the system and method have been described in terms of what are presently considered to be specific aspects, the disclosure need not be limited to the disclosed aspects. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all aspects of the following claims. | A wireless device and a process of authorizing a wireless device are disclosed. The process includes storing a list of authorized terminals within a memory accessible by a wireless device. The process further includes comparing the list of authorized terminals in the memory to at least one of terminal profile data and an IMEI of the wireless device and allowing network access if at least one of the terminal profile data and the IMEI are found on the list of authorized terminals and limiting network access if at least one of the terminal profile data and the IMEI are not found on the list of authorized terminals. | Summarize the patent document, focusing on the invention's functionality and advantages. | [
"CROSS REFERENCE TO PRIOR APPLICATIONS This application is a continuation of U.S. patent application Ser.",
"No. 13/409,720, filed Mar. 1, 2012, now U.S. Pat. No. 8,660,533, which claims the benefit of U.S. Provisional Application No. 61/448,002 filed on Mar. 1, 2011, which is hereby incorporated by reference in its entirety for all purposes as if fully set forth herein.",
"BACKGROUND OF THE DISCLOSURE 1.",
"Field of the Disclosure This disclosure relates generally to a system, method and apparatus for pairing postpaid SIM or UICC cards with authorized wireless devices.",
"More specifically, this disclosure relates to a system, method and apparatus for pairing postpaid SIM or UICC cards with authorized wireless devices in order to restrict usage of the postpaid SIM or UICC cards to certain devices.",
"Related Art Certain companies that provide postpaid wireless services, such as mobile phone service, can be wireless carriers that maintain and control their own wireless networks, where carriers rely heavily on backend systems to address any provisional, billing, security and data issues that might threaten the health of their networks.",
"Wireless carriers also typically offer multi-tiered postpaid offerings which allow their subscriber's unrestricted access to their network by progressively charging or taxing them based on their network usage based on data usage and airtime usage.",
"A Mobile Virtual Network Operator (MVNO) is a mobile operator that typically does not own its own frequency spectrum and typically does not have its own network infrastructure.",
"Instead, MVNOs have business arrangements and contracts with wireless carriers to purchase usage of their networks (e.g., minutes of use, volume of data transfer, number of SMS messages, etc.) that the MVNOs in turn sell to their own subscribers.",
"Based on these business arrangements and contracts, carriers and MVNOs have established detailed Terms of Service (TOS) and conditions for their subscribers.",
"As such, if a subscriber is found in violation of these conditions they are typically given a warning, they have their subscription/service terminated or the like.",
"In today's MVNO prepaid marketplace, the prepaid phones that implement identification devices such as a subscriber identity module or a subscriber identification module (SIM) cards or Universal Integrated Circuit Cards (UICC) are strictly regulated in order to keep costs low and prepaid phone/rate offerings attractive.",
"In an effort to diversify their revenue portfolio, MVNOs are now looking towards the postpaid market as a means to diversify their revenue portfolio but face a number of challenges based on the fact that: (1) MVNOs do not operate and control their own wireless networks and thus do not have the same ability as the carriers to implement provisional, billing, security and data controls on the backend to control network usage;",
"and (2) MVNOs and, in turn, their subscribers are bound by the terms of services and conditions of the MVNO's business arrangements and contracts with the carriers associated with purchased network usage.",
"In order for MVNOs to provide a comparable postpaid experience for its customers as provided for by the carriers, there is a need for MVNOs to provide customers with enough freedom of choice while still regulating the customers'",
"usage of the network.",
"To be competitive with carriers, MVNOs further need to provide attractive postpaid offerings to its customers while still keeping costs low enough to turn a profit based on the contractual obligations the MVNOs have with the carriers.",
"For example, if MVNO customers exceed the collective network usage that has been contracted for by a MVNO, the MVNO is typically heavily charged or penalized.",
"The solutions for controlling and charging customers typically implemented by carriers do not mitigate the risks enough from the perspective of MVNOs whose business model is quite different of that of network carriers.",
"Furthermore, the network solution implemented by carriers is extensive and complex, thus making it a slow solution to integrate.",
"Additionally, it is also expensive in its implementation and expansive in its affects since this encompasses everyone on the network.",
"Yet another shortcoming of the existing network solution is that it is easier for a carrier to absorb the cost of network traffic generated by its subscribers (violators of TOS) as they own the network versus MVNOs who have to pay exorbitant out of pocket fees for violations of its TOS with the carrier.",
"Moreover, to date, MVNOs have no meaningful way to prevent TOS violators which can have a significant impact on their rate/phone offerings.",
"For example, conventional postpaid SIM and UICC cards on the Global System for Mobile Communication (GSM) network are now unlocked (or can be unlocked) and can be moved between mobile phones without restriction, which can be particularly troublesome for MVNOs that only want their subscribers to use certain devices that have certain offerings.",
"Accordingly, there is a need for a Mobile Virtual Network Operator to be able to provide subscribers with the ability to have greater choice of services and devices while allowing the Mobile Virtual Network Operator the ability to limit the choice of services and devices.",
"SUMMARY OF THE INVENTION Aspects of the invention advantageously provide a process of authorizing a wireless device including storing a list of authorized terminals within a memory accessible by a wireless device, comparing the list of authorized terminals in the memory to at least one of terminal profile data and an IMEI of the wireless device, and allowing network access if at least one of the terminal profile data and the IMEI are found on the list of authorized terminals and limiting network access if the terminal profile data and the IMEI are not found on the list of authorized terminals.",
"The memory may include a removable memory associated with the wireless device.",
"The removable memory may include at least one of a Subscriber Identity Module (SIM) and Universal Integrated Circuit Card (UICC).",
"The list of authorized terminals may include at least one of a previously stored International Mobile Equipment Identity (IMEI) and a listing of authorized terminal profile data values.",
"The process may include sending a report comprising at least one of a current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), a current IMEI, and an Universal Integrated Circuit Card (UICC) Integrated Circuit Card ID (ICC-ID) to a backend server.",
"The process may include storing securely in the removable memory at least one of a current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), a current IMEI, and an UICC Integrated Circuit Card ID (ICC-ID).",
"The process may include at least one of provisioning and updating Over The Air (OTA) at least one of switches of an authorizing application and the list of authorized terminals.",
"The network may include at least one of a Global System for Mobile Communication (GSM) network and a UMTS/LTE telecommunication network.",
"The process may include functioning in at least one of a Global System for Mobile Communication (GSM) network and a UMTS/LTE telecommunication network as a Mobile Virtual Network Operator (MVNO) comprising using the process of authorizing a wireless device above.",
"Further aspects of the invention advantageously provide a wireless device configured to control network authorization including a removable memory storing a list of authorized terminals within the wireless device, a comparator to compare the list of authorized terminals in the removable memory to at least one of terminal profile data and an IMEI of the wireless device, and the wireless device being configured to allow network access if at least one the terminal profile data and the IMEI of the wireless device is found on the list of authorized terminals and the wireless device being further configured to limit network access if the terminal profile data and the IMEI of the wireless device is not found on the list of authorized terminals.",
"The removable memory may include at least one of a Subscriber Identity Module (SIM) and Universal Integrated Circuit Card (UICC).",
"The list of authorized terminals may include at least one of a previously stored International Mobile Equipment Identity (IMEI) and a listing of authorized terminal profiles.",
"The wireless device may be configured to send a report comprising at least one of the current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), the current IMEI, and an Universal Integrated Circuit Card (UICC) Integrated Circuit Card ID (ICC-ID) to a backend server.",
"The wireless device may include storing securely in the memory at least one of the current Terminal Profile Data, last accepted International Mobile Equipment Identity (IMEI), the current IMEI, and a Universal Integrated Circuit Card (UICC) Integrated Circuit Card ID (ICC-ID).",
"The wireless device may be configured to provision an application authorizing a wireless device using one of an Over The Air (OTA) process and a non-OTA process.",
"In one or more aspects, a system, apparatus and method are provided for pairing postpaid SIM or UICC cards with authorized wireless devices in order to restrict usage of the postpaid SIM or UICC cards to certain authorized wireless devices.",
"In one or more aspects, a SIM or UICC pairing software application installed on or associated with a SIM or UICC card is provided that only allows usage of the SIM or UICC card with certain authorized wireless devices in order to restrict usage of the SIM or UICC card to such authorized wireless devices.",
"This allows the MVNO (or a wireless carrier) to control the particular wireless devices that are able to connect to a wireless network without fundamentally requiring any modifications to the wireless devices themselves, where such network access controls are implemented by the SIM or UICC pairing application that only pairs or marries the SIM or UICC card with certain authorized wireless devices.",
"The SIM or UICC pairing application also prevents a user or subscriber of wireless service from accessing the network by removing their SIM or UICC card from an authorized wireless device and inserting the SIM or UICC card into another device that is not authorized, since the SIM or UICC pairing application would cause wireless service to be limited when the SIM or UICC card is inserted into an unauthorized device in this manner.",
"This limits users or subscribers to accessing the wireless network from only authorized wireless devices.",
"In one or more aspects, postpaid SIM or UICC cards (e.g., GSM/UMTS/LTE SIM cards and UICC cards) are paired to wireless handsets appearing on an approved or authorized list of wireless devices in a new and creative way, where the wireless devices appearing on the approved list can be chosen by the MVNO, carrier or another trusted source.",
"This way of securing the SIM or UICC card will ensure to the best of its ability that only those wireless devices offered (approved) by a particular MVNO/carrier will be able to access a wireless network.",
"This solution is advantageous in that it does not require any fundamental modification of the wireless device in order to restrict their access to particular networks, thereby making the solution forwards and backwards compatible with all compatible wireless devices.",
"In one or more aspects, the postpaid SIM or UICC cards can be configured to possess a reporting feature that will transmit critical information about the SIM or UICC card/wireless device over the network to a backend server, system, or component operated by the carrier/MVNO for appropriate action, if deemed necessary, in a real-time manner.",
"One benefit of this solution is that it helps carriers and MVNOs keep unauthorized, rogue wireless handsets and devices from accessing limited network resources, thereby helping in reducing unwanted traffic and associated costs.",
"Another benefit of this solution is that MVNOs will have more control over what equipment (i.e., wireless handset) is used on a carrier's network without needing to have the same level of access to network and backend resources as the carrier themselves.",
"For instance, this solution can help in differentiating between those subscribers that violate the terms of service (TOS) versus those that are simply using unapproved devices.",
"For example, a subscriber may have TOS that prevent the subscriber from performing certain actions (e.g., tethering, Internet browsing, etc.), where the subscriber may have been provided a wireless device that is configured consistent with such TOS (e.g., it may not have the capability to perform tethering, Internet browsing, etc.).",
"If the subscriber were to remove the SIM or UICC card and reinstall it into another authorized wireless device that possessed different capabilities and use thereof would violate the subscriber's TOS, the reporting feature of the SIM or UICC card can allow the MVNO (or carrier) to monitor whether a particular subscriber is performing actions that are inconsistent with their TOS and allow the MVNO (or carrier) to disable or otherwise restrict functionality of the SIM or UICC card and, in turn, restrict access to the network.",
"As a specific example, a MVNO may have a basic metric that identifies a user violation of terms of service (TOS) for some plans as whether such users exceed a particular data usage.",
"Once the user hits that level, the MVNO will typically shutdown the device, whether through the system or by making such requests to the carriers.",
"While the particular data usage does offer a metric, there are costs with data usage.",
"While an MVNO has typically controlled such usage with device selection, the invention has become additionally applicable and more critical with unlocked SIMs or UICCs to be used with third-party devices.",
"Yet another benefit of this solution is that it can operate in 2G, 3G, 3.5G, 4G and subsequent generations of environments.",
"It is backwards and forwards compatible with appropriate enhancements.",
"In addition, this solution offers enhanced flexibility where the SIM or UICC card itself would also have the capability of being preloaded with the SIM or UICC pairing application or having the SIM or UICC pairing application updated OTA (over the air) if required with various possible rules and policies.",
"Lastly, this solution is simple, cost effective and flexible to the needs of both carriers and MVNOs which will inevitability lead to more competitive post-paid offerings.",
"It is important to note that this solution could also have other practical applications for small businesses, government entities, private organizations, parents, etc.",
"who would want to take advantage of managing and tracking a subscriber in various ways.",
"There has thus been outlined, rather broadly, certain aspects of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated.",
"There are, of course, additional aspects of the invention that will be described below and which will form the subject matter of the claims appended hereto.",
"In this respect, before explaining at least one aspect of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings.",
"The invention is capable of aspects in addition to those described and of being practiced and carried out in various ways.",
"Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.",
"As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the invention.",
"It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the invention.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows wireless device and a GSM network in accordance with aspects of the invention.",
"FIG. 2 shows a terminal profile validation process in accordance with aspects of the invention.",
"FIG. 3 shows a wireless identification validation process in accordance with aspects of the invention.",
"FIG. 4 shows Table I that includes exemplary variations of a configuration and logic possible in accordance with aspects of the invention.",
"DETAILED DESCRIPTION In the description that follows, the inventions may be described in reference to one or more aspects for the authorized use of SIM or UICC cards in verified wireless devices.",
"The inventions, however, are not limited to any particular application nor is it limited by the examples described below.",
"Various modifications to the disclosed aspects may be apparent to those skilled in the art and the general principles defined herein may be applied to other aspects and applications without departing from the spirit and scope of the inventions.",
"Therefore, the description of the aspects that follow are for purposes of illustration and not limitation.",
"In particular, the invention may be implemented with SIM cards, UICC cards, and any equivalent.",
"However, the description will describe an implementation for a SIM card only for brevity.",
"Reference in this specification to “one aspect,” “an aspect,” “other aspects,” “one or more aspects”",
"or the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect of the disclosure.",
"The appearances of, for example, the phrase “in one aspect”",
"in various places in the specification are not necessarily all referring to the same aspect, nor are separate or alternative aspects mutually exclusive of other aspects.",
"Moreover, various features are described which may be exhibited by some aspects and not by others.",
"Similarly, various requirements are described which may be requirements for some aspects but not other aspects.",
"Reference in this specification to a “wireless device”",
"is intended to encompass any compatible mobile technology computing device that connects to a wireless communication network and utilizes a UICC, SIM card, or the like, such as mobile phones, mobile equipment, mobile stations, user equipment, cellular phones, smartphones or the like (e.g., Apple iPhone, iPad, Google Android based devices, BlackBerry based devices, other types of PDAs or smartphones), wireless dongles, or other mobile computing devices.",
"The term “wireless device”",
"may be interchangeably used and referred to herein as “wireless handset,” “handset,” “mobile device,” “device,” “mobile phones,” “mobile equipment,” “mobile station,” “user equipment,” “cellular phone,” “smartphones,” or “phone.”",
"Further, reference in this specification to a “wireless network”",
"or “network”",
"is intended to encompass any type of wireless network from which a MVNO contracts with a wireless carrier to provide mobile phone services through the use of a wireless device having a SIM card installed therein, such as the Global System for Mobile Communication (GSM) network.",
"However, other cellular wireless communication protocols, such as CDMA or the like, may utilize the teachings of the present application to the extent such other cellular wireless communication protocols are modified to utilize a replaceable memory or the like that can be installed in a wireless device to allow a wireless device to connect to a wireless network.",
"In one or more aspects, a system, apparatus and method are provided for pairing postpaid SIM cards with authorized wireless devices in order to track and/or restrict usage of the postpaid SIM cards to certain authorized wireless devices.",
"In one or more aspects, a postpaid SIM pairing application (PSP) is installed on, operates on, and/or is associated with a postpaid SIM card to provide the functionality of the various aspects described herein.",
"Of course, the PSP application may be installed on, operate on, and/or associated with other aspects of the invention.",
"The following acronyms used herein will be defined as follows: APPD—Authorized PostPaid Device (as authorized by the MVNO) BSC—Base Station Controller BTS—Base Transceiver Station GSM—Global System for Mobile Communication HLR—Home Location Register ICCID—Integrated Circuit Card ID IMEI—International Mobile Equipment Identity IMSI—International Mobile Subscriber Identity Ki—Authentication Key LAI—Local Area Identity LTE—Long Term Evolution MSC—Mobile services Switching Center MVNO—Mobile Virtual Network Operator NACC—Network ACCess (allowing 2G/3G/3.5G network authentication, reading from and writing to EF-Kc and EF-LOCI, EF-KcGPRS, EF-LOCI GPRS (EF_PSLOCI), EF-Keys, EFPSKeys and reading from EF-IMSI) OTA—Over-The-Air PLMN—Public Land Mobile Network PP—PostPaid PSP—PostPaid SIM Pairing (Application) SIM—Subscriber Identity Module or UICC SMS—Short Message Service TOS—Terms Of Service TPD—Terminal Profile Data UICC—Universal Integrated Circuit Card or SIM UMTS—Universal Mobile Telecommunications Service VLR—Visitor Location Register FIG. 1 shows a wireless device and a GSM network in accordance with aspects of the invention.",
"In particular, FIG. 1 shows a user handset or wireless device 104 .",
"The wireless device 104 provides the radio and signal processing needed to access a GSM network 102 for services.",
"The wireless device 104 includes a processor 114 , memory 116 , display 118 , transceiver 120 , user interface 122 , and the like as is known in the art.",
"The processor is configured to process call functions, provide other services to the user, and may also execute any programs including the PSP application.",
"It should be noted that the PSP application may also execute on a subscriber identification module (SIM) or on dedicated hardware including semiconductors, application specific integrated circuits (ASIC), programmable logic arrays, and other hardware devices.",
"The PSP application may also execute partially or completely on the network 102 and/or any other network including any form of cloud computing and the like.",
"A subscriber identity module or subscriber identification module (SIM) 112 is associated with the wireless device 104 .",
"The SIM 112 is an integrated circuit that stores an International Mobile Subscriber Identity (IMSI) and also stores a key used to identify and authenticate subscribers on the wireless device 104 and other devices.",
"The SIM 112 may be configured to be transferred between different wireless devices.",
"SIM 112 may also store network-specific information used to authenticate and identify subscribers on the network 102 .",
"The network-specific information may include the ICCID, Authentication Key (Ki), Local Area Identity (LAI), Operator-Specific Emergency Number, and so on.",
"The SIM 112 (or UICC) may allow full/limited Network ACCess (NACC) by default.",
"In one aspect, Network ACCess may include allowing 2G/3G/3.5G/4G LTE network authentication, reading from and writing to one or more of the following elementary files: EF-Kc, EF-LOCI, EF-KcGPRS, EF-LOCI GPRS, EF_PSLOCI, EF-Keys, and EFPSKeys and reading from EF-IMSI.",
"The PSP application is configured to ensure to the best extent possible that the MVNO (or carrier) subscription is used in only APPD devices.",
"Also, the PSP application may also be configured to track and report device changes occurring with GSM subscriptions.",
"FIG. 1 further shows that the GSM network 102 may include a Mobile services Switching Center (MSC) 106 that may perform the switching of calls and that may include a Visitor Location Register (VLR).",
"The GSM network 102 may also include a Base Transceiver Station (BTS) 108 and a Base Station Controller (BSC) 110 .",
"The Base Transceiver Station 108 houses the radio transceivers that define a cell and handle the radio-link protocols with the wireless device 104 .",
"The Base Station Controller 110 manages the radio resources for one or more BTSs 108 .",
"The BSC 110 is the connection between the wireless device 104 and the Mobile service Switching Center (MSC) 106 .",
"A Home Location Register (HLR (not shown)) and the VLR together with the MSC 106 , provide the call-routing and roaming capabilities.",
"The HLR contains all the administrative information of each subscriber registered in the corresponding GSM network 102 , along with the current location of the wireless device 104 .",
"Detailed Description of PSP Application In one or more aspects, the PSP application may have four secure switches.",
"As referred to herein, the term “switch”",
"can refer to configurable, logical flags internally stored within the SIM application domain.",
"Of course the PSP application may have more or less switches as needed.",
"The switches may include one switch for terminal profile validation, one switch for IMEI locking, one switch for OTA provisioning, and one switch for sending SMS reporting messages to a backend server, system, or component and to toggle between a specific validation/reporting to process and not to process.",
"During a power-up on the wireless device 104 , the PSP application may perform validation and/or a reporting process based on the switch settings.",
"The switches may be updated via a secure non-OTA programming method or may be updated using an OTA programming method.",
"In one or more aspects, the PSP application may include any combination of these secure switches activated at any given time, may include only a portion of these secure switches or may include further switches for validation, reporting, and the like.",
"Additionally, the invention contemplates any aspect that provides similar functionality of the switches.",
"In one or more aspects, the PSP application may include OTA programming functionality in case the PSP application needs to be updated via OTA programming.",
"Furthermore, when provided, OTA based provisioning and updating may be secure with a specific access domain created for the MVNO based on the PSP application.",
"In one or more aspects, the PSP Application may include the following switches: First Switch—Terminal Profile Validation The first switch may analyze terminal profile data (TPD) in the wireless device 104 and match it against a listing stored on the SIM 112 for validation.",
"Upon power-up, the PSP application may receive the identifying information about the wireless device 104 , such as its TPD, from the wireless device 104 and compare this identifying information partially or completely against a listing of authorized terminal profile listings.",
"The terminal profile listings may be stored on the SIM 112 .",
"If the terminal profile listing matches the TPD, the wireless device 104 may be authorized for continued use of the wireless network 102 .",
"In one or more aspects, the TPD may include the International Mobile Equipment Identity (IMEI) or other identifying information of the wireless device 104 .",
"Second Switch—Pairing to Specific Wireless Device The SIM 112 may be originally paired or married to a specific wireless device 104 .",
"In this regard, the original IMEI of the wireless device 104 may be stored securely in the SIM 112 or in the PSP application upon initial power-up.",
"Upon subsequent power-ups of the wireless device 104 , the PSP application may verify that it is still installed in an authorized wireless device 104 by checking the IMEI presently retrieved with the originally paired IMEI for continued use of the wireless network.",
"Third Switch—SIM Reports Activity to Backend Server The PSP application may also be configured to send activity reports, such as by SMS messages (e.g., text SMS, binary SMS, or the like), to a backend server, system, or component controlled by the MVNO or wireless carrier for additional validation or monitoring by the backend server, system, or component.",
"For example, whenever there has been a detected IMEI change when a SIM 112 has been installed into a new wireless device 104 associated with the new IMEI, this information may be transmitted by the PSP application to the backend server, system, or component for validation and/or monitoring.",
"These reports can also include activity of the wireless device 104 to ensure that a particular subscriber is only using those services that are allowed under their Terms of Service (TOS).",
"Fourth Switch—Over-the-Air (OTA) Provisioning The PSP application may also be configured to receive OTA updates to refresh its programming and procedures.",
"For example, the OTA updates may include initial PSP application setup, new listings of authorized parameters, revised methods for sending activity reports, updated switch settings, connectivity with the BTS, handoff between BTSs, bandwidth/frequency control etc.",
"Terminal Profile Validation FIG. 2 shows a terminal profile validation process in accordance with aspects of the invention.",
"In one or more aspects, a Terminal Profile Validation process may be performed responsive to the first switch and may include one or more of the following processes: 1.",
"The TPD may be received by the wireless device 104 to the PSP application or requested by the PSP application during step 202 .",
"Subsequently, the TPD of the wireless device 104 may be checked against a listing of multiple Terminal Profile values during step 204 .",
"The listing of multiple Terminal Profile values may be configurable based on a secure non-OTA configuration method and/or an OTA configuration method.",
"The Terminal Profile values may be stored on the SIM 112 and may correspond to authorized wireless devices.",
"In one or more aspects, the listing of multiple Terminal Profile values may be kept in a proprietary and secure file on the SIM 112 .",
"The listing may be securely modifiable before/after production of the SIM 112 .",
"The listing may take into account any future additions, modifications or deletions of authorized wireless devices.",
"If the TPD does not match one of the values in the listing of multiple Terminal Profile values, then the Terminal Profile Verification fails as shown in step 206 .",
"In one or more aspects, either the entire TPD or parts of the TPD of variable length (e.g., up to 32 bytes or an adjustable length) may be checked against the authorized terminal profile listings on the SIM 112 during step 204 .",
"Each entry in the Terminal Profile listing may have a length, a value, and/or a mask.",
"The mask may serve the purpose of determining which bits of the Terminal Profile listing must be checked against the entry's value during step 204 .",
"At each SIM 112 power cycle, the PSP application may verify that the Terminal Profile value for the wireless device 104 in which the SIM 112 is installed matches at least one entry of the Terminal Profile listing of an authorized wireless device 104 if the Terminal Profile Verification flag is set.",
"If the Terminal Profile Verification flag is set and the wireless device's TPD is not received within a certain period of time, then the Terminal Profile Verification may also fail as shown in step 206 .",
"The TPD listing of authorized wireless devices can be provided to a SIM manufacturer to be included on the SIM 112 at the time of card personalization and the TPD listing of authorized wireless devices can be updated via a secure non-OTA programming method or an OTA programming method.",
"Wireless Device Acceptance/Rejection In one or more aspects, at each SIM 112 power cycle, the PSP application may accept the wireless device 104 if all required wireless device verifications are successful (e.g., the device TPD or other verifications).",
"Otherwise, the PSP may limit the capabilities of the wireless device 104 in which the SIM 112 has been installed as shown in step 206 .",
"In one or more aspects, the valid IMSI value must be present by default in the elementary file of the IMSI (EF IMSI) in the SIM 112 at production of the SIM card.",
"If the PSP application rejects the wireless device 104 and/or the elementary file of the IMSI (EF IMSI) or the SIM 112 already contains an invalid value, the PSP application may display an error message, such as “Handset rejected. Insert SIM in proper handset.”",
"In one or more aspects, the PSP application may restore the original, valid IMSI in the elementary file of the IMSI if the application accepts the wireless device 104 and EF-IMSI had contained an invalid IMSI value.",
"In a specific GSM implementation of the invention, the following procedures may be performed when dealing with an IMSI value.",
"When setting a valid IMSI, the PSP application may perform the following operations in this order: Reset the elementary files of: EF-FPLMN, EF-LOCI and EF-LOCIGPRS (EF_PSLOCI in 2G &",
"3G).",
"Refresh the wireless device using the Full File Change Notification and SIM Init option.",
"The PSP application may display a message, such as “Please power cycle the handset,” if the Refresh operation returns an error while in an accepted wireless device.",
"In one or more aspects, the PSP application may store an invalid IMSI in EF-IMSI if the PSP application rejects the wireless device and EF-IMSI contains a valid IMSI value.",
"When setting an invalid IMSI, in one or more aspects, the PSP application may perform the following operations in this order: Reset the elementary files of: EF-FPLMN, EF-LOCI and EF-LOCIGPRS (EF_PSLOCI in 2G &",
"3G).",
"Refresh using the Reset option.",
"The PSP application may retry a Refresh on a subsequent Status if Refresh returns a temporary error code while in a rejected wireless device.",
"Resetting the elementary files of: EF-FPLMN, EF-LOCI, and EF-LOCIGPRS (EF_PSLOCI in 2G &",
"3G) may ensure that the handset is not confused by the information stored in those files when using a different IMSI.",
"IMEI Locking (Second Switch) FIG. 3 shows a wireless identification validation process in accordance with aspects of the invention.",
"In one or more aspects, an IMEI locking procedure may be performed by the second switch of the PSP application.",
"This procedure may include marrying or pairing the SIM 112 to the current IMEI of the wireless device 104 that is being used.",
"The IMEI of the wireless device 104 to which the SIM 112 may be locked to may be stored in a secure location on the SIM 112 .",
"The location of the IMEI of the wireless device 104 on the SIM 112 may be updated or cleared based on a secure non-OTA programming method and/or updated or cleared based on an OTA programming configuration method.",
"At each subsequent power-up of the wireless device 104 , the PSP application may accept the wireless device 104 if all required wireless device verifications are successful.",
"In particular, the PSP application may conduct IMEI verification when the second switch has been activated.",
"In this regard, the PSP application may request or receive the IMEI of the wireless device as shown in step 302 .",
"The PSP application may then compare the IMEI of the wireless device with the IMEI that was locked and/or stored in the secure location on the SIM 112 as shown in step 304 .",
"If the IMEI provided/requested does not match the stored IMEI, then the PSP application may limit network access by the wireless device 104 in which the SIM card has been installed as shown in step 306 .",
"SIM Reporting Activities In one or more aspects, the third switch of the PSP application may be configured to send activity reports, such as by SMS messages or the like, to a backend server, system, or component controlled by the MVNO, wireless carrier, or the like for additional validation or monitoring by the backend server, system, or component.",
"The PSP application may report any one or more of the current Terminal Profile Data (TPD), last accepted (previous) IMEI, the current IMEI, a UICC ICC-ID along with other possible parameters via the SMS messages to the backend server, system, or component.",
"The reporting activity may be transparent to the end user.",
"The listing of parameters that may be reported may be stored securely on the SIM 112 .",
"In one or more aspects, for such SMS reporting messages, the PSP application may be configured to possess a destination address for the messages and a detail format (e.g., as provided by the MVNO or carrier) of the messages.",
"In one aspect, the wireless device 104 change SMS fields may be coded as a clear text ASCII comma separated value.",
"In one or more aspects, the PSP application may use a secure nonvolatile variable called Last Accepted IMEI, where the Last Accepted IMEI is initially blank when the SIM card is manufactured.",
"Upon request, SMS reporting parameters, including the destination address and other parameters, can be modified at the time of SIM card 112 personalization via a secure non-OTA programming method and they can be updated via OTA programming or non-OTA programming procedures.",
"In one or more aspects, the PSP application may send a SMS reporting message whenever there is an IMEI change detected and the wireless device 104 obtains network service (including reporting of the originally-installed wireless device 104 ).",
"This may be checked via the execution of various commands including the PLI (LOCI) command (the execution of which indicates the wireless device currently has normal service on a valid public land mobile network (PLMN) (different than 000000 or FFFFFF)) and if the PLI (LOCI) command is not supported the PSP application may still attempt to send a SMS reporting message.",
"In one or more aspects, all of the following conditions should be met before sending of a SMS reporting message: 1.",
"Reporting SMS switch (i.e., third switch) is enabled for sending SMS messages.",
"Wireless device is accepted, i.e. passes TPD validation if enabled and/or device IMEI verification if enabled.",
"An IMEI change is detected (including original installation).",
"The wireless device reports not supporting the PLI (LOCI) command in its Terminal Profile and 10 Status command has been received since power-up OR if the wireless device reports supporting the PLI (LOCI) command, the execution of the command indicates the wireless device currently has normal service on a valid PLMN (different than 000000 or FFFFFF).",
"If all of the SMS reporting conditions are met, except the last (fourth) condition, the PSP application may retry the PLI (LOCI) command if supported by the wireless device at each subsequent Status command should all conditions be finally met.",
"When all the conditions are met, the PSP application may attempt to send a wireless device change reporting SMS.",
"In one or more aspects, if the sending of the wireless device change reporting SMS fails, the PSP application may retry to send the wireless device Change reporting SMS only on the next SIM power cycle.",
"In one or more aspects, the PSP application may update the Last Accepted IMEI with the wireless device's current IMEI, if one of the following conditions is met: The wireless device 104 reports that Device Change SMS has been successfully sent, or A certain number of reporting SMS message attempts have failed (e.g., 3 attempts).",
"In one or more aspects, the reporting SMS message may be sent with the following information: the current TPD (such as its entire value up to 32 bytes, up to 64 hexadecimal digits), the Last Accepted IMEI (e.g., 16 decimal digits), the Current IMEI (e.g., 16 decimal digits), and the UICC ICC-ID (e.g., 20 decimal digits).",
"OTA Provisioning The PSP application can also be configured to self-initiate a request for OTA programming updates to refresh its programming and procedures as necessary based on backend rules and procedures (e.g., initial PSP application setup, new listings of authorized parameters, revised methods for sending activity reports, updated switch settings, etc.).",
"The OTA Provisioning switch may work independently of standard OTA platform functionality for the wireless device 104 and SIM 112 .",
"For example, standard wireless carrier based OTA updates or standard backend initiated OTA updates to PSP application, may work independent of and regardless of OTA Provisioning switch status.",
"SIM Variants In one or more aspects, the PSP application may include any combination of the secure switches described in various aspects described herein or otherwise, which may be activated at any given time, which may include only a portion of these secure switches or which may include even further switches for validation and/or reporting.",
"In one or more aspects, several exemplary variations of the SIM 112 configuration and logic are possible, for example, as represented in Table I shown in FIG. 4 .",
"For UICC configuration Variant 1 in Table I shown in FIG. 4 , if a wireless device 104 passes the terminal profile validation test of the first switch, only then may the SIM 112 be paired or married to that specific wireless device's IMEI which would then be stored securely in the SIM 112 .",
"Once a SIM 112 has been successfully paired or married to a wireless device 104 with a valid IMEI stored on the SIM 112 , then the IMEI lock, i.e. verifying that the SIM 112 is being placed into the wireless device 104 with correct corresponding IMEI, may take precedence and the PSP application may skip TPD verification for subsequent SIM 112 power-ups.",
"This should be done without turning off TPD verification switch so that, for example, if the IMEI stored on the UICC is possibly cleared in the future (e.g., via OTA) then the PSP application may resort to TPD verification described above.",
"For SIM 112 configuration Variant 2 in Table I shown in FIG. 4 , the IMEI Locking switch may be disabled such that the PSP application relies on the TPD Verification and Reporting SMS switches for wireless device verification.",
"For SIM 112 configuration Variant 3 in Table I shown in FIG. 4 , the TPD Verification switch may be turned off and the PSP application may give precedence to the IMEI Locking switch, which locks the SIM 112 to the first wireless device 104 IMEI that the PSP application encounters upon power-up.",
"For SIM 112 configuration Variant 4 in Table I shown in FIG. 4 , the TPD Verification and IMEI Locking switches are turned off, where the PSP application relies solely on the Reporting SMS switch for wireless device 104 verification, such that the condition #2 for sending a Reporting SMS would be ignored (i.e., the conditions for acceptance of the wireless device by passing TPD validation if enabled and/or device IMEI verification if enabled would be ignored).",
"For SIM 112 configuration Variant 5 in Table I shown in FIG. 4 , since all switches are set to OFF, the SIM 112 may behave in a standard manner similar to a post-paid SIM.",
"For SIM 112 configuration Variant 6 in Table I shown in FIG. 4 , when the OTA Provisioning switch is set to ON, then this may trigger the PSP application to initiate OTA provisioning via a TPD (Terminal Profile Data) update request to the OTA platform.",
"The OTA platform may handle the TPD update request based on backend rules and communicate appropriate updates as necessary.",
"Once the PSP application receives the necessary OTA updates, it may subsequently send a Proof of receipt to the OTA platform confirming the update was successful.",
"The initial state of the PSP application for OTA Provisioning may include the following configuration: The OTA Provisioning switch may be set to ON, the TPD Verification and IMEI Locking switches may be set to OFF, while the Reporting SMS switch may remain ON;",
"and SMS Service may be activated.",
"(e.g., the GSM line may be fully provisioned before OTA provisioning request or other SMS message is sent to OTA platform or SMSC).",
"The workflow of the OTA Provisioning switch may include: When wireless device 104 is powered up, the PSP application may send the current TPD, IMEI and UICC ICC-ID as part of wireless device change reporting for backend records.",
"In addition, the PSP application may request that the OTA platform update the TPD listing of authorized wireless devices.",
"The PSP application may continue to retry sending out the OTA request(s) until it receives appropriate OTA response(s).",
"The PSP application may display a message on the wireless device 104 , such as “Activation in Progress,” during this process for the end user.",
"The OTA platform may then push the necessary responses such as but not limited to setting the TPD verification and IMEI Locking switches ON as well as pushing the most current TPD(s), if needed, for updating the TPD listing of authorized wireless devices.",
"A refresh command may be sent upon backend discretion.",
"For example, if the backend determines from available data that the UICC is in a legitimate wireless device, then it may not send a refresh command to avoid possible customer impact.",
"If a refresh command is sent due to the backend determining the UICC is in an unintended wireless device or for any reason such as the backend logic not being implemented, then upon encountering a full refresh (reset) command the PSP application may attempt to display a warning message to the end user before committing the refresh (i.e., “The phone may be rebooting shortly”).",
"The PSP Application may then reboot the wireless device and complete the TPD verification and IMEI pairing operations associated with their respective switches described herein.",
"Upon accepting the OTA responses, the PSP application may send a POR (proof of receipt) to the OTA platform as well as remove any activation prompts being displayed for the end user.",
"Complete account activation (e.g., SMS+voice+data) may be completed by the account provider (e.g., MVNO or carrier), if not already done.",
"In one or more aspects, on wireless devices that are verified or accepted, the following Card Application Toolkit (CAT) commands (otherwise known as STK or SIM Toolkit commands or other similar commands) should be provided, where additional CAT support may be required as needed: Terminal Profile—this command is mandatory to accept a device.",
"Refresh (Full File Change Notification and SIM Init)—if not supported, the user would be required to manually power cycle the handset when swapping the UICC from a rejected handset to an accepted handset.",
"PLI (IMEI)—if not supported, the device change notification reporting SMS may miss some information.",
"PLI (MCC, MNC, LAC and Cell ID)—if not supported, the applet may assume there is coverage after 10 Status command has been received.",
"Send SMS—if not supported, the device change notification SMS cannot be sent.",
"Display Text (high priority, user defined)—if not supported, the user may not be informed to power cycle the handset if Refresh is not supported as well.",
"In one or more aspects, on wireless devices that are rejected, the following CAT support should be provided, where additional CAT support may be required as needed: Refresh (Reset)—if not supported, the device would still be usable until the next power cycle.",
"Display Text (high priority, user defined)—if not supported, the user may not be informed that the device is not supported.",
"In one or more aspects, for an identical use case and PSP application configuration, the user experience may vary depend on the wireless device 104 , on the wireless network and possibly on the UICC profile.",
"In one or more aspects, the PSP application installed on and operating on the UICC (i.e., SIM card) and its associated functionality described herein may be implemented in software, stored on a computer readable medium or computer readable storage medium, such as a memory of the UICC, where the memory may store computer readable instructions, e.g., program code, that can be executed by a processor or controller in a device (e.g., on the UICC or mobile device) to carry out one or more of the techniques described herein.",
"Additionally, it should be noted that if needed, the invention and/or PSP application may also use other areas of memory to implement the invention including memory in the wireless device, network based memory, or the like.",
"As described above, the invention provides a Mobile Virtual Network Operator the ability to provide subscribers with greater choice of services and devices.",
"Moreover, the invention allows the Mobile Virtual Network Operator the ability to limit the choice of services and devices.",
"For the purposes of this disclosure a computer readable medium stores computer data, which data can include computer program code that is executable by a processor of the SIM or mobile device, in machine readable form.",
"By way of example, and not limitation, a computer readable medium may comprise computer readable storage media, for tangible or fixed storage of data, or communication media for transient interpretation of code-containing signals.",
"Computer readable storage media, as used herein, refers to physical or tangible storage (as opposed to signals) and includes without limitation volatile and non-volatile, removable and nonremovable storage media implemented in any method or technology for the tangible storage of information such as computer-readable instructions, data structures, program modules or other data.",
"Computer readable storage media includes, but is not limited to, RAM, ROM, EPROM, EEPROM, flash memory or other solid state memory technology, optical storage media, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other physical or material medium which can be used to tangibly store the desired information or data or instructions and which can be accessed by a processor or computing device.",
"In one or more aspects, the actions and/or events of a method, algorithm or module may reside as one or any combination or set of codes and/or instructions on a computer readable medium or machine readable medium, which may be incorporated into a computer program product.",
"The invention may include communication channels that may be any type of wired or wireless electronic communications network, such as, e.g., a wired/wireless local area network (LAN), a wired/wireless personal area network (PAN), a wired/wireless home area network (HAN), a wired/wireless wide area network (WAN), a campus network, a metropolitan network, an enterprise private network, a virtual private network (VPN), an internetwork, a backbone network (BBN), a global area network (GAN), the Internet, an intranet, an extranet, an overlay network, a cellular telephone network, a Personal Communications Service (PCS), using known protocols such as the Global System for Mobile Communications (GSM), CDMA (Code-Division Multiple Access), W-CDMA (Wideband Code-Division Multiple Access), Wireless Fidelity (Wi-Fi), Bluetooth, and/or the like, and/or a combination of two or more thereof.",
"In an embodiment, the invention may be implemented in any type of mobile smartphones that are operated by any type of advanced mobile data processing and communication operating system, such as, e.g., an Apple™ iOS™ operating system, a Google™ Android™ operating system, a RIM™ Blackberry™ operating system, a Nokia™ Symbian™ operating system, a Microsoft™ Windows Mobile™ operating system, a Microsoft™ Windows Phone™ operating system, a Linux™ operating system or the like.",
"Further in accordance with various embodiments of the invention, the methods described herein are intended for operation with dedicated hardware implementations including, but not limited to, PCs, PDAs, SIM cards, semiconductors, application specific integrated circuits (ASIC), programmable logic arrays, cloud computing devices, and other hardware devices constructed to implement the methods described herein.",
"While the system and method have been described in terms of what are presently considered to be specific aspects, the disclosure need not be limited to the disclosed aspects.",
"It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures.",
"The present disclosure includes any and all aspects of the following claims."
] |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an optical switch for use in optical fiber communication and optical network technology, and particularly to an optical switch that can precisely locate a movable optical component to preselected positions for realizing optical paths switching.
[0003] 2. Description of Related Art
[0004] Optical signals are commonly transmitted in optical fibers, which provide efficient light channels through which optical signals can pass. Recently, optical fibers have been used in various fields, including telecommunications, where light passing through an optical fiber is used to convey either digital or analog information. Efficient switching of optical signals between individual fibers is necessary in most optical processing systems or networks to achieve the desired routing of the signals.
[0005] In optical fiber systems, various mechanisms have been previously developed for switching optical signals between fiber cables. Among these previously developed mechanisms, one important category is mechanical optical switches.
[0006] Mechanically operated optical switches come in two different designs: in one design, the optical components move, and in the other design, the fibers move. Factors for assessing the capability of an optical switch include low insertion loss (<1 dB), good isolation performance (>50 dB) and bandwidth capacity compatible with the fiber network the switch is supporting.
[0007] In moving optical component switches, a driving mechanism drives one or more optical components to move between different positions to effect the switching operation. The driving mechanism may be a motor or a solenoid with no self-latching mechanism, which needs an attached latching mechanism to locate the optical component in the different positions. In general, the attached mechanism is large in size. As shown in FIG. 10, U.S. Pat. No. 5,742,712 describes a mechanical optical switch 910 having a relay 912 . The relay 912 includes an arm 940 , which supports a mirror 920 . In response to electrical signals supplied to the relay 912 , the arm 940 of the relay 912 moves the mirror 920 between a first position 944 and a second position 946 . The travel of the arm 940 is limited by stops 948 , which determine the first and second positions of the mirror 920 .
[0008] In this mechanical optical switch 910 , the stops 948 are opposite a middle part of the arm 940 . The weight of the mirror 920 bends the arm 940 over time, which results in misalignment of the mirror 920 and connected fibers 990 .
[0009] For the above reasons, an improved optical switch is desired. In particular, an optical switch is desired which has high optical efficiency and which can precisely position the switching element in the different switching states.
BRIEF SUMMARY OF THE INVENTION
[0010] An object of the invention is to provide an optical switch which includes a rotating mechanism to effect switching states.
[0011] Another object of the invention is to provide an optical switch which provides precise positioning of associated switching elements in the different switching states and which has a low insertion loss.
[0012] Yet another object of the present invention is to provide an optical switch which is small in size.
[0013] An optical switch in accordance with one embodiment of the present invention comprises a housing, a switching element, a driver, a holder, an input port and an output port. The switching element, the driver and the holder are accommodated in a chamber formed in the housing. The holder holds the input and output ports in alignment with one another and is assembled with the switching element, which comprises an optical component assembly and a rotating mechanism. The optical component assembly is soldered to the rotating mechanism and can be moved between a bottom stopper (a downward position), where a prism of the optical component assembly is in the optical paths between the input port and the output port, and a top stopper (a upward position), where the prism of the optical component assembly is out of the optical paths.
[0014] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is an exploded view of an optical switch of the present invention;
[0016] [0016]FIG. 2 is a perspective view of a holder and aligned collimators of the optical switch in FIG. 1;
[0017] [0017]FIG. 3 is a partially exploded view of a holder, aligned collimators, and a switching element of the optical switch in FIG. 1;
[0018] [0018]FIG. 4 is an assembled view of FIG. 3, without an optical component assembly;
[0019] [0019]FIG. 5 is an assembled view of FIG. 3, from a reverse aspect, additionally having a driver shaft and showing the optical component assembly in a downward position;
[0020] [0020]FIG. 6 is an essential optical paths diagram of the optical switch of FIG. 1, when the optical component assembly is in the downward position;
[0021] [0021]FIG. 7 is the same as FIG. 5, but with the optical component assembly in an upward position;
[0022] [0022]FIG. 8 is a cross-sectional view taken along the line 8 - 8 in FIG. 7;
[0023] [0023]FIG. 9 is an essential optical paths diagram of the optical switch in FIG. 1, when the optical component assembly is in the upward position;
[0024] [0024]FIG. 10 is a partially cross-sectional view of a prior art optical switch.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIG. 1, an optical switch 10 according to the present invention switches signals coming from a first and second input fibers 41 , 42 between first and second output fibers 51 , 52 . The optical switch 10 comprises a housing 3 , a switching element 6 , a driver 63 , a holder 7 , an input port 4 , an output port 5 , a top stopper 85 and a bottom stopper 86 . The housing 3 comprises an elongate, box-shaped base 31 defining two opposite side holes 311 , 312 having interior threads therein, and a top cover 2 defining a slot 21 . The housing 3 accommodates the switching element 6 , the driver 63 the holder 7 , the top stopper 86 , the bottom stopper 86 , and parts of the input and output ports 4 , 5 , as described below, therewithin.
[0026] As shown in FIGS. 2 and 3, the holder 7 has a horizontal base plate 741 with an elongate mounting pedestal 74 extending upwardly from a central portion (not labeled) of the base plate 741 . A first and second collimator holders 731 , 732 protrude upward at a forward side of the base plate 741 , each defining two collimator notches (not labeled) therein. A pair of shaft supporters 743 , 744 protrudes upwardly from a rear side of the base plate 741 , each defining a V-angled slot 746 , 747 therein for accepting two ends of an axle shaft 65 . A pair of anchor holes 71 , 72 is defined in a top of the mounting pedestal 74 . Two spring mounting holes 742 are defined in a rear side of the mounting pedestal 74 and a guiding hole 733 is defined in the forward side of the base plate 741 between the two collimator holders 731 , 732 . A chamber 73 is formed between the base plate 741 , the two collimator holders 731 , 732 , and the mounting pedestal 74 . A bracket mounting notch 745 is formed between the base plate 741 , the two shaft supporters 743 , 744 , and the mounting pedestal 74 .
[0027] Also referring to FIGS. 2 - 4 , the switching element 6 comprises an optical component assembly 61 and a rotating mechanism 60 . The optical component assembly 61 includes an optical component 612 and an optical component holder 611 engaged with the optical component 612 . In this embodiment, the optical component 612 is a diamond-shaped prism 612 .
[0028] The rotating mechanism 60 comprises a bracket 62 , a cantilevered spring 64 , and the axle shaft 65 . The bracket 62 is formed from one bended piece of sheet metal and comprises a frame 622 and a lifting arm 621 . The frame 622 is roughly in the shape of an elongate rectangular box, with the lifting arm 621 bending upward and outward from a side (not labeled) of the frame 622 . A pair of drive bearings 625 protrude upward from a top side (not labeled) of the frame 622 , each drive bearing 625 defining one of a pair of aligned drive holes 624 therethrough. A pair of frame end walls (not labeled) each defines a shaft hole 623 therethrough.
[0029] The cantilevered spring 64 is made of a resilient material and has a fixing arm 642 on one end and a spring arm 641 on an opposite end. The fixing arm 642 defines two arm holes (not labeled). The spring arm 641 is bended in a sinuous shape to provide a spring force against the axle shaft 65 . The axle shaft 65 is long and cylindrical in shape and is beveled on one end to aid in inserting the axle shaft through the shaft holes 623 .
[0030] The driver 63 (see FIG. 1) is a relay having a self-latching function and drives the bracket 62 to rotate. The driver 63 has a driver arm 632 extending outward from the driver 63 , and an L-shaped driver shaft 631 soldered on the driver arm 632 . The driver arm 632 moves in a forward and rearward direction.
[0031] Referring to FIGS. 1 - 2 , the input port 4 comprises a first and a second input collimators 81 , 82 , a coupler 44 , and a boot 43 . The output port 5 comprises a first and a second output collimators 91 , 92 , a coupler 54 , and a boot 53 . The first input collimator 81 has a ferrule 801 and a lens 802 , which are held in fixed relation to one another using epoxy or solder between angled front and back surfaces 803 , 804 of the ferrule 801 and the lens 802 , respectively. The lens 802 may be a GRIN (Graded Index) lens. The ferrule 801 is an elongate tube having a hollowed out interior aperture (not labeled) extending longitudinally therethrough, wherein the first input fiber 41 can be inserted. The second input collimator 82 and the first and second output collimators 91 , 92 are identical in structure with the first input collimator 81 , but respectively receive the second input fiber 42 , the first output fiber 51 , and the second output fiber 52 . Each coupler 44 , 54 has a tubular construction with a threaded outer surface (not labeled) on one end.
[0032] In assembly, the optical component assembly 61 is connected to the bracket 62 by soldering the optical component holder 611 to the lifting arm 621 .The axle shaft 65 is inserted through the shaft holes 623 in each frame end wall (not labeled) and ends (not labeled) of the axle shaft 65 are engaged with a corresponding V-angled slots 746 , 747 , while the frame 622 of the bracket 62 fits into the bracket mounting notch 745 . The fixing arm 642 of the cantilevered spring 64 fits against the mounting pedestal 74 , with the two arm holes (not labeled) aligned with the spring mounting holes 742 and with the spring arm 641 pressing against the axle shaft 65 . Two arm screws 89 are inserted through the arm holes of the fixing arm 642 and are engaged in the spring mounting holes 742 . The first and second input collimators 81 , 82 are fixed in the collimator notches (not labeled) of the input collimator holder 731 , and the first and second output collimators 91 , 92 are fixed in the collimator notches (not labeled) of the second collimator holder 732 . The first input collimator 81 is aligned with the first output collimator 91 , and the second input collimator 82 is aligned with the second output collimator 92 . The bottom stopper 86 is engaged with the guiding hole 733 in the holder 7 . The driver shaft 631 of the driver 63 is inserted through the drive holes 624 in the bracket 62 and the holder 7 and driver 63 are inserted into the base 31 . A pair of anchor screws 88 is inserted through the anchor holes 71 , 72 and is engaged with the base 31 , fixing the holder 7 securely in the base 31 . The couplers 44 , 54 are threadedly engaged with the respective side holes 311 , 312 . The first and second input fibers 41 , 42 are threaded through the boot 43 and the coupler 44 and are fixed in the ferrules of, respectively, the first and second input collimators 81 , 82 . The first and second output fibers 51 , 52 are threaded through the boot 53 and the coupler 54 and are fixed in the ferrules of, respectively, the first and second output collimators 91 , 92 . The boots 43 , 53 are moved to cover a rearward end of the respective couplers 44 , 54 . The top stopper 85 is fixed in the slot 21 of the top cover 2 , which is fixed to the base 31 .
[0033] In use, the optical component assembly 61 is moved between a lowered position and a raised position. When the driver arm 632 of the driver 63 is in a forward position, the prism 612 is in the lowered position, as shown in FIG. 5. When the driver 63 receives a signal to move to a rearward position, the driver arm 632 , with the attached driver shaft 631 moves rearward. Since the driver shaft 631 is engaged with drive bearing 625 on the bracket 62 via the drive holes 624 , the drive bearing 625 is also driven rearward with the driver shaft 631 . This rearward movement of the drive bearing 625 rotates the bracket 62 around the axle shaft 65 , which raises the lifting arm 621 and the prism 612 , as shown in FIGS. 7 - 8 , until the lifting arm 621 abuts the top stopper 85 . When the driver 63 receives a signal to move to the forward position, the process is reversed and the prism 612 is lowered until the optical component assembly 61 abuts against the bottom stopper 86 .
[0034] FIGS. 5 - 9 illustrate the operation of the optical switch 10 . In the downward position (FIGS. 5 and 6), the optical component assembly 61 is downward, stopped against the bottom stopper 86 and the prism 612 aligns with the input and output collimators 81 , 82 , 91 , 92 . Light beams from the first and second input fibers 41 , 42 transmit through the first and second input collimators 81 , 82 , respectively. Each light beam is transmitted through the prism 612 , and is bended along symmetrically opposite paths by the prism, to pass through the second and first output collimators 92 , 91 and into the second and first output fibers 52 , 51 , respectively.
[0035] In the upward position (FIGS. 7 - 9 ), the optical component assembly 61 is upward with the lifting arm 621 abutting against the top stopper 85 and the prism 612 being out of the optical paths between the input and output ports 4 , 5 . In this position, light beams from the first and second input fibers 41 , 42 are transmitted through the first and second input collimators 81 , 82 and transmit through the first and second output collimators 91 , 92 into the first and second output fibers 51 , 52 , respectively.
[0036] The optical switch 10 of the present invention makes use of the rotating mechanism 60 , the top stopper 85 and the bottom stopper 86 to move the prism 612 between two precisely located positions.
[0037] Advantages of the optical switch 10 of the present invention over those of the prior art include the following. First, the driver has a self-latching function. Second, the size of the optical switch is small, since no separately attached latching mechanism is required. Third, the moveable optical component 612 is precisely located in the two different positions. Thus, the insertion loss of the optical switch is minimized.
[0038] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the fill extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An optical switch ( 10 ) includes a housing ( 3 ), an input port ( 4 ), an output port ( 5 ), a switching element ( 6 ), a holder ( 7 ), and a driver ( 63 ). The holder holds the input and output ports in alignment with one another and is assembled with the switching element. The switching element comprises an optical component assembly ( 61 ) and a rotating mechanism ( 60 ). The optical component assembly is fixed on the rotating mechanism and is brought to move between a top stopper ( 85 ) (an upward position), wherein the optical component assembly is out of optical paths running between the input port and the output port, and a bottom stopper ( 86 ) (a downward position), wherein the optical component assembly is in the optical paths. The optical component assembly includes a prism 612, which redirects optical paths passing through it, effecting a switching between input ports and output ports. | Identify and summarize the most critical features from the given passage. | [
"BACKGROUND OF THE INVENTION [0001] 1.",
"Field of the Invention [0002] The present invention relates to an optical switch for use in optical fiber communication and optical network technology, and particularly to an optical switch that can precisely locate a movable optical component to preselected positions for realizing optical paths switching.",
"[0003] 2.",
"Description of Related Art [0004] Optical signals are commonly transmitted in optical fibers, which provide efficient light channels through which optical signals can pass.",
"Recently, optical fibers have been used in various fields, including telecommunications, where light passing through an optical fiber is used to convey either digital or analog information.",
"Efficient switching of optical signals between individual fibers is necessary in most optical processing systems or networks to achieve the desired routing of the signals.",
"[0005] In optical fiber systems, various mechanisms have been previously developed for switching optical signals between fiber cables.",
"Among these previously developed mechanisms, one important category is mechanical optical switches.",
"[0006] Mechanically operated optical switches come in two different designs: in one design, the optical components move, and in the other design, the fibers move.",
"Factors for assessing the capability of an optical switch include low insertion loss (<1 dB), good isolation performance (>50 dB) and bandwidth capacity compatible with the fiber network the switch is supporting.",
"[0007] In moving optical component switches, a driving mechanism drives one or more optical components to move between different positions to effect the switching operation.",
"The driving mechanism may be a motor or a solenoid with no self-latching mechanism, which needs an attached latching mechanism to locate the optical component in the different positions.",
"In general, the attached mechanism is large in size.",
"As shown in FIG. 10, U.S. Pat. No. 5,742,712 describes a mechanical optical switch 910 having a relay 912 .",
"The relay 912 includes an arm 940 , which supports a mirror 920 .",
"In response to electrical signals supplied to the relay 912 , the arm 940 of the relay 912 moves the mirror 920 between a first position 944 and a second position 946 .",
"The travel of the arm 940 is limited by stops 948 , which determine the first and second positions of the mirror 920 .",
"[0008] In this mechanical optical switch 910 , the stops 948 are opposite a middle part of the arm 940 .",
"The weight of the mirror 920 bends the arm 940 over time, which results in misalignment of the mirror 920 and connected fibers 990 .",
"[0009] For the above reasons, an improved optical switch is desired.",
"In particular, an optical switch is desired which has high optical efficiency and which can precisely position the switching element in the different switching states.",
"BRIEF SUMMARY OF THE INVENTION [0010] An object of the invention is to provide an optical switch which includes a rotating mechanism to effect switching states.",
"[0011] Another object of the invention is to provide an optical switch which provides precise positioning of associated switching elements in the different switching states and which has a low insertion loss.",
"[0012] Yet another object of the present invention is to provide an optical switch which is small in size.",
"[0013] An optical switch in accordance with one embodiment of the present invention comprises a housing, a switching element, a driver, a holder, an input port and an output port.",
"The switching element, the driver and the holder are accommodated in a chamber formed in the housing.",
"The holder holds the input and output ports in alignment with one another and is assembled with the switching element, which comprises an optical component assembly and a rotating mechanism.",
"The optical component assembly is soldered to the rotating mechanism and can be moved between a bottom stopper (a downward position), where a prism of the optical component assembly is in the optical paths between the input port and the output port, and a top stopper (a upward position), where the prism of the optical component assembly is out of the optical paths.",
"[0014] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0015] [0015 ]FIG. 1 is an exploded view of an optical switch of the present invention;",
"[0016] [0016 ]FIG. 2 is a perspective view of a holder and aligned collimators of the optical switch in FIG. 1;",
"[0017] [0017 ]FIG. 3 is a partially exploded view of a holder, aligned collimators, and a switching element of the optical switch in FIG. 1;",
"[0018] [0018 ]FIG. 4 is an assembled view of FIG. 3, without an optical component assembly;",
"[0019] [0019 ]FIG. 5 is an assembled view of FIG. 3, from a reverse aspect, additionally having a driver shaft and showing the optical component assembly in a downward position;",
"[0020] [0020 ]FIG. 6 is an essential optical paths diagram of the optical switch of FIG. 1, when the optical component assembly is in the downward position;",
"[0021] [0021 ]FIG. 7 is the same as FIG. 5, but with the optical component assembly in an upward position;",
"[0022] [0022 ]FIG. 8 is a cross-sectional view taken along the line 8 - 8 in FIG. 7;",
"[0023] [0023 ]FIG. 9 is an essential optical paths diagram of the optical switch in FIG. 1, when the optical component assembly is in the upward position;",
"[0024] [0024 ]FIG. 10 is a partially cross-sectional view of a prior art optical switch.",
"DETAILED DESCRIPTION OF THE INVENTION [0025] Referring to FIG. 1, an optical switch 10 according to the present invention switches signals coming from a first and second input fibers 41 , 42 between first and second output fibers 51 , 52 .",
"The optical switch 10 comprises a housing 3 , a switching element 6 , a driver 63 , a holder 7 , an input port 4 , an output port 5 , a top stopper 85 and a bottom stopper 86 .",
"The housing 3 comprises an elongate, box-shaped base 31 defining two opposite side holes 311 , 312 having interior threads therein, and a top cover 2 defining a slot 21 .",
"The housing 3 accommodates the switching element 6 , the driver 63 the holder 7 , the top stopper 86 , the bottom stopper 86 , and parts of the input and output ports 4 , 5 , as described below, therewithin.",
"[0026] As shown in FIGS. 2 and 3, the holder 7 has a horizontal base plate 741 with an elongate mounting pedestal 74 extending upwardly from a central portion (not labeled) of the base plate 741 .",
"A first and second collimator holders 731 , 732 protrude upward at a forward side of the base plate 741 , each defining two collimator notches (not labeled) therein.",
"A pair of shaft supporters 743 , 744 protrudes upwardly from a rear side of the base plate 741 , each defining a V-angled slot 746 , 747 therein for accepting two ends of an axle shaft 65 .",
"A pair of anchor holes 71 , 72 is defined in a top of the mounting pedestal 74 .",
"Two spring mounting holes 742 are defined in a rear side of the mounting pedestal 74 and a guiding hole 733 is defined in the forward side of the base plate 741 between the two collimator holders 731 , 732 .",
"A chamber 73 is formed between the base plate 741 , the two collimator holders 731 , 732 , and the mounting pedestal 74 .",
"A bracket mounting notch 745 is formed between the base plate 741 , the two shaft supporters 743 , 744 , and the mounting pedestal 74 .",
"[0027] Also referring to FIGS. 2 - 4 , the switching element 6 comprises an optical component assembly 61 and a rotating mechanism 60 .",
"The optical component assembly 61 includes an optical component 612 and an optical component holder 611 engaged with the optical component 612 .",
"In this embodiment, the optical component 612 is a diamond-shaped prism 612 .",
"[0028] The rotating mechanism 60 comprises a bracket 62 , a cantilevered spring 64 , and the axle shaft 65 .",
"The bracket 62 is formed from one bended piece of sheet metal and comprises a frame 622 and a lifting arm 621 .",
"The frame 622 is roughly in the shape of an elongate rectangular box, with the lifting arm 621 bending upward and outward from a side (not labeled) of the frame 622 .",
"A pair of drive bearings 625 protrude upward from a top side (not labeled) of the frame 622 , each drive bearing 625 defining one of a pair of aligned drive holes 624 therethrough.",
"A pair of frame end walls (not labeled) each defines a shaft hole 623 therethrough.",
"[0029] The cantilevered spring 64 is made of a resilient material and has a fixing arm 642 on one end and a spring arm 641 on an opposite end.",
"The fixing arm 642 defines two arm holes (not labeled).",
"The spring arm 641 is bended in a sinuous shape to provide a spring force against the axle shaft 65 .",
"The axle shaft 65 is long and cylindrical in shape and is beveled on one end to aid in inserting the axle shaft through the shaft holes 623 .",
"[0030] The driver 63 (see FIG. 1) is a relay having a self-latching function and drives the bracket 62 to rotate.",
"The driver 63 has a driver arm 632 extending outward from the driver 63 , and an L-shaped driver shaft 631 soldered on the driver arm 632 .",
"The driver arm 632 moves in a forward and rearward direction.",
"[0031] Referring to FIGS. 1 - 2 , the input port 4 comprises a first and a second input collimators 81 , 82 , a coupler 44 , and a boot 43 .",
"The output port 5 comprises a first and a second output collimators 91 , 92 , a coupler 54 , and a boot 53 .",
"The first input collimator 81 has a ferrule 801 and a lens 802 , which are held in fixed relation to one another using epoxy or solder between angled front and back surfaces 803 , 804 of the ferrule 801 and the lens 802 , respectively.",
"The lens 802 may be a GRIN (Graded Index) lens.",
"The ferrule 801 is an elongate tube having a hollowed out interior aperture (not labeled) extending longitudinally therethrough, wherein the first input fiber 41 can be inserted.",
"The second input collimator 82 and the first and second output collimators 91 , 92 are identical in structure with the first input collimator 81 , but respectively receive the second input fiber 42 , the first output fiber 51 , and the second output fiber 52 .",
"Each coupler 44 , 54 has a tubular construction with a threaded outer surface (not labeled) on one end.",
"[0032] In assembly, the optical component assembly 61 is connected to the bracket 62 by soldering the optical component holder 611 to the lifting arm 621 .",
"The axle shaft 65 is inserted through the shaft holes 623 in each frame end wall (not labeled) and ends (not labeled) of the axle shaft 65 are engaged with a corresponding V-angled slots 746 , 747 , while the frame 622 of the bracket 62 fits into the bracket mounting notch 745 .",
"The fixing arm 642 of the cantilevered spring 64 fits against the mounting pedestal 74 , with the two arm holes (not labeled) aligned with the spring mounting holes 742 and with the spring arm 641 pressing against the axle shaft 65 .",
"Two arm screws 89 are inserted through the arm holes of the fixing arm 642 and are engaged in the spring mounting holes 742 .",
"The first and second input collimators 81 , 82 are fixed in the collimator notches (not labeled) of the input collimator holder 731 , and the first and second output collimators 91 , 92 are fixed in the collimator notches (not labeled) of the second collimator holder 732 .",
"The first input collimator 81 is aligned with the first output collimator 91 , and the second input collimator 82 is aligned with the second output collimator 92 .",
"The bottom stopper 86 is engaged with the guiding hole 733 in the holder 7 .",
"The driver shaft 631 of the driver 63 is inserted through the drive holes 624 in the bracket 62 and the holder 7 and driver 63 are inserted into the base 31 .",
"A pair of anchor screws 88 is inserted through the anchor holes 71 , 72 and is engaged with the base 31 , fixing the holder 7 securely in the base 31 .",
"The couplers 44 , 54 are threadedly engaged with the respective side holes 311 , 312 .",
"The first and second input fibers 41 , 42 are threaded through the boot 43 and the coupler 44 and are fixed in the ferrules of, respectively, the first and second input collimators 81 , 82 .",
"The first and second output fibers 51 , 52 are threaded through the boot 53 and the coupler 54 and are fixed in the ferrules of, respectively, the first and second output collimators 91 , 92 .",
"The boots 43 , 53 are moved to cover a rearward end of the respective couplers 44 , 54 .",
"The top stopper 85 is fixed in the slot 21 of the top cover 2 , which is fixed to the base 31 .",
"[0033] In use, the optical component assembly 61 is moved between a lowered position and a raised position.",
"When the driver arm 632 of the driver 63 is in a forward position, the prism 612 is in the lowered position, as shown in FIG. 5. When the driver 63 receives a signal to move to a rearward position, the driver arm 632 , with the attached driver shaft 631 moves rearward.",
"Since the driver shaft 631 is engaged with drive bearing 625 on the bracket 62 via the drive holes 624 , the drive bearing 625 is also driven rearward with the driver shaft 631 .",
"This rearward movement of the drive bearing 625 rotates the bracket 62 around the axle shaft 65 , which raises the lifting arm 621 and the prism 612 , as shown in FIGS. 7 - 8 , until the lifting arm 621 abuts the top stopper 85 .",
"When the driver 63 receives a signal to move to the forward position, the process is reversed and the prism 612 is lowered until the optical component assembly 61 abuts against the bottom stopper 86 .",
"[0034] FIGS. 5 - 9 illustrate the operation of the optical switch 10 .",
"In the downward position (FIGS.",
"5 and 6), the optical component assembly 61 is downward, stopped against the bottom stopper 86 and the prism 612 aligns with the input and output collimators 81 , 82 , 91 , 92 .",
"Light beams from the first and second input fibers 41 , 42 transmit through the first and second input collimators 81 , 82 , respectively.",
"Each light beam is transmitted through the prism 612 , and is bended along symmetrically opposite paths by the prism, to pass through the second and first output collimators 92 , 91 and into the second and first output fibers 52 , 51 , respectively.",
"[0035] In the upward position (FIGS.",
"7 - 9 ), the optical component assembly 61 is upward with the lifting arm 621 abutting against the top stopper 85 and the prism 612 being out of the optical paths between the input and output ports 4 , 5 .",
"In this position, light beams from the first and second input fibers 41 , 42 are transmitted through the first and second input collimators 81 , 82 and transmit through the first and second output collimators 91 , 92 into the first and second output fibers 51 , 52 , respectively.",
"[0036] The optical switch 10 of the present invention makes use of the rotating mechanism 60 , the top stopper 85 and the bottom stopper 86 to move the prism 612 between two precisely located positions.",
"[0037] Advantages of the optical switch 10 of the present invention over those of the prior art include the following.",
"First, the driver has a self-latching function.",
"Second, the size of the optical switch is small, since no separately attached latching mechanism is required.",
"Third, the moveable optical component 612 is precisely located in the two different positions.",
"Thus, the insertion loss of the optical switch is minimized.",
"[0038] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the fill extent indicated by the broad general meaning of the terms in which the appended claims are expressed."
] |
BACKGROUND OF THE INVENTION
The present invention relates to an air-bag arrangement, and more particularly relates to an air-bag arrangement adapted to protect a driver or passenger in a motor vehicle such as a motor car.
It has been proposed to provide an air-bag in a motor car positioned in front of the driver or in front of a passenger of the motor car, the bag being adapted to inflate in the event that an accident arises. The bag thus provides a "cushion" for the driver or the passenger.
The design of air-bags is nor very sophisticated and the bag is adapted to be inflated before the driver or passenger moves forwardly within the motor vehicle during an accident as a result of vehicle retardation.
Reference may be made to EP-A-0344422 which discloses a bag in which parts of the bag are folded together to form a "tuck" by stitching, the stitching forming a "tear seam". The main purpose of this is to control the way that the bag is inflated. Thus the "tear seam" effectively controls the speed of inflation or the direction in which the bag expands during inflation so that the bag, when it is inflated, does not hit the driver or passenger with a significant force. The "tear seam" is designed to tear or rip, enabling the "tuck" to open out at a predetermined instant during the inflation of the bag thus effectively increasing the permissible interior volume of the bag at that instant.
One disadvantage of the system of EP-A-0344422 is that the "tear seam" comprises stitching which passes through part of the bag and which forms the boundary between the interior of the bag and the exterior of the bag. When the "tear seam" tears or rips, either the thread forming the stitching can break or the fabric in the region of the seam can tear. It is possible that the fabric will tear along the line of the stitching, since the fabric will have been pierced by the needle when the stitches have been put in place, and the fabric may thus have been punctured or weakened in the line of the stitching. However, it is also possible that the fabric adjacent the actual stitching may tear or rip. In any event, it is quit possible that the fabric of the bag may become damaged. If the fabric of the bag is damaged, and is apertured, the bag may deflate in an undesirable manner, and the bag will then not provide the desired cushioning effect.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved air-bag arrangement.
According to this invention there is provided an inflatable bag adapted to protect a driver or passenger in a motor vehicle, wherein the bag is provided with one or more tearable means comprising at least one element provided with an area of weakness at which the element is designed to tear, the tearable means being so located that when the bag is exposed to an internal pressure in excess of a predetermined pressure, the tearable means tear and control the way the bag is inflated, the interior volume of the bag being greater when the tearable means have torn than before the tearable means have torn.
Thus, when the bag is inflated and the tearable means tear, the integrity of the bag is not affected, and the bag remains substantially air-tight.
Preferable the tearable means comprise one or more elements of fabric each provided with a notch or recess, or aperture to define said area of weakness at which tearing across the fabric can occur.
The tearable means may comprise fabric that is formed integrally with the fabric forming the bag or may comprise separate elements which are secured to the fabric forming the bag.
The fabric of the tearable means may be flame-retardant fabric.
Conveniently the fabric of the tearable means is secured to the fabric defining the air-bag at a position surrounding an aperture formed in the material forming the air-bag intended to provide an inlet for gas from a gas generator.
In one arrangement one or both ends of each tearable means is secured to the bag by a seam provided to hold areas or components of the bag together, but alternatively one or both ends of the tearable means is secured to the fabric forming the bag by a seam which serves the sole purpose of securing the tearable means to the fabric of the bag.
In one embodiment the or each tearable means extends across a tuck formed in the bag, but alternatively the or each tearable means extends across parts of the bag which are of "concertina" form (in the uninflated state).
In one arrangement the or each tearable means is on the exterior of the bag, but alternatively the or each tearable means is on the interior of the bag.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more readily understood, and so that further features thereof may be appreciated, the invention will now be described, by way of example, with reference to the accompanying drawings in which
FIG. 1 is a plan view of the component "blanks" used in constructing a bag in accordance with the invention,
FIG. 2 is a perspective view of the bag made from the components of FIG. 1,
FIG. 3 is a sectional view taken on the line III--III of FIG. 2,
FIG. 4 is a perspective view with parts cut away of an alternative embodiment of the invention,
FIG. 5 is a perspective view of yet another embodiment of the invention, and
FIG. 6 is a view corresponding to FIG. 5 but with parts out away to illustrate the operative parts of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1 the component parts of an air-bag are illustrated. The components comprise a first or central component 1 formed of fabric or an appropriate fabric laminate, the component 1 being of elongate form and having a central region 2 which is of greater width than the widths of the ends 3, 4.
At positions intermediate the central region 2 and each end, the component 1 is provided with four substantially symmetrically located projecting tabs 5,6,7,8 which extend outwardly from the edges of the component, each of rectangular form and each formed integrally with the component 1. Each tab is provided, in one long side thereof, with a substantially "V"-shaped notch 9,10,11,12.
FIG. 1 illustrates two further 13,14 each of the same form. The components 13,14 may be formed of the same fabric or laminate as the component 1. Each component 13,14 is of elongate form, having a length approximately half the length of the component 1. Each component 13,14 has a relatively narrow end 15,16 and an opposite, wider end 21,22 and has diverging side edges 17,18,19,20 extending from a larger end 21,22 to the narrow end 15,16.
The components of FIG. 1 may be assembled to form an air-bag having the general configuration shown in FIG. 2. It is to be observed that the main component 1 is folded to have a substantially "U"-shaped form, to form, in the orientation illustrated, the bottom, end and top of an air-bag, and the components 13 and 14 are located in position to form the side walls of the air-bag.
The side edges 17,18 and the end 21 of the component 13 are aligned with one edge of the component 1 and stitched in position by means of stitching 23. The component 14 is placed in position in a similar way and is retained by stitching 24.
At this stage of fabrication the bag has the four tabs 5,6,7 and 8 projecting outwardly.
Subsequently two "tucks" 25,26 are formed on opposite sides of the bag, in the region of the tabs 5,6,7,8. As can be seen most clearly by considering FIG. 2 and FIG. 3, the tab 6 extends from one side of the tuck across the tuck 25, and is stitched, by means of stitching 27 to the component 13 and the main component 1 on the opposite side of the tuck, such stitching being through the border region of components 13 and adjacent the edges thereof. Thus, the tab 6 has one end formed integrally with the main component 1 and has the other end stitched to the main component 1, the tab extending across the tuck 25. It can be seen that each of the tabs 5,6,7 and 8 is stitched in position in this way.
The tabs serve to retain the tucks 25,26 in position, thus limiting the total volume of the interior of the air-bag.
It is to be appreciated, however, that when the air-bag is inflated, when the air-bag reaches an inflated condition as illustrated in FIG. 2, a significant force will be applied to the tabs 5,6,7,8 and the tabs 5,6,7,8 will tear transversely, the tears being aligned with the notch 9,10,11,12 provided in the tabs. The notch is, of course, provided for this very purpose and ensures that the tab tears at a position which is substantially central between the two ends of the tab, that is to say the end formed integrally with the main component 1 and the end that is stitched to the main component 1. Thus each notch serves to define an area of less width, and thus of relative weakness, at which the tab is designed to tear. The strength of the fabric between the end of the V notch and the other side of the tab determines the force needed to make the tab tear. The amount of the fabric between the end of the V notch and the other side of the tab determines the elongation which the tab will undergo due to tearing, before the tab breaks. Different tabs may be designed to tear at different forces to control the inflation of the bag. As the tabs tear, the tucks 25,26 are released, thus increasing the maximum permissible volume of the bag. It is to be observed that the tabs 5,6,7,8 do not form any part of the bag that constitutes the boundary between the interior of the bag and the exterior of the bag. Thus, any damage effected to the tabs 5,6,7,8 does not in any way influence the integrity of the bag.
It is thus to be appreciated that by providing tear tabs of the type described above, the inflation of the air-bag may be controlled without any risk of the integrity of the air-bag being damaged.
FIG. 4 illustrated an embodiment of the invention which is very similar to that of FIGS. 1 to 3. Like reference refer to like parts which will not be re-described. In the embodiment of FIG. 4, however, a tear tab 30 is provided which is totally separate from the main components of the bag. The tear tab 30 comprises a substantially triangular shaped element of fabric, which may be a fabric completely different from the fabric forming the components 1, 13 and 14 of the air-bag. When the tear tab is located on the outside of the bag, the fabric of the tear tab 30 will not be exposed to hot gas within the interior of the air-bag, and can thus be selected purely for its physical or "tearing" properties rather than its heat-resisting properties. In the arrangement shown in FIG. 4, the tear tab 30 is provided with two rearwardly folded flaps 31,32 which are stitched to regions adjacent the edge 18 of the component 13 on opposite sides of a tuck 25. The stitching will, of course, also pass through the edge region of the main component 1 in the vicinity of the tuck. The stitching may be stitching provided solely for the purpose of holding the tab 30 in position, or may comprise the stitching 23 provided primarily to secure the main component 1 and the components 13.
The tear tab 30 is provided with a notch or recess 33 in its lower edge provided to form an initiating point for a tear. The air-bag of the embodiment of FIG. 4 will operate in the same way as the air-bag of the embodiment of FIGS. 1 to 3.
Turning now to FIGS. 5 and 6, a further embodiment of the invention is illustrated.
In this embodiment of the invention an air-bag 40 is provided having a front wall 41, a rear wall 42 interconnected by upper and lower walls 43,44 of "concertina" form (i.e., before air-bag 40 is fully inflated). Side walls 45,46 are stitched in position, the side walls also being of substantially "concertina" form.
An aperture 47 is formed in the front wall 41 to constitute an inlet for gas from a gas generator.
An element 48 is provided within the air-bag, the element 48 being formed of a flame-proof or heat-resistant material. The element 48 defines an aperture 49 which is co-aligned with the aperture 47 provided in the front wall 41. The element 48 is stitched to the front wall 41 by stitching 50 which surrounds the apertures 47,49. The portion of the element 48 surrounding the aperture 49 serves to protect the front wall 41 of the air-bag from heat and flame from the gas generator during inflation of the air-bag.
The element 48 is provided with two elements 51,52 which extend to the rear wall 42 of the bag. In order to illustrate two alternative constructions, in FIG. 6 the elements 51,52 are shown as being secured in different ways at their ends remote from front wall 41, but it will be appreciated that normally one or the other of these two ways of securing the elements will be used for both elements 51,52. In the drawing, however, the element 51 is shown as having its terminal region stitched to the rear wall 42 by stitching 53 which is the stitching which secures the side wall 46 to the rear wall 42. The element 52, however, is shown as having its terminal region stitched to the rear wall 42 by stitching 54 which serves the sole purpose of securing the end of the rearwardly extending portion 52 to the rear wall 42.
It is to be noted that the rearwardly extending element 51 defines, at a substantially central position, a transversely extending (or alternatively, a transversely extending oval aperture) 55 slit a similar slit 56 (or oval aperture) is provided in the rearwardly extending portion 52. The apertures 55' or slits which can be, for example, a notch or recess 56 serve to define a weakened area of the respective element 51,52 at which each element is designed to tear.
It can be seen that the rearwardly extending element 51 and the rearwardly extending element 52 each effectively form a tear tab, being an element which initially restricts the amount of inflation of the air-bag but which, by tearing, permits a fuller inflation of the air-bag.
It will be appreciated that whilst, for purposes of illustration, the bags shown in the drawings are shown as having the free edges of the fabric presented to the exterior, in practice it will frequently be desired to have the bags shown effectively turned inside out, so that the free edges of the fabric are concealed within, and the bag, when inflated, presents a relatively smooth exterior. In such an arrangement, of course, it may not be practicable to have the tearable elements on the exterior of the bag.
Whilst the invention has been described with reference to embodiments in which the bag is made of different components of fabric which are stitched together, it is to be appreciated that an embodiment of the invention may be constituted by a bag formed from one single element of fabric or manufactured in one weaving process. | An inflatable bag to protect a driver or passenger in a motor vehicle is provided with one or more tear elements which do not form part of the bag defining the boundary between the interior of the bag and the exterior of the bag. The tear elements initially limit the interior volume of the bag but, tear as the bag is inflated, thus increasing the permissible interior volume of the bag. | Provide a concise summary of the essential information conveyed in the given context. | [
"BACKGROUND OF THE INVENTION The present invention relates to an air-bag arrangement, and more particularly relates to an air-bag arrangement adapted to protect a driver or passenger in a motor vehicle such as a motor car.",
"It has been proposed to provide an air-bag in a motor car positioned in front of the driver or in front of a passenger of the motor car, the bag being adapted to inflate in the event that an accident arises.",
"The bag thus provides a "cushion"",
"for the driver or the passenger.",
"The design of air-bags is nor very sophisticated and the bag is adapted to be inflated before the driver or passenger moves forwardly within the motor vehicle during an accident as a result of vehicle retardation.",
"Reference may be made to EP-A-0344422 which discloses a bag in which parts of the bag are folded together to form a "tuck"",
"by stitching, the stitching forming a "tear seam".",
"The main purpose of this is to control the way that the bag is inflated.",
"Thus the "tear seam"",
"effectively controls the speed of inflation or the direction in which the bag expands during inflation so that the bag, when it is inflated, does not hit the driver or passenger with a significant force.",
"The "tear seam"",
"is designed to tear or rip, enabling the "tuck"",
"to open out at a predetermined instant during the inflation of the bag thus effectively increasing the permissible interior volume of the bag at that instant.",
"One disadvantage of the system of EP-A-0344422 is that the "tear seam"",
"comprises stitching which passes through part of the bag and which forms the boundary between the interior of the bag and the exterior of the bag.",
"When the "tear seam"",
"tears or rips, either the thread forming the stitching can break or the fabric in the region of the seam can tear.",
"It is possible that the fabric will tear along the line of the stitching, since the fabric will have been pierced by the needle when the stitches have been put in place, and the fabric may thus have been punctured or weakened in the line of the stitching.",
"However, it is also possible that the fabric adjacent the actual stitching may tear or rip.",
"In any event, it is quit possible that the fabric of the bag may become damaged.",
"If the fabric of the bag is damaged, and is apertured, the bag may deflate in an undesirable manner, and the bag will then not provide the desired cushioning effect.",
"SUMMARY OF THE INVENTION The present invention seeks to provide an improved air-bag arrangement.",
"According to this invention there is provided an inflatable bag adapted to protect a driver or passenger in a motor vehicle, wherein the bag is provided with one or more tearable means comprising at least one element provided with an area of weakness at which the element is designed to tear, the tearable means being so located that when the bag is exposed to an internal pressure in excess of a predetermined pressure, the tearable means tear and control the way the bag is inflated, the interior volume of the bag being greater when the tearable means have torn than before the tearable means have torn.",
"Thus, when the bag is inflated and the tearable means tear, the integrity of the bag is not affected, and the bag remains substantially air-tight.",
"Preferable the tearable means comprise one or more elements of fabric each provided with a notch or recess, or aperture to define said area of weakness at which tearing across the fabric can occur.",
"The tearable means may comprise fabric that is formed integrally with the fabric forming the bag or may comprise separate elements which are secured to the fabric forming the bag.",
"The fabric of the tearable means may be flame-retardant fabric.",
"Conveniently the fabric of the tearable means is secured to the fabric defining the air-bag at a position surrounding an aperture formed in the material forming the air-bag intended to provide an inlet for gas from a gas generator.",
"In one arrangement one or both ends of each tearable means is secured to the bag by a seam provided to hold areas or components of the bag together, but alternatively one or both ends of the tearable means is secured to the fabric forming the bag by a seam which serves the sole purpose of securing the tearable means to the fabric of the bag.",
"In one embodiment the or each tearable means extends across a tuck formed in the bag, but alternatively the or each tearable means extends across parts of the bag which are of "concertina"",
"form (in the uninflated state).",
"In one arrangement the or each tearable means is on the exterior of the bag, but alternatively the or each tearable means is on the interior of the bag.",
"BRIEF DESCRIPTION OF THE DRAWINGS In order that the invention may be more readily understood, and so that further features thereof may be appreciated, the invention will now be described, by way of example, with reference to the accompanying drawings in which FIG. 1 is a plan view of the component "blanks"",
"used in constructing a bag in accordance with the invention, FIG. 2 is a perspective view of the bag made from the components of FIG. 1, FIG. 3 is a sectional view taken on the line III--III of FIG. 2, FIG. 4 is a perspective view with parts cut away of an alternative embodiment of the invention, FIG. 5 is a perspective view of yet another embodiment of the invention, and FIG. 6 is a view corresponding to FIG. 5 but with parts out away to illustrate the operative parts of the invention.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring initially to FIG. 1 the component parts of an air-bag are illustrated.",
"The components comprise a first or central component 1 formed of fabric or an appropriate fabric laminate, the component 1 being of elongate form and having a central region 2 which is of greater width than the widths of the ends 3, 4.",
"At positions intermediate the central region 2 and each end, the component 1 is provided with four substantially symmetrically located projecting tabs 5,6,7,8 which extend outwardly from the edges of the component, each of rectangular form and each formed integrally with the component 1.",
"Each tab is provided, in one long side thereof, with a substantially "V"-shaped notch 9,10,11,12.",
"FIG. 1 illustrates two further 13,14 each of the same form.",
"The components 13,14 may be formed of the same fabric or laminate as the component 1.",
"Each component 13,14 is of elongate form, having a length approximately half the length of the component 1.",
"Each component 13,14 has a relatively narrow end 15,16 and an opposite, wider end 21,22 and has diverging side edges 17,18,19,20 extending from a larger end 21,22 to the narrow end 15,16.",
"The components of FIG. 1 may be assembled to form an air-bag having the general configuration shown in FIG. 2. It is to be observed that the main component 1 is folded to have a substantially "U"-shaped form, to form, in the orientation illustrated, the bottom, end and top of an air-bag, and the components 13 and 14 are located in position to form the side walls of the air-bag.",
"The side edges 17,18 and the end 21 of the component 13 are aligned with one edge of the component 1 and stitched in position by means of stitching 23.",
"The component 14 is placed in position in a similar way and is retained by stitching 24.",
"At this stage of fabrication the bag has the four tabs 5,6,7 and 8 projecting outwardly.",
"Subsequently two "tucks"",
"25,26 are formed on opposite sides of the bag, in the region of the tabs 5,6,7,8.",
"As can be seen most clearly by considering FIG. 2 and FIG. 3, the tab 6 extends from one side of the tuck across the tuck 25, and is stitched, by means of stitching 27 to the component 13 and the main component 1 on the opposite side of the tuck, such stitching being through the border region of components 13 and adjacent the edges thereof.",
"Thus, the tab 6 has one end formed integrally with the main component 1 and has the other end stitched to the main component 1, the tab extending across the tuck 25.",
"It can be seen that each of the tabs 5,6,7 and 8 is stitched in position in this way.",
"The tabs serve to retain the tucks 25,26 in position, thus limiting the total volume of the interior of the air-bag.",
"It is to be appreciated, however, that when the air-bag is inflated, when the air-bag reaches an inflated condition as illustrated in FIG. 2, a significant force will be applied to the tabs 5,6,7,8 and the tabs 5,6,7,8 will tear transversely, the tears being aligned with the notch 9,10,11,12 provided in the tabs.",
"The notch is, of course, provided for this very purpose and ensures that the tab tears at a position which is substantially central between the two ends of the tab, that is to say the end formed integrally with the main component 1 and the end that is stitched to the main component 1.",
"Thus each notch serves to define an area of less width, and thus of relative weakness, at which the tab is designed to tear.",
"The strength of the fabric between the end of the V notch and the other side of the tab determines the force needed to make the tab tear.",
"The amount of the fabric between the end of the V notch and the other side of the tab determines the elongation which the tab will undergo due to tearing, before the tab breaks.",
"Different tabs may be designed to tear at different forces to control the inflation of the bag.",
"As the tabs tear, the tucks 25,26 are released, thus increasing the maximum permissible volume of the bag.",
"It is to be observed that the tabs 5,6,7,8 do not form any part of the bag that constitutes the boundary between the interior of the bag and the exterior of the bag.",
"Thus, any damage effected to the tabs 5,6,7,8 does not in any way influence the integrity of the bag.",
"It is thus to be appreciated that by providing tear tabs of the type described above, the inflation of the air-bag may be controlled without any risk of the integrity of the air-bag being damaged.",
"FIG. 4 illustrated an embodiment of the invention which is very similar to that of FIGS. 1 to 3.",
"Like reference refer to like parts which will not be re-described.",
"In the embodiment of FIG. 4, however, a tear tab 30 is provided which is totally separate from the main components of the bag.",
"The tear tab 30 comprises a substantially triangular shaped element of fabric, which may be a fabric completely different from the fabric forming the components 1, 13 and 14 of the air-bag.",
"When the tear tab is located on the outside of the bag, the fabric of the tear tab 30 will not be exposed to hot gas within the interior of the air-bag, and can thus be selected purely for its physical or "tearing"",
"properties rather than its heat-resisting properties.",
"In the arrangement shown in FIG. 4, the tear tab 30 is provided with two rearwardly folded flaps 31,32 which are stitched to regions adjacent the edge 18 of the component 13 on opposite sides of a tuck 25.",
"The stitching will, of course, also pass through the edge region of the main component 1 in the vicinity of the tuck.",
"The stitching may be stitching provided solely for the purpose of holding the tab 30 in position, or may comprise the stitching 23 provided primarily to secure the main component 1 and the components 13.",
"The tear tab 30 is provided with a notch or recess 33 in its lower edge provided to form an initiating point for a tear.",
"The air-bag of the embodiment of FIG. 4 will operate in the same way as the air-bag of the embodiment of FIGS. 1 to 3.",
"Turning now to FIGS. 5 and 6, a further embodiment of the invention is illustrated.",
"In this embodiment of the invention an air-bag 40 is provided having a front wall 41, a rear wall 42 interconnected by upper and lower walls 43,44 of "concertina"",
"form (i.e., before air-bag 40 is fully inflated).",
"Side walls 45,46 are stitched in position, the side walls also being of substantially "concertina"",
"form.",
"An aperture 47 is formed in the front wall 41 to constitute an inlet for gas from a gas generator.",
"An element 48 is provided within the air-bag, the element 48 being formed of a flame-proof or heat-resistant material.",
"The element 48 defines an aperture 49 which is co-aligned with the aperture 47 provided in the front wall 41.",
"The element 48 is stitched to the front wall 41 by stitching 50 which surrounds the apertures 47,49.",
"The portion of the element 48 surrounding the aperture 49 serves to protect the front wall 41 of the air-bag from heat and flame from the gas generator during inflation of the air-bag.",
"The element 48 is provided with two elements 51,52 which extend to the rear wall 42 of the bag.",
"In order to illustrate two alternative constructions, in FIG. 6 the elements 51,52 are shown as being secured in different ways at their ends remote from front wall 41, but it will be appreciated that normally one or the other of these two ways of securing the elements will be used for both elements 51,52.",
"In the drawing, however, the element 51 is shown as having its terminal region stitched to the rear wall 42 by stitching 53 which is the stitching which secures the side wall 46 to the rear wall 42.",
"The element 52, however, is shown as having its terminal region stitched to the rear wall 42 by stitching 54 which serves the sole purpose of securing the end of the rearwardly extending portion 52 to the rear wall 42.",
"It is to be noted that the rearwardly extending element 51 defines, at a substantially central position, a transversely extending (or alternatively, a transversely extending oval aperture) 55 slit a similar slit 56 (or oval aperture) is provided in the rearwardly extending portion 52.",
"The apertures 55'",
"or slits which can be, for example, a notch or recess 56 serve to define a weakened area of the respective element 51,52 at which each element is designed to tear.",
"It can be seen that the rearwardly extending element 51 and the rearwardly extending element 52 each effectively form a tear tab, being an element which initially restricts the amount of inflation of the air-bag but which, by tearing, permits a fuller inflation of the air-bag.",
"It will be appreciated that whilst, for purposes of illustration, the bags shown in the drawings are shown as having the free edges of the fabric presented to the exterior, in practice it will frequently be desired to have the bags shown effectively turned inside out, so that the free edges of the fabric are concealed within, and the bag, when inflated, presents a relatively smooth exterior.",
"In such an arrangement, of course, it may not be practicable to have the tearable elements on the exterior of the bag.",
"Whilst the invention has been described with reference to embodiments in which the bag is made of different components of fabric which are stitched together, it is to be appreciated that an embodiment of the invention may be constituted by a bag formed from one single element of fabric or manufactured in one weaving process."
] |
This application is a continuation of application Ser. No. 638,046 filed Jan. 7, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to soil decontamination and particularly to apparatus for and methods of removing hydrocarbon and other contaminants from contaminated soil. The decontaminated soil may then be returned to the ground from which it was removed without being a potential environmental hazard.
2. Discussion of the Prior Art
Current efforts in the environmental areas have brought fourth efforts to alleviate and clean up hazardous soil conditions that are likely to present health hazards by leaking potentially cancer causing hydrocarbons into water supplies. Hazardous conditions are caused, for example, by leaks from outdated underground storage tanks of long established gas stations. The remedial work which is typically undertaken is the removal of contaminated soil and replacement of old and rusty gasoline tanks with new tanks. The removal and storage of the contaminated soil in another location does, unfortunately, not alleviate the problem of the existence of the contaminated soil. Efforts have therefore recently been made in providing apparatus for separating hydrocarbons from the soil.
DISCUSSION OF THE INVENTION
The invention pertains particularly to improve current material handling apparatus to cope with problems associated with the removal of hydrocarbons. Soil excavations produce various gradations and types of soil. The excavated soil may be powdery and dry and include only portions of caked and contaminated soil. Or the soil may be largely moist and water laden, including in only certain volumes thereof significant amounts of hazardous contaminants. Other soil may be rocky and again may include contaminated pockets of polluted fines, the pollution including caked fines. Decontamination apparatus, consequently, needs to efficiently handle soil of various constitutions.
The invention consequently provides for a feeder system which readily permits the feed rate and route of materials to be altered to precondition the materials to be fed to the decontamination apparatus. The feeder system includes a screening operation which separates materials above a preselected size, for example one inch diameter, from the remaining bulk materials. It is intended to break up soil conclomerations which may contain large amounts of contaminants. The screened bulk of materials is routed to a feed hopper. Oversize materials are subjected to a comminution operation, such as by a horizontal shaft impeller crusher. The crushed materials may then be fed directly into the decontamination apparatus by a main feed conveyor. In the alternative, the crushed materials may be returned to the screening operation to continue the route of oversized materials until comminuted to pass through the screen mesh of preselected size.
According to the invention it is preferred to feed materials into the decontamination apparatus at a controlled rate. When crushed materials are routed from the comminution apparatus directly to the main feed conveyor, it is contemplated to feed materials from the feed hopper to the feed conveyor at a controlled rate to supplement the materials passing through the comminution apparatus. As a result, materials may be fed from the feed hopper to the main feed conveyor either intermittently or at a variable rate to supply the decontamination apparatus with materials at a substantially constant rate. The supply rate may be adjusted to compensate for amounts of contaminants or moisture contents in the materials to be contaminated.
According to a preferred embodiment of the invention materials may be discharged from the feed hopper to the main feed conveyor at a controlled rate by a secondary feed conveyor. Both the main feed conveyor and the secondary feed conveyor may be slat conveyors. A leading edge of the hopper includes a plurality of material dispersing spiked, rotating shafts to break up soil jams which might otherwise clog the hopper discharge end when the materials are moisture laden and cohesive. The main feed conveyor preferably includes a weigh cell which determines the feed rate of material into the decontamination apparatus. When the weigh cell senses a change in the feed rate away from a preferred feed rate of materials on the conveyor, the feed of materials from the feed hopper is adjusted accordingly to normalize the amount of material on the main feed conveyor. Any speed change of the secondary conveyor may be in small, incremental steps or it may be as severe as a stop and go operation. In such latter type of operation a gate is incrementally adjusted to even the material flow rate on the main feed conveyor.
The decontamination apparatus according to the preferred mode separates the hydrocarbons from the soil in a heat treatment rather than by a water treatment. In passing the soil through a stream of hot gases, the hydrocarbons become vaporized and are thereby removed from the soil. Fine dust particles which constitute a major portion of the contaminated soil have, however, also a tendency to become airborne and remain in a hot air stream carrying off the hydrocarbon vapors. The dust, also referred to as fines, needs to be removed from the air stream in a filter operation. A cyclone filter may used to precede a baghouse filter and alleviate the throughput of materials through the baghouse filter. The air stream may be cleaned by combustion in an after-burner. Such operation oxidizes hydrocarbon vapors into carbon dioxide and water vapor.
Decontamination of dust or fines may be aided in a particular, improved operation beyond an initial decontamination of the fines by the hot air stream. The hot air stream has been found to vaporize substantially the hydrocarbons carried by the dust particles in the fines. However, after separation of the fines from soil particles larger than the fines by the hot gases, the course soil remains in contact with the decontamination gases. The fines may now be recombined with the course soil, also referred to as base material, while the base material is still in a superheated state after completion of the decontamination operation. In an area of the apparatus removed from gas flow, and while the base materials are still at substantially their peak temperature, the fines are brought into contact with the base materials and are mixed therewith. The mixing results in heat transfer from the base material to the fines. The result is beneficial in that it is desired to ultimately cool the decontaminated soil to normal or ambient temperatures. Further the heated base materials reheat the fines to a temperature above the vapor point of any hydrocarbons that may still reside in the fines.
The latter process overcomes a possible source of incomplete decontamination of wet soil, hence contaminated soil which also carries originally a substantial amount of water. In such a case the initial contact of the soil with the hot gases brings about a drying action and the fines may be carried off by already cooled gases and resulting steam. In extreme cases of moisture contents in the soil, the gases may cool to a range in which vaporization of hydrocarbons is less than complete. Temperature probes may be provided to monitor product and gas temperatures and burner outputs can be increases accordingly. However, heat energy may only provided up to the limit of the burner capacity. When extremely wet soil conditions prevail, a solution is to slow the feed rate of the materials to be decontaminated.
A particular aspect of the invention addresses a mobile decontamination system combining various discussed advantage of the invention with the added advantage of mobility. Such a mobile decontamination system may combine the soil feeder system and the decontamination apparatus on a common mobile frame to increase the mobility of the apparatus with resultant economic advantages. The mobile system is advantageous in allowing the decontamination process to be relatively quickly set up at sites where contaminated soil has been located. Such site may be remotely located from an established stationary decontamination system as disclosed herein.
A stationary system with respect to which the various features are described herein does not have the size restrictions that a mobile decontamination system is subjected to. A mobile system disclosed herein may be provided with a saddle-shaped baghouse filter system which straddles a drier drum of the decontamination apparatus. Longitudinally extending auger conveyors on both sides of the drum may carry the fines from the baghouse filter to the discharge chute of drier drum to combine the decontaminated fines with the decontaminated base material at the discharge end of the drier drum. Alternatively the fines may be combined with the base material in a zone of the drum which is removed from the flow of gases.
In view of the above considerations of various aspects of the invention, it is therefore an object of the invention to provide an apparatus for decontaminating soil at an optimum rate with a decontamination apparatus having a controlled feed rate.
Another object of the invention is to decontaminate soil in a hot air stream and to recombine fines separated by the hot air stream from the base material with the base material in an operation removed from the hot air stream and while the base material is still in a superheated state above the vaporization temperature of the contaminants.
Still another object of the invention is to adapt the feeding of materials into a soil decontamination operation to the condition of the starting material and to vary the feed rate of material into the decontamination apparatus to provide for an increase of available energy per volume of contaminated soil when a correspondingly increased drying action becomes necessary before the materials are heated to a preferred decontamination temperature.
Another object of the invention is to provide an integrated contaminant separation and capture apparatus which is compact and which may be transported without substantial dismantling operations.
A further object of the invention is to reconstitute the decontaminated soil in a pre-discharge zone of the decontamination apparatus.
Various advantages and features of the invention in accordance herewith will become apparent from the further description of the invention and from the description of the described preferred embodiments thereof which may be read in reference to the appended drawings.
SUMMARY OF THE INVENTION
In accordance with the invention, apparatus for decontaminating soil includes a compound feeder system for feeding material into a soil decontamination apparatus. The feeder system includes a feed conveyor for feeding the material into the soil decontamination apparatus. The feed conveyor includes first and second provisions for loading materials onto the feed conveyor. A provision for determining the feed rate from the first feed conveyor loading provision is used to control the feed rate of the second feed conveyor loading provision.
According to a more particular aspect of the invention, a mobile soil decontamination system is mounted to a mobile frame and includes a feeder system and a decontamination apparatus fed by the feeder system. A filter system may be mounted to straddle a drier drum of the decontamination apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
The Detailed Description below will be best understood when read in reference to the accompanying drawings wherein:
FIG. 1 is a simplified schematic plan view of a soil decontamination apparatus which illustrates various features of the present invention;
FIG. 2 is a side elevation of a portable soil decontamination apparatus in accordance with the present invention;
FIG. 3 is a schematic plan view showing a particular operational setup of the apparatus in FIG. 2 in conjunction with a ferrous material removal loop and with a baghouse filter station;
FIG. 4 is a side elevation of an alternate embodiment of a portable soil decontamination apparatus showing a baghouse filter station integrated with the apparatus; and
FIG. 5 is a sectional view of the baghouse filter arrangement of the apparatus shown in FIG. 4, taken in the direction "5--5" as indicated in FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a stationary soil decontamination system designated generally by the numeral 10. In the order of material flow through the soil decontamination system 10, the system includes subsystems of apparatus which may be categorized broadly as a feed system 12, decontamination apparatus 14, air remediation apparatus 16, and soil reconditioning apparatus 18.
The feed system 12 includes a first material feed hopper 20 into which contaminated soil is first loaded. The feed hopper 20 is the charging point of the soil decontamination system 10. Typically, the feed hopper 20 includes an upper grating or "grizzly" 21 which keeps out oversized rocks and other foreign material that is not within the material handling capabilities of the soil decontamination system 10. A feed conveyor 22 transports the material from the hopper 20 in the direction of arrow 23 toward a screening plant 24. Just before being discharged from an upper end 25 of the feed conveyor 22, the material on the conveyor 22 moves into an active range of a ferrous material separation apparatus 26. In accordance with the typical operation of such a ferrous material separator, an overhead, inverted conveyor band 27 shown on upper return path moves past a magnet which is disposed above the upper end of the feed conveyor 22. Magnetically attracted materials become attracted to the magnet and stick to the underside of the adjacent conveyor band 27 which moves in the same direction as the conveyor 22. Thus, the soil and non-magnetic materials are discharged at the end 25 of the conveyor 22 onto a screen 28 of the screening plant 24, while magnetically attracted materials continue to move on the underside of the ferrous material separator to be discharged therefrom at a discharge point 29 adjacent the screening plant 24. It should be noted, however, that the presence or absence of the ferrous material separator is not essential to the broad scope of the invention, rather is one of specific advantage, in that metals may be considered environmental hazards in themselves and the removal of ferrous elements in the course of soil decontamination may be an additional element, though not a necessary element of soil decontamination. Only to a miniscule degree may the presence of rusted ferrous elements affect the inadvertent retention of contaminating hydrocarbons which are expected to be removed in accordance with the present invention.
The screen 28 of the screening plant 24 is selected to pass the maximum soil particle size of material which can be heated in the course of being processed within the decontamination apparatus 14 to above the vaporization point of hydrocarbons suspected of contaminating such soil particles. Typically, a screen grid between one and two inches may be chosen. The screening plant 24 is contemplated to be a typical vibratory screening apparatus. The soil which passes through the chosen grid size of the screen 28 advances in the direction of arrow 31 on a m in feed conveyor 32 toward the decontamination apparatus 14. A weigh cell, or weigh bridge 33, disposed in a section of the main feed conveyor 32 measures in a known manner the weight of material on the respective section of the conveyor at any one time. Thus, when coupled to the linear speed of the feed conveyor 32, the weigh bridge 33 determines the feed rate of material into the decontamination apparatus 14. The feed rate of material is a criterion for controlling the operation of the soil decontamination system 10.
Soil constituents which do not pass through the grids of the screen 28 are routed onto a crusher conveyor 35 and proceed in the direction of arrow 36 toward a comminution apparatus 38, which may be, for example a horizontal shaft impeller impact crusher, also hammermill 38. Such type of crusher is preferred in that it preferentially breaks up larger lumps of soil which may have existed because of caking of smaller soil particles, such as by the presence of moisture or contaminating hydrocarbon oils. From the crusher 38 the materials are routed via a crusher discharge conveyor 41 in the direction of arrow 42 toward the first feed conveyor 22 to be redirected for another path through the screening plant 24. It should be realized that materials may be subjected to the described crushing operation more than one time, in that as long as the materials do not fall through the grids of the screen 28, the materials will again be routed through the crusher 38.
Though the conveyor 41 is shown as discharging the materials from the crusher 38 onto the conveyor 22, it may be deemed desirable to return the comminuted materials to the first feed hopper 20. The hopper 20 serves as a material storage provision to distribute incremental charges, such as from trucks or loader buckets to a continuous feed rate. It should be realized, however, that the material fed into the first feeder hopper is itself not uniformly homogenious. The constitution of the material may vary between consecutive incremental charges. Thus, one charge may be of materials which primarily become routed toward the crusher, while a subsequent charge of the first feed hopper may consist primarily of materials that pass through the grids of the screen 28. It will be realized that the materials may then combine on the feed conveyor 22 to result in a non-uniform discharge from the screening plant 24. The screening plant 24 may, consequently, further include a second feed hopper and feed provisions for controlling the amounts of material discharged from the screening plant 24 in response to the feed rate obtained from the weigh bridge 33, as may be better understood in reference to and from the description of the apparatus shown in FIGS. 2 or 4, for example. As a crude alternative, the conveyor 41 may be directed to discharge into the first feed hopper 20 and the feed conveyor may be controlled to increase or decrease its feed rate as a result of feed rate readings obtained from the weigh bridge 33.
The main feed conveyor 32 discharges the soil material into a feed end 44 of what may generally be referred to as a drum drier 45. In the preferred embodiment described herein the drum drier 45 is of the type commonly referred to as a counterflow type apparatus. The apparatus 45 includes various features beneficial to the practice of the invention as described herein. As is typical for drum driers, the apparatus includes a drum 46 which is mounted for rotation about a longitudinal axis and includes internal flighting to lift and advance the material in a direction from the feed end 44, also referred to as intake end, to a discharge end 47 at the end opposite to the intake end 44 of the drum 46.
The designation of counterflow apparatus results from the direction in which hot gases flow within the drum 46. In a counterflow apparatus, hot gases flow against the general direction in which the material flows through the drum, such that the material intake end 44 of the drum also includes an exit port 48 of hot gases which dry and decontaminate the soil introduced into the drum 46 at the intake end 44. Material moves through the drum 46 in a well known manner driven by the axial rotation of the drum and by flighting attached to the inner wall of the drum 46. The flighting raises the material and drops it in a veil substantially at right angles to the flow of the hot gases. In the flame region modifications of the flighting prevent material from falling directly through the flame. The flighting and movement of the material through the drum 46 are substantially similar to that in known counterflow drums and proceeds similar to their operation.
To fully understand the decontamination operation is should be realized that the smallest constituents are substantially the first to dry and to rise to a temperature above the vaporization temperature of the hydrocarbons to be vaporized and thereby removed from the soil. As the soil remains in prolonged contact with hot gases, increasingly larger soil particles dry and are heated to the desired vaporization temperature of the hydrocarbons. This latter process becomes accelerated as the material travels against the flow of the hot gases toward and into a flame region 49 of the drum drier 45. The fines, the smallest particles of the soil, after having been dried and decontaminated, are found to become entrained in the stream of hot gases and are drawn off through the exit port 48 together with the exhausted hot gases. The removal of the fines which already have been decontaminated increases the contact and exposure of the remaining soil particles with the hot gases to further the decontamination process.
FIG. 1 shows a preferred embodiment of a counterflow apparatus in which a burner head 50 is displaced from a typical location at the discharge end 47 of the drum 46 to a position toward a more central location between the intake end 44 and the discharge end 47 of the drum drier 45. It should be realized that because of such displacement gas flow as initiated by the burner head 50 exist only between the burner head 50 and the exit or exhaust port 48 of the drum drier 45. Gas flow necessary to sustain the combustion process is also prevented from freely flowing within the drum in the region between the discharge end 47 and the burner head 50 by a secondary air tube 51 which extends as support structure from the discharge end 47 concentrically with the drum 46 into the drum. The secondary air tube 51 terminates at the intermediate position along the axis of the drum 46 at which the burner head 50 is disposed. Fuel lines and a primary air duct 53 are disposed and supported within the secondary air tube 51. Thus, both primary air flow supplied by a primary air blower 54 under pressure to the burner head 50 and any required amount of secondary air flow supplied through the secondary air tube remain are confined to within its conduits in the secondary air tube 51. Consequently, in the absence of other gas movement, an annular region between the secondary air tube 51 and the drum 46 becomes a region of gaseous stagnation. Thus, while the annular region is considered to have substantially no gaseous movement, the term stagnation does not take into consideration minor movement of gases or air within the region as a result of the rotation of the drum 46 during the operation of the drum drier, or as result of movement of material such as the soil within such annular region. It is understood that this action has an effect of the gases within the region. However, in relation to the stream of gases within the heating and drying region of the drum, such is substantially no movement of gases or atmosphere within the annular region.
The annular region of gaseous stagnation may, according to a particular aspect of the invention, be further divided into a first or soil combination zone or region 55 and a soil reconstitution zone or region 56. The soil combination zone 55 is disposed adjacent the burner head 50 and adjoins the flame region 49 of a heating and decontamination zone 57 of the drum drier 45. In the soil combination zone 55 the fines are recombined with the base material that has just moved through the flame region 49 and is at that time at its peak temperature. Since there is essentially no gas flow in the annular soil combination zone, the fines previously removed by the hot gas stream can be recombined with the bulk or base material of the soil without the fines or dust being carried off again by the air flow. At the same time, the recombined dust which may have cooled following the removal from the drum drier 45 experiences a heat transfer from the heated base material. This reheats the dust or fines to above the vaporization temperature of the hydrocarbons. Thus, if there are still hydrocarbons attached to the dust particles which have not yet been vaporized, the hydrocarbons will now vaporize. As an added advantage the peak temperature of the base material begins to cool. In advancing toward the discharge end 47 of the drum drier 45, the fines and the base material are intermixed with each other.
The second or soil reconstitution zone 56 may be included as an integral element of the decontamination apparatus 14. The inclusion of the second zone 56 in the annular region between the soil combination zone 55 and the discharge end 47 of the drum drier 45 necessitates the inclusion of a material passage gate 58 which restricts gaseous movement in a direction opposite to the general flow of the soil through the drum drier 45. Typically the material is advanced through the drum drier 45 by well known flighting 59 extending the length of the drum 46. Though the flighting is modified so as not to interfere with the flame, the flighting generally advances the material by lifting and dropping the material, or by urging it, somewhat supported by an angle of incline of the drum 46 in the direction of movement. Generally, however, the flighting supports free material movement within the drum. The construction of the gate 58 differs from that of the typical flighting. The gate may be constructed by scoop type material advancing vanes 61 mounted in an annular region directly adjacent the inner wall of the drum 46, and an annular baffle plate 62 which is stationary and may be mounted to the secondary air tube 51, for example. The baffle plate 62 would substantially seal off substantially the entire annular space between the secondary air tube 51 and the inner surface of the drum 46 except for a lowermost open sector thereof, through which the vanes 61 would advance the soil from the soil combination zone 55 to the soil reconstitution zone 56. However, the soil material passing through the open sector constitutes in itself a blockage to gaseous flow through the open sector.
A liquid supply 65 provides a liquid such as water or other approved and non-contaminating emulsions for introduction into the soil reconstitution zone 56. A conduit 66 for introduction of such liquid communicates between the supply 65 and the zone 56. One or more axially spaced openings 67 in the conduit 66 introduce the liquid into the annular space of the zone 56 and direct the liquid into contact with the soil before it is discharged from the drum. Contact of the liquid with the hot and dry soil generates excessive amounts of steam. Steam generation in turn cools the soil toward temperatures at which water will no longer vaporize, such that ultimately a certain amount of moisture may be retained in the soil before it is discharged from the drum.
Excess steam generated within the soil reconstitution zone 56 is drawn from the drum 46 at a discharge collar 68 through a steam duct 69 by a turbo blower 71 and routed to a final filter house 72 as indicated by arrow 73. From the final filter house, which may be a typical baghouse filter, the steam together with other exhaust and cooling gases as will become apparent may be discharged to the atmosphere through an exhaust stack 74. The final filter 72 is the main gas filter of the decontamination system 10, the exhaust of which is expected to be within allowable limits when being exhausted through the stack 74. Dust laden and hydrocarbon rich hot gases exiting from the exhaust port 48 of the drum drier 45 are consequently drawn by an intake of a turbo blower 76 from an exhaust box 77 through an exhaust conduit 78 into a cyclone separator 79, for example. The cyclone dust separator 79 may be used to provide a first stage of dust reduction. Fine soil particles collected in the separator 79 are returned to the soil combination zone 55 via a conduit 81 and a material feed collar 82 similar to known feed collars for feeding recycle materials at intermediate axial drum positions into aggregate drying drums, for example. The gases with at least some of the fines removed by the separator 79 advance through conduit 83 toward the turbo blower 76 and are forced into an afterburner 85. The afterburner 85 burns the hydrocarbon gases to reduce them to environmentally acceptable carbon dioxide and water vapor. However, the gases exiting the afterburner 85 through an exit duct 86 are too hot to be routed without cooling to the baghouse filter 72. The turbo blower 71 has, consequently, a further function of providing through an intake port 87 outside air to mix with the exhausted gases from the afterburner 85 before they are introduced into the filter 72.
Baffles 88 and 89 are adjustable. Thus, a portion of the gases discharged from the afterburner 85 may be routed in the direction of arrow 91 to mix with cooling air and steam from the turbo blower 71 and be routed through the filter 72 to the stack 74. However, another portion of the hot exhaust from the afterburner may on momentary demand be routed in the direction of arrow 92 through duct 93 to be returned to the secondary air supply of the burner 50. It is to be realized, however, that such routing is a pressure equalization routing and for other short term demands, in that ultimately all gases introduced into the decontamination system 10 are discharged through the stack 74 after passing through the final filter 72. Typically, secondary air may be supplied under pressure by turbo blower 94.
Dust collected in the final filter 72 is routed via a return conduit 95 to the material feed collar 82 and is introduced into the soil combination zone 55 to be recombined with the base material of the decontaminated soil as described above. The recombined decontaminated soil which may also have been reconstituted as described herein is subsequently discharged at the discharge end 47 into a discharge chute 96 and carried by a convenient transport system, such as a discharge conveyor 97 to a convenient storage or transfer bin 98. From there the decontaminated soil may be loaded onto transport vehicles and be transferred to ground fill sites as required.
FIG. 2 is a side elevation of a preferred portable soil decontamination apparatus which is designated generally by the numeral 100. The soil decontamination apparatus 100 is shown as being mounted on a truck frame 101 including a front saddle 102, allowing the frame to be hitched to a truck tractor and hence be pulled as a semi-trailer between job sites. The frame 101 is shown as being supported by jacks 103 steadying the apparatus 100 for operation. The apparatus 100 comprises a soil feed system 110 and a decontamination drum drier 112.
It should be understood that a number of changes and variations or substitutions are possible in the selection and physical characteristics of the drum drier 112 without departing from the spirit and scope of the present invention. It is, for example, possible to mount the drum drier 45 as described with respect to FIG. 1 as a portable or mobile drum drier on a frame such as the frame 101 in substitution of the drum drier 112. Often, drum driers are mounted on frames for convenience, even if later use is expected to be from a fixed location, such as a larger aggregate production facility. The drum drier 112 is in essence considered to be the equivalent of the drum drier 45 described with respect to FIG. 1. Changes and modifications within the scope and spirit of the invention are further described. It should be noted that the frame 101 has a bend which positions the drum drier 112 at an incline with respect to the feed system 110. This is an advantage in the contemplated operation of the apparatus 100, in that time savings may be derived in setting the apparatus up for operation at a new location, in that the incline of the drum drier corresponds to a normal operational angle of a drum 114 in which gravity is used to aid the flow of material from an intake end 115 to a discharge end 116 of the drum 114. As the drum drier 45, the drum drier 112 is a preferred counterflow apparatus, such that a burner unit 117 extends from the discharge end 116 into the drum 114, and hot exhaust gases exit through an exhaust box 118 disposed at the material intake end 115 of the drum 114. For the apparatus 100 to become operational, the exhaust box 118 needs to become coupled to exhaust treatment apparatus substantially similar to the apparatus described in detail with respect to FIG. 1 and including a final filter similar to the baghouse filter 72 shown in FIG. 1. Collected fines and dust from the filter are returned from the filter to be recombined with the remaining base material having passed through the drum drier 112 to become decontaminated of hydrocarbons. It should be understood that this may be accomplished via an intermediate material feed port, such as the feed port 82 described with respect to the drum drier 45. A significant criterion, however, is that the fines be returned to a stagnant zone of the the drier, as previously described. FIG. 2 shows an alternative dust return structure 119 for previously separated fines. The fines may be returned to the structure 119 either by pneumatic transport ducting or by alternative screw conveyors. Both of these equivalents are indicated by a duct termination 121. From the duct termination 121 the fines are advanced by gravity through a chute 122 into a discharge box 123 of the drum drier 112. The discharge box 123 is disposed in all instances out of the stream of gases generated within the drum 114 by the burner 117 or any turbo blower associated therewith, such as the turbo blower 125 mounted on the saddle 102. As is typical for drums of drum driers, the drum 114 is equipped with discharge paddles at the discharge end 116 which urge the material from the discharge end of the drum 114 into the discharge box 123. The agitation of the paddles (not shown) may be used to mix the fines with the discharging base material, while both the fines and the base material are being urged by the paddles to a discharge chute 126 at a lower end of the discharge box.
Exhaust temperature of the hot gases being exhausted from the drum drier is of concern. When the material being fed into the drum contains considerable amounts of moisture, the temperature of exhaust gases may drop to a point at which water vapor condenses in the baghouse filter, caking the dust and fines on filter elements and thereby necessitating a temporary shutdown of the apparatus. FIG. 2 shows a veil modification apparatus comprising adjustable plates 127 by which the exposure of material to the hot gases can be altered, such that the temperature of the exhaust gases may be instantaneously raised by an adjustment above the condensation temperature of water to avoid a filter clogging condition. The structure and operation of the veil modification apparatus is disclosed in detail in a copending patent application by Don R. Linkletter and Joseph E. Musil, Ser. No. 529,136, filed on May 25, 1990, now U.S. Pat. No. 5,067,254 which is assigned to the assignee of the present application.
The soil feed system 110 includes features of the feed system 12 described in reference to FIG. 1. A grizzly 131 is disposed above a vibrating screen 132 to remove oversize materials. Materials which fail to pass through the selected grids of the vibrating screen 132 are discharged into a comminution apparatus, such as a hammermill 133. Soil which passes through the screen 132 falls into a feed hopper 134 disposed directly below the screen 132.
A main feed conveyor 135 extends the entire length below the feed hopper 132 from the hammermill 133 to the intake end 115 of the drum drier 112. A short feeder conveyor 136 extends below the hammermill between a forward discharge end 137 and a rear discharge end 138. The feeder conveyor is operable in either direction to discharge toward the forward or rear ends 137 or 138. When operated toward the forward discharge end 137, materials having passed through the hammermill 133 are deposited on the main feed conveyor and are advanced to be fed into the drum 114. The feeder conveyor 136 consequently is a first provision for loading materials onto the main feed conveyor 135 to charge materials into the drum drier 112. A hopper conveyor 140 is a second provision for loading materials onto the main feed conveyor 135.
As described with respect to the feed system 12 of FIG. 1, the amount of soil passing through the comminution apparatus, such as the hammermill 133 is variable and cannot be accurately estimated beforehand. It is, however, important to control the rate at which the material is introduced into the drum drier 112. Consequently, a weigh cell 142 is placed into the main feed conveyor 135 to determine at any given moment the feed rate of material into the drum drier 112. The feed rate of the hopper conveyor 140 is coupled to the weigh cell 142 in a control box 145 of the apparatus 100. The control box may include may respond to moisture contents and other decontamination parameters to establish an optimum feed rate for the main feed conveyor 135. In the alternative, an operator may pre-establish an optimum feed rate for observed soil conditions of soil before it is loaded onto the feed system 110. If an increased amount of soil passes through the hammermill 133 and is loaded onto the main feeder conveyor 135, such increase in output from the hammermill is measured by the weigh cell 142 and the hopper feed conveyor 140 is correspondingly slowed down to compensate for the increased output from the hammermill. A lag in response because of the downstream location of the weigh cell 142 may require a damping or averaging circuit in responding to variations in the feed rate of the main feed conveyor 135. A problem of feeding wet and clay type soil constituents from the feed hopper may be experienced because of materials sticking together and clogging the operation of the feed hopper conveyor 140. These problems may be alleviated by the operation of spiked rotating shafts 146 which are disposed at the front discharge end of the feed hopper 134. A plate (not shown) may be placed against the inward facing extremes of the stacked shafts 146 when extremely dry soil of primarily granular consistency is being treated by the apparatus 100. Also, a control gate 147 may be placed above the main feed conveyor 135 adjacent and ahead of the weigh cell 142 to control and even the flow of material across the weigh cell and into the drum drier 112.
A particular setup of the apparatus 100 in which the exhaust box 118 is connected to a final filter is shown in FIG. 3. In particular, the exhaust box 118 is coupled through a duct 151 to a turbo blower 152 which pushes the exhaust gases into a baghouse filter 153. After passing through the baghouse filter 153 the gases may be exhausted into the environment via exhaust stack 154. Fines removed from the gases in the baghouse filter 154 are ducted through a conduit 156 into the discharge box 123 of the drum drier 112. FIG. 2 further shows a conveyor 157 having a charging hopper disposed below the rear end 138 of the conveyor 136. An upper end 159 of the conveyor 157 conveniently includes a ferrous material separator 161. A return conveyor is disposed to direct the crushed materials back onto the screen 132, from where the materials enter ultimately the feed hopper 134. Thus, when the crusher conveyor 136 is operated to discharge crushed materials onto the conveyor 157 to be returned by the conveyor 162 directly to the feed system 110, there remains only a single load provision for charging the main feed conveyor 135. As a result, the control of the feed rate of the main feed conveyor 135 becomes more accurate and more readily executable.
FIG. 4 is a side elevation of a soil decontamination apparatus designated generally by the numeral 180, which is an alternate embodiment of the invention. The soil decontamination apparatus 180 shows particular features which enhances the compactness and portability of the apparatus and, hence, has cost advantages in performing the decontamination operation in remote areas. As is the apparatus 100, the apparatus 180 is mounted on a single frame 181 which allows the apparatus to be transported as a semi-trailer. A soil feed system 185 is somewhat modified with respect to the feed system 110. In particular, the comminution apparatus or, as preferred, the hammermill 133 is mounted ahead of a feed hopper 186 of the feed system 185. As in the described feed system 110, the discharge of oversized soil particles from the screen 132 is directly guided into the hammermill 133. Crushed materials from the hammermill 133 are, however, discharged directly onto a main feed conveyor 187 which also includes a weigh cell or weigh bridge 188. A control gate 189 disposed in the direction of travel of the the main feed conveyor 187 may be incrementally adjusted to control and smoothen the feed rate of material into the respective drum drier 112. The main feed conveyor 187 may be operated at a preset constant speed, the weigh cell 188 measuring the feed rate of the conveyor 187 on a real time basis. In such a mode the feed rate of a feed hopper conveyor 191 may be varied in response to a variation from a predetermined material feed rate of the main feed conveyor 187 as determined by the weigh cell 188. In another mode of operation, the speed of the main feed conveyor 187 may be varied to compensate instantaneously to variations in the feed rate determined by the weigh cell 188. In this latter mode the speed of the feed hopper conveyor 191 may also be varied in response to control signals from the control box 145 of the apparatus 180. In either of the two above modes of operation the control gate may not be needed to smoothen the amounts of material on the main feed conveyor 187. A third mode of operation contemplates the use of the control gate 189 to control the material flow rate on the main feed conveyor 187. In such a mode and with the control gate set at a predetermined height above the conveyor 187, the speed of the conveyor may be varied to directly control the feed rate of the conveyor into the drum drier 112. In this latter mode it is contemplated to operate the feed hopper conveyor 191 in a stop and go mode. In such a mode the primary feed onto the conveyor occurs from feed through the crusher 133. When a decrease in the desired feed rate is detected of less than the preset minimum feed rate and the speed of the main feed conveyor can no longer be increased to increase the feed rate of the conveyor 187, at that time the conveyor 191 is activated and feeds material onto the main feed conveyor until the main feed conveyor again is in control of the feed rate into the drum drier 112.
The apparatus 180 in FIG. 4 also shows a baghouse filter 195 which straddles the drum drier 112. Hot gases are directly discharged at the material intake end 115 of the drum drier 112 into an exhaust header section 196 of the filter 195. Screw conveyors 197 disposed coaxially with the drum drier 112 on both sides thereof are coupled into the discharge box 123 of the drum drier 112 to discharge the collected fines directly into the discharge box to combine with the decontaminated base material of the soil. An exhaust fan 198 is coupled to an exhaust manifold 199 of the filter 195 and draws the exhaust from the drum drier 112 through the filter. An exhaust duct 201 coupled to the turbo output from the fan 198 may be coupled to an afterburner 202 mounted directly onto the frame 181. Exhaust may then be released after a final treatment in the afterburner 202.
FIG. 5 shows the baghouse filter 195 in section, showing particularly an upper exhaust collection chamber 205 which is coupled to the input of the exhaust fan 198. At base extensions 206 on both sides of the drum drier 112, the screw conveyors 197 are disposed within a lowermost trough to collect the filtered dust in an effective manner for direct transfer to the base material at the discharge box 123 as heretofore described. Sloped walls 207 of the inner surface of the filter house 195 guide the collected fines from the filter bags like funnels toward the screw conveyors 197.
Various changes and modifications in the structure of the described embodiment are possible without departing from the spirit and scope of the invention as defined by the terms of the claims appended hereto and reasonable equivalents thereof. | A soil decontamination apparatus is based on a heating operation performed on soil to be contaminated to vaporize and burn off hydrocarbons. The soil is fed into a drum drier at a constant rate which is related to the moisture contents in the soil and the energy available from the burner of the drum drier. Soil particles in the form of dust which become entrained in the hot gases which are used in the decontamination process are removed from the gas stream and are recombined with the base material of the soil in a region of the drum drier which is substantially devoid of gas flow. The substantially calm atmosphere in the region of the drum drier in which the recombination takes place permits the fines to be mixed with the base material without the fines again being carried off by gaseous movement. A soil reconditioning is provided for in an isolated third zone of the drum drier. | Provide a concise summary of the essential information conveyed in the given context. | [
"This application is a continuation of application Ser.",
"No. 638,046 filed Jan. 7, 1991, now abandoned.",
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates generally to soil decontamination and particularly to apparatus for and methods of removing hydrocarbon and other contaminants from contaminated soil.",
"The decontaminated soil may then be returned to the ground from which it was removed without being a potential environmental hazard.",
"Discussion of the Prior Art Current efforts in the environmental areas have brought fourth efforts to alleviate and clean up hazardous soil conditions that are likely to present health hazards by leaking potentially cancer causing hydrocarbons into water supplies.",
"Hazardous conditions are caused, for example, by leaks from outdated underground storage tanks of long established gas stations.",
"The remedial work which is typically undertaken is the removal of contaminated soil and replacement of old and rusty gasoline tanks with new tanks.",
"The removal and storage of the contaminated soil in another location does, unfortunately, not alleviate the problem of the existence of the contaminated soil.",
"Efforts have therefore recently been made in providing apparatus for separating hydrocarbons from the soil.",
"DISCUSSION OF THE INVENTION The invention pertains particularly to improve current material handling apparatus to cope with problems associated with the removal of hydrocarbons.",
"Soil excavations produce various gradations and types of soil.",
"The excavated soil may be powdery and dry and include only portions of caked and contaminated soil.",
"Or the soil may be largely moist and water laden, including in only certain volumes thereof significant amounts of hazardous contaminants.",
"Other soil may be rocky and again may include contaminated pockets of polluted fines, the pollution including caked fines.",
"Decontamination apparatus, consequently, needs to efficiently handle soil of various constitutions.",
"The invention consequently provides for a feeder system which readily permits the feed rate and route of materials to be altered to precondition the materials to be fed to the decontamination apparatus.",
"The feeder system includes a screening operation which separates materials above a preselected size, for example one inch diameter, from the remaining bulk materials.",
"It is intended to break up soil conclomerations which may contain large amounts of contaminants.",
"The screened bulk of materials is routed to a feed hopper.",
"Oversize materials are subjected to a comminution operation, such as by a horizontal shaft impeller crusher.",
"The crushed materials may then be fed directly into the decontamination apparatus by a main feed conveyor.",
"In the alternative, the crushed materials may be returned to the screening operation to continue the route of oversized materials until comminuted to pass through the screen mesh of preselected size.",
"According to the invention it is preferred to feed materials into the decontamination apparatus at a controlled rate.",
"When crushed materials are routed from the comminution apparatus directly to the main feed conveyor, it is contemplated to feed materials from the feed hopper to the feed conveyor at a controlled rate to supplement the materials passing through the comminution apparatus.",
"As a result, materials may be fed from the feed hopper to the main feed conveyor either intermittently or at a variable rate to supply the decontamination apparatus with materials at a substantially constant rate.",
"The supply rate may be adjusted to compensate for amounts of contaminants or moisture contents in the materials to be contaminated.",
"According to a preferred embodiment of the invention materials may be discharged from the feed hopper to the main feed conveyor at a controlled rate by a secondary feed conveyor.",
"Both the main feed conveyor and the secondary feed conveyor may be slat conveyors.",
"A leading edge of the hopper includes a plurality of material dispersing spiked, rotating shafts to break up soil jams which might otherwise clog the hopper discharge end when the materials are moisture laden and cohesive.",
"The main feed conveyor preferably includes a weigh cell which determines the feed rate of material into the decontamination apparatus.",
"When the weigh cell senses a change in the feed rate away from a preferred feed rate of materials on the conveyor, the feed of materials from the feed hopper is adjusted accordingly to normalize the amount of material on the main feed conveyor.",
"Any speed change of the secondary conveyor may be in small, incremental steps or it may be as severe as a stop and go operation.",
"In such latter type of operation a gate is incrementally adjusted to even the material flow rate on the main feed conveyor.",
"The decontamination apparatus according to the preferred mode separates the hydrocarbons from the soil in a heat treatment rather than by a water treatment.",
"In passing the soil through a stream of hot gases, the hydrocarbons become vaporized and are thereby removed from the soil.",
"Fine dust particles which constitute a major portion of the contaminated soil have, however, also a tendency to become airborne and remain in a hot air stream carrying off the hydrocarbon vapors.",
"The dust, also referred to as fines, needs to be removed from the air stream in a filter operation.",
"A cyclone filter may used to precede a baghouse filter and alleviate the throughput of materials through the baghouse filter.",
"The air stream may be cleaned by combustion in an after-burner.",
"Such operation oxidizes hydrocarbon vapors into carbon dioxide and water vapor.",
"Decontamination of dust or fines may be aided in a particular, improved operation beyond an initial decontamination of the fines by the hot air stream.",
"The hot air stream has been found to vaporize substantially the hydrocarbons carried by the dust particles in the fines.",
"However, after separation of the fines from soil particles larger than the fines by the hot gases, the course soil remains in contact with the decontamination gases.",
"The fines may now be recombined with the course soil, also referred to as base material, while the base material is still in a superheated state after completion of the decontamination operation.",
"In an area of the apparatus removed from gas flow, and while the base materials are still at substantially their peak temperature, the fines are brought into contact with the base materials and are mixed therewith.",
"The mixing results in heat transfer from the base material to the fines.",
"The result is beneficial in that it is desired to ultimately cool the decontaminated soil to normal or ambient temperatures.",
"Further the heated base materials reheat the fines to a temperature above the vapor point of any hydrocarbons that may still reside in the fines.",
"The latter process overcomes a possible source of incomplete decontamination of wet soil, hence contaminated soil which also carries originally a substantial amount of water.",
"In such a case the initial contact of the soil with the hot gases brings about a drying action and the fines may be carried off by already cooled gases and resulting steam.",
"In extreme cases of moisture contents in the soil, the gases may cool to a range in which vaporization of hydrocarbons is less than complete.",
"Temperature probes may be provided to monitor product and gas temperatures and burner outputs can be increases accordingly.",
"However, heat energy may only provided up to the limit of the burner capacity.",
"When extremely wet soil conditions prevail, a solution is to slow the feed rate of the materials to be decontaminated.",
"A particular aspect of the invention addresses a mobile decontamination system combining various discussed advantage of the invention with the added advantage of mobility.",
"Such a mobile decontamination system may combine the soil feeder system and the decontamination apparatus on a common mobile frame to increase the mobility of the apparatus with resultant economic advantages.",
"The mobile system is advantageous in allowing the decontamination process to be relatively quickly set up at sites where contaminated soil has been located.",
"Such site may be remotely located from an established stationary decontamination system as disclosed herein.",
"A stationary system with respect to which the various features are described herein does not have the size restrictions that a mobile decontamination system is subjected to.",
"A mobile system disclosed herein may be provided with a saddle-shaped baghouse filter system which straddles a drier drum of the decontamination apparatus.",
"Longitudinally extending auger conveyors on both sides of the drum may carry the fines from the baghouse filter to the discharge chute of drier drum to combine the decontaminated fines with the decontaminated base material at the discharge end of the drier drum.",
"Alternatively the fines may be combined with the base material in a zone of the drum which is removed from the flow of gases.",
"In view of the above considerations of various aspects of the invention, it is therefore an object of the invention to provide an apparatus for decontaminating soil at an optimum rate with a decontamination apparatus having a controlled feed rate.",
"Another object of the invention is to decontaminate soil in a hot air stream and to recombine fines separated by the hot air stream from the base material with the base material in an operation removed from the hot air stream and while the base material is still in a superheated state above the vaporization temperature of the contaminants.",
"Still another object of the invention is to adapt the feeding of materials into a soil decontamination operation to the condition of the starting material and to vary the feed rate of material into the decontamination apparatus to provide for an increase of available energy per volume of contaminated soil when a correspondingly increased drying action becomes necessary before the materials are heated to a preferred decontamination temperature.",
"Another object of the invention is to provide an integrated contaminant separation and capture apparatus which is compact and which may be transported without substantial dismantling operations.",
"A further object of the invention is to reconstitute the decontaminated soil in a pre-discharge zone of the decontamination apparatus.",
"Various advantages and features of the invention in accordance herewith will become apparent from the further description of the invention and from the description of the described preferred embodiments thereof which may be read in reference to the appended drawings.",
"SUMMARY OF THE INVENTION In accordance with the invention, apparatus for decontaminating soil includes a compound feeder system for feeding material into a soil decontamination apparatus.",
"The feeder system includes a feed conveyor for feeding the material into the soil decontamination apparatus.",
"The feed conveyor includes first and second provisions for loading materials onto the feed conveyor.",
"A provision for determining the feed rate from the first feed conveyor loading provision is used to control the feed rate of the second feed conveyor loading provision.",
"According to a more particular aspect of the invention, a mobile soil decontamination system is mounted to a mobile frame and includes a feeder system and a decontamination apparatus fed by the feeder system.",
"A filter system may be mounted to straddle a drier drum of the decontamination apparatus.",
"BRIEF DESCRIPTION OF THE DRAWINGS The Detailed Description below will be best understood when read in reference to the accompanying drawings wherein: FIG. 1 is a simplified schematic plan view of a soil decontamination apparatus which illustrates various features of the present invention;",
"FIG. 2 is a side elevation of a portable soil decontamination apparatus in accordance with the present invention;",
"FIG. 3 is a schematic plan view showing a particular operational setup of the apparatus in FIG. 2 in conjunction with a ferrous material removal loop and with a baghouse filter station;",
"FIG. 4 is a side elevation of an alternate embodiment of a portable soil decontamination apparatus showing a baghouse filter station integrated with the apparatus;",
"and FIG. 5 is a sectional view of the baghouse filter arrangement of the apparatus shown in FIG. 4, taken in the direction "5--5"",
"as indicated in FIG. 4. DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a stationary soil decontamination system designated generally by the numeral 10.",
"In the order of material flow through the soil decontamination system 10, the system includes subsystems of apparatus which may be categorized broadly as a feed system 12, decontamination apparatus 14, air remediation apparatus 16, and soil reconditioning apparatus 18.",
"The feed system 12 includes a first material feed hopper 20 into which contaminated soil is first loaded.",
"The feed hopper 20 is the charging point of the soil decontamination system 10.",
"Typically, the feed hopper 20 includes an upper grating or "grizzly"",
"21 which keeps out oversized rocks and other foreign material that is not within the material handling capabilities of the soil decontamination system 10.",
"A feed conveyor 22 transports the material from the hopper 20 in the direction of arrow 23 toward a screening plant 24.",
"Just before being discharged from an upper end 25 of the feed conveyor 22, the material on the conveyor 22 moves into an active range of a ferrous material separation apparatus 26.",
"In accordance with the typical operation of such a ferrous material separator, an overhead, inverted conveyor band 27 shown on upper return path moves past a magnet which is disposed above the upper end of the feed conveyor 22.",
"Magnetically attracted materials become attracted to the magnet and stick to the underside of the adjacent conveyor band 27 which moves in the same direction as the conveyor 22.",
"Thus, the soil and non-magnetic materials are discharged at the end 25 of the conveyor 22 onto a screen 28 of the screening plant 24, while magnetically attracted materials continue to move on the underside of the ferrous material separator to be discharged therefrom at a discharge point 29 adjacent the screening plant 24.",
"It should be noted, however, that the presence or absence of the ferrous material separator is not essential to the broad scope of the invention, rather is one of specific advantage, in that metals may be considered environmental hazards in themselves and the removal of ferrous elements in the course of soil decontamination may be an additional element, though not a necessary element of soil decontamination.",
"Only to a miniscule degree may the presence of rusted ferrous elements affect the inadvertent retention of contaminating hydrocarbons which are expected to be removed in accordance with the present invention.",
"The screen 28 of the screening plant 24 is selected to pass the maximum soil particle size of material which can be heated in the course of being processed within the decontamination apparatus 14 to above the vaporization point of hydrocarbons suspected of contaminating such soil particles.",
"Typically, a screen grid between one and two inches may be chosen.",
"The screening plant 24 is contemplated to be a typical vibratory screening apparatus.",
"The soil which passes through the chosen grid size of the screen 28 advances in the direction of arrow 31 on a m in feed conveyor 32 toward the decontamination apparatus 14.",
"A weigh cell, or weigh bridge 33, disposed in a section of the main feed conveyor 32 measures in a known manner the weight of material on the respective section of the conveyor at any one time.",
"Thus, when coupled to the linear speed of the feed conveyor 32, the weigh bridge 33 determines the feed rate of material into the decontamination apparatus 14.",
"The feed rate of material is a criterion for controlling the operation of the soil decontamination system 10.",
"Soil constituents which do not pass through the grids of the screen 28 are routed onto a crusher conveyor 35 and proceed in the direction of arrow 36 toward a comminution apparatus 38, which may be, for example a horizontal shaft impeller impact crusher, also hammermill 38.",
"Such type of crusher is preferred in that it preferentially breaks up larger lumps of soil which may have existed because of caking of smaller soil particles, such as by the presence of moisture or contaminating hydrocarbon oils.",
"From the crusher 38 the materials are routed via a crusher discharge conveyor 41 in the direction of arrow 42 toward the first feed conveyor 22 to be redirected for another path through the screening plant 24.",
"It should be realized that materials may be subjected to the described crushing operation more than one time, in that as long as the materials do not fall through the grids of the screen 28, the materials will again be routed through the crusher 38.",
"Though the conveyor 41 is shown as discharging the materials from the crusher 38 onto the conveyor 22, it may be deemed desirable to return the comminuted materials to the first feed hopper 20.",
"The hopper 20 serves as a material storage provision to distribute incremental charges, such as from trucks or loader buckets to a continuous feed rate.",
"It should be realized, however, that the material fed into the first feeder hopper is itself not uniformly homogenious.",
"The constitution of the material may vary between consecutive incremental charges.",
"Thus, one charge may be of materials which primarily become routed toward the crusher, while a subsequent charge of the first feed hopper may consist primarily of materials that pass through the grids of the screen 28.",
"It will be realized that the materials may then combine on the feed conveyor 22 to result in a non-uniform discharge from the screening plant 24.",
"The screening plant 24 may, consequently, further include a second feed hopper and feed provisions for controlling the amounts of material discharged from the screening plant 24 in response to the feed rate obtained from the weigh bridge 33, as may be better understood in reference to and from the description of the apparatus shown in FIGS. 2 or 4, for example.",
"As a crude alternative, the conveyor 41 may be directed to discharge into the first feed hopper 20 and the feed conveyor may be controlled to increase or decrease its feed rate as a result of feed rate readings obtained from the weigh bridge 33.",
"The main feed conveyor 32 discharges the soil material into a feed end 44 of what may generally be referred to as a drum drier 45.",
"In the preferred embodiment described herein the drum drier 45 is of the type commonly referred to as a counterflow type apparatus.",
"The apparatus 45 includes various features beneficial to the practice of the invention as described herein.",
"As is typical for drum driers, the apparatus includes a drum 46 which is mounted for rotation about a longitudinal axis and includes internal flighting to lift and advance the material in a direction from the feed end 44, also referred to as intake end, to a discharge end 47 at the end opposite to the intake end 44 of the drum 46.",
"The designation of counterflow apparatus results from the direction in which hot gases flow within the drum 46.",
"In a counterflow apparatus, hot gases flow against the general direction in which the material flows through the drum, such that the material intake end 44 of the drum also includes an exit port 48 of hot gases which dry and decontaminate the soil introduced into the drum 46 at the intake end 44.",
"Material moves through the drum 46 in a well known manner driven by the axial rotation of the drum and by flighting attached to the inner wall of the drum 46.",
"The flighting raises the material and drops it in a veil substantially at right angles to the flow of the hot gases.",
"In the flame region modifications of the flighting prevent material from falling directly through the flame.",
"The flighting and movement of the material through the drum 46 are substantially similar to that in known counterflow drums and proceeds similar to their operation.",
"To fully understand the decontamination operation is should be realized that the smallest constituents are substantially the first to dry and to rise to a temperature above the vaporization temperature of the hydrocarbons to be vaporized and thereby removed from the soil.",
"As the soil remains in prolonged contact with hot gases, increasingly larger soil particles dry and are heated to the desired vaporization temperature of the hydrocarbons.",
"This latter process becomes accelerated as the material travels against the flow of the hot gases toward and into a flame region 49 of the drum drier 45.",
"The fines, the smallest particles of the soil, after having been dried and decontaminated, are found to become entrained in the stream of hot gases and are drawn off through the exit port 48 together with the exhausted hot gases.",
"The removal of the fines which already have been decontaminated increases the contact and exposure of the remaining soil particles with the hot gases to further the decontamination process.",
"FIG. 1 shows a preferred embodiment of a counterflow apparatus in which a burner head 50 is displaced from a typical location at the discharge end 47 of the drum 46 to a position toward a more central location between the intake end 44 and the discharge end 47 of the drum drier 45.",
"It should be realized that because of such displacement gas flow as initiated by the burner head 50 exist only between the burner head 50 and the exit or exhaust port 48 of the drum drier 45.",
"Gas flow necessary to sustain the combustion process is also prevented from freely flowing within the drum in the region between the discharge end 47 and the burner head 50 by a secondary air tube 51 which extends as support structure from the discharge end 47 concentrically with the drum 46 into the drum.",
"The secondary air tube 51 terminates at the intermediate position along the axis of the drum 46 at which the burner head 50 is disposed.",
"Fuel lines and a primary air duct 53 are disposed and supported within the secondary air tube 51.",
"Thus, both primary air flow supplied by a primary air blower 54 under pressure to the burner head 50 and any required amount of secondary air flow supplied through the secondary air tube remain are confined to within its conduits in the secondary air tube 51.",
"Consequently, in the absence of other gas movement, an annular region between the secondary air tube 51 and the drum 46 becomes a region of gaseous stagnation.",
"Thus, while the annular region is considered to have substantially no gaseous movement, the term stagnation does not take into consideration minor movement of gases or air within the region as a result of the rotation of the drum 46 during the operation of the drum drier, or as result of movement of material such as the soil within such annular region.",
"It is understood that this action has an effect of the gases within the region.",
"However, in relation to the stream of gases within the heating and drying region of the drum, such is substantially no movement of gases or atmosphere within the annular region.",
"The annular region of gaseous stagnation may, according to a particular aspect of the invention, be further divided into a first or soil combination zone or region 55 and a soil reconstitution zone or region 56.",
"The soil combination zone 55 is disposed adjacent the burner head 50 and adjoins the flame region 49 of a heating and decontamination zone 57 of the drum drier 45.",
"In the soil combination zone 55 the fines are recombined with the base material that has just moved through the flame region 49 and is at that time at its peak temperature.",
"Since there is essentially no gas flow in the annular soil combination zone, the fines previously removed by the hot gas stream can be recombined with the bulk or base material of the soil without the fines or dust being carried off again by the air flow.",
"At the same time, the recombined dust which may have cooled following the removal from the drum drier 45 experiences a heat transfer from the heated base material.",
"This reheats the dust or fines to above the vaporization temperature of the hydrocarbons.",
"Thus, if there are still hydrocarbons attached to the dust particles which have not yet been vaporized, the hydrocarbons will now vaporize.",
"As an added advantage the peak temperature of the base material begins to cool.",
"In advancing toward the discharge end 47 of the drum drier 45, the fines and the base material are intermixed with each other.",
"The second or soil reconstitution zone 56 may be included as an integral element of the decontamination apparatus 14.",
"The inclusion of the second zone 56 in the annular region between the soil combination zone 55 and the discharge end 47 of the drum drier 45 necessitates the inclusion of a material passage gate 58 which restricts gaseous movement in a direction opposite to the general flow of the soil through the drum drier 45.",
"Typically the material is advanced through the drum drier 45 by well known flighting 59 extending the length of the drum 46.",
"Though the flighting is modified so as not to interfere with the flame, the flighting generally advances the material by lifting and dropping the material, or by urging it, somewhat supported by an angle of incline of the drum 46 in the direction of movement.",
"Generally, however, the flighting supports free material movement within the drum.",
"The construction of the gate 58 differs from that of the typical flighting.",
"The gate may be constructed by scoop type material advancing vanes 61 mounted in an annular region directly adjacent the inner wall of the drum 46, and an annular baffle plate 62 which is stationary and may be mounted to the secondary air tube 51, for example.",
"The baffle plate 62 would substantially seal off substantially the entire annular space between the secondary air tube 51 and the inner surface of the drum 46 except for a lowermost open sector thereof, through which the vanes 61 would advance the soil from the soil combination zone 55 to the soil reconstitution zone 56.",
"However, the soil material passing through the open sector constitutes in itself a blockage to gaseous flow through the open sector.",
"A liquid supply 65 provides a liquid such as water or other approved and non-contaminating emulsions for introduction into the soil reconstitution zone 56.",
"A conduit 66 for introduction of such liquid communicates between the supply 65 and the zone 56.",
"One or more axially spaced openings 67 in the conduit 66 introduce the liquid into the annular space of the zone 56 and direct the liquid into contact with the soil before it is discharged from the drum.",
"Contact of the liquid with the hot and dry soil generates excessive amounts of steam.",
"Steam generation in turn cools the soil toward temperatures at which water will no longer vaporize, such that ultimately a certain amount of moisture may be retained in the soil before it is discharged from the drum.",
"Excess steam generated within the soil reconstitution zone 56 is drawn from the drum 46 at a discharge collar 68 through a steam duct 69 by a turbo blower 71 and routed to a final filter house 72 as indicated by arrow 73.",
"From the final filter house, which may be a typical baghouse filter, the steam together with other exhaust and cooling gases as will become apparent may be discharged to the atmosphere through an exhaust stack 74.",
"The final filter 72 is the main gas filter of the decontamination system 10, the exhaust of which is expected to be within allowable limits when being exhausted through the stack 74.",
"Dust laden and hydrocarbon rich hot gases exiting from the exhaust port 48 of the drum drier 45 are consequently drawn by an intake of a turbo blower 76 from an exhaust box 77 through an exhaust conduit 78 into a cyclone separator 79, for example.",
"The cyclone dust separator 79 may be used to provide a first stage of dust reduction.",
"Fine soil particles collected in the separator 79 are returned to the soil combination zone 55 via a conduit 81 and a material feed collar 82 similar to known feed collars for feeding recycle materials at intermediate axial drum positions into aggregate drying drums, for example.",
"The gases with at least some of the fines removed by the separator 79 advance through conduit 83 toward the turbo blower 76 and are forced into an afterburner 85.",
"The afterburner 85 burns the hydrocarbon gases to reduce them to environmentally acceptable carbon dioxide and water vapor.",
"However, the gases exiting the afterburner 85 through an exit duct 86 are too hot to be routed without cooling to the baghouse filter 72.",
"The turbo blower 71 has, consequently, a further function of providing through an intake port 87 outside air to mix with the exhausted gases from the afterburner 85 before they are introduced into the filter 72.",
"Baffles 88 and 89 are adjustable.",
"Thus, a portion of the gases discharged from the afterburner 85 may be routed in the direction of arrow 91 to mix with cooling air and steam from the turbo blower 71 and be routed through the filter 72 to the stack 74.",
"However, another portion of the hot exhaust from the afterburner may on momentary demand be routed in the direction of arrow 92 through duct 93 to be returned to the secondary air supply of the burner 50.",
"It is to be realized, however, that such routing is a pressure equalization routing and for other short term demands, in that ultimately all gases introduced into the decontamination system 10 are discharged through the stack 74 after passing through the final filter 72.",
"Typically, secondary air may be supplied under pressure by turbo blower 94.",
"Dust collected in the final filter 72 is routed via a return conduit 95 to the material feed collar 82 and is introduced into the soil combination zone 55 to be recombined with the base material of the decontaminated soil as described above.",
"The recombined decontaminated soil which may also have been reconstituted as described herein is subsequently discharged at the discharge end 47 into a discharge chute 96 and carried by a convenient transport system, such as a discharge conveyor 97 to a convenient storage or transfer bin 98.",
"From there the decontaminated soil may be loaded onto transport vehicles and be transferred to ground fill sites as required.",
"FIG. 2 is a side elevation of a preferred portable soil decontamination apparatus which is designated generally by the numeral 100.",
"The soil decontamination apparatus 100 is shown as being mounted on a truck frame 101 including a front saddle 102, allowing the frame to be hitched to a truck tractor and hence be pulled as a semi-trailer between job sites.",
"The frame 101 is shown as being supported by jacks 103 steadying the apparatus 100 for operation.",
"The apparatus 100 comprises a soil feed system 110 and a decontamination drum drier 112.",
"It should be understood that a number of changes and variations or substitutions are possible in the selection and physical characteristics of the drum drier 112 without departing from the spirit and scope of the present invention.",
"It is, for example, possible to mount the drum drier 45 as described with respect to FIG. 1 as a portable or mobile drum drier on a frame such as the frame 101 in substitution of the drum drier 112.",
"Often, drum driers are mounted on frames for convenience, even if later use is expected to be from a fixed location, such as a larger aggregate production facility.",
"The drum drier 112 is in essence considered to be the equivalent of the drum drier 45 described with respect to FIG. 1. Changes and modifications within the scope and spirit of the invention are further described.",
"It should be noted that the frame 101 has a bend which positions the drum drier 112 at an incline with respect to the feed system 110.",
"This is an advantage in the contemplated operation of the apparatus 100, in that time savings may be derived in setting the apparatus up for operation at a new location, in that the incline of the drum drier corresponds to a normal operational angle of a drum 114 in which gravity is used to aid the flow of material from an intake end 115 to a discharge end 116 of the drum 114.",
"As the drum drier 45, the drum drier 112 is a preferred counterflow apparatus, such that a burner unit 117 extends from the discharge end 116 into the drum 114, and hot exhaust gases exit through an exhaust box 118 disposed at the material intake end 115 of the drum 114.",
"For the apparatus 100 to become operational, the exhaust box 118 needs to become coupled to exhaust treatment apparatus substantially similar to the apparatus described in detail with respect to FIG. 1 and including a final filter similar to the baghouse filter 72 shown in FIG. 1. Collected fines and dust from the filter are returned from the filter to be recombined with the remaining base material having passed through the drum drier 112 to become decontaminated of hydrocarbons.",
"It should be understood that this may be accomplished via an intermediate material feed port, such as the feed port 82 described with respect to the drum drier 45.",
"A significant criterion, however, is that the fines be returned to a stagnant zone of the the drier, as previously described.",
"FIG. 2 shows an alternative dust return structure 119 for previously separated fines.",
"The fines may be returned to the structure 119 either by pneumatic transport ducting or by alternative screw conveyors.",
"Both of these equivalents are indicated by a duct termination 121.",
"From the duct termination 121 the fines are advanced by gravity through a chute 122 into a discharge box 123 of the drum drier 112.",
"The discharge box 123 is disposed in all instances out of the stream of gases generated within the drum 114 by the burner 117 or any turbo blower associated therewith, such as the turbo blower 125 mounted on the saddle 102.",
"As is typical for drums of drum driers, the drum 114 is equipped with discharge paddles at the discharge end 116 which urge the material from the discharge end of the drum 114 into the discharge box 123.",
"The agitation of the paddles (not shown) may be used to mix the fines with the discharging base material, while both the fines and the base material are being urged by the paddles to a discharge chute 126 at a lower end of the discharge box.",
"Exhaust temperature of the hot gases being exhausted from the drum drier is of concern.",
"When the material being fed into the drum contains considerable amounts of moisture, the temperature of exhaust gases may drop to a point at which water vapor condenses in the baghouse filter, caking the dust and fines on filter elements and thereby necessitating a temporary shutdown of the apparatus.",
"FIG. 2 shows a veil modification apparatus comprising adjustable plates 127 by which the exposure of material to the hot gases can be altered, such that the temperature of the exhaust gases may be instantaneously raised by an adjustment above the condensation temperature of water to avoid a filter clogging condition.",
"The structure and operation of the veil modification apparatus is disclosed in detail in a copending patent application by Don R. Linkletter and Joseph E. Musil, Ser.",
"No. 529,136, filed on May 25, 1990, now U.S. Pat. No. 5,067,254 which is assigned to the assignee of the present application.",
"The soil feed system 110 includes features of the feed system 12 described in reference to FIG. 1. A grizzly 131 is disposed above a vibrating screen 132 to remove oversize materials.",
"Materials which fail to pass through the selected grids of the vibrating screen 132 are discharged into a comminution apparatus, such as a hammermill 133.",
"Soil which passes through the screen 132 falls into a feed hopper 134 disposed directly below the screen 132.",
"A main feed conveyor 135 extends the entire length below the feed hopper 132 from the hammermill 133 to the intake end 115 of the drum drier 112.",
"A short feeder conveyor 136 extends below the hammermill between a forward discharge end 137 and a rear discharge end 138.",
"The feeder conveyor is operable in either direction to discharge toward the forward or rear ends 137 or 138.",
"When operated toward the forward discharge end 137, materials having passed through the hammermill 133 are deposited on the main feed conveyor and are advanced to be fed into the drum 114.",
"The feeder conveyor 136 consequently is a first provision for loading materials onto the main feed conveyor 135 to charge materials into the drum drier 112.",
"A hopper conveyor 140 is a second provision for loading materials onto the main feed conveyor 135.",
"As described with respect to the feed system 12 of FIG. 1, the amount of soil passing through the comminution apparatus, such as the hammermill 133 is variable and cannot be accurately estimated beforehand.",
"It is, however, important to control the rate at which the material is introduced into the drum drier 112.",
"Consequently, a weigh cell 142 is placed into the main feed conveyor 135 to determine at any given moment the feed rate of material into the drum drier 112.",
"The feed rate of the hopper conveyor 140 is coupled to the weigh cell 142 in a control box 145 of the apparatus 100.",
"The control box may include may respond to moisture contents and other decontamination parameters to establish an optimum feed rate for the main feed conveyor 135.",
"In the alternative, an operator may pre-establish an optimum feed rate for observed soil conditions of soil before it is loaded onto the feed system 110.",
"If an increased amount of soil passes through the hammermill 133 and is loaded onto the main feeder conveyor 135, such increase in output from the hammermill is measured by the weigh cell 142 and the hopper feed conveyor 140 is correspondingly slowed down to compensate for the increased output from the hammermill.",
"A lag in response because of the downstream location of the weigh cell 142 may require a damping or averaging circuit in responding to variations in the feed rate of the main feed conveyor 135.",
"A problem of feeding wet and clay type soil constituents from the feed hopper may be experienced because of materials sticking together and clogging the operation of the feed hopper conveyor 140.",
"These problems may be alleviated by the operation of spiked rotating shafts 146 which are disposed at the front discharge end of the feed hopper 134.",
"A plate (not shown) may be placed against the inward facing extremes of the stacked shafts 146 when extremely dry soil of primarily granular consistency is being treated by the apparatus 100.",
"Also, a control gate 147 may be placed above the main feed conveyor 135 adjacent and ahead of the weigh cell 142 to control and even the flow of material across the weigh cell and into the drum drier 112.",
"A particular setup of the apparatus 100 in which the exhaust box 118 is connected to a final filter is shown in FIG. 3. In particular, the exhaust box 118 is coupled through a duct 151 to a turbo blower 152 which pushes the exhaust gases into a baghouse filter 153.",
"After passing through the baghouse filter 153 the gases may be exhausted into the environment via exhaust stack 154.",
"Fines removed from the gases in the baghouse filter 154 are ducted through a conduit 156 into the discharge box 123 of the drum drier 112.",
"FIG. 2 further shows a conveyor 157 having a charging hopper disposed below the rear end 138 of the conveyor 136.",
"An upper end 159 of the conveyor 157 conveniently includes a ferrous material separator 161.",
"A return conveyor is disposed to direct the crushed materials back onto the screen 132, from where the materials enter ultimately the feed hopper 134.",
"Thus, when the crusher conveyor 136 is operated to discharge crushed materials onto the conveyor 157 to be returned by the conveyor 162 directly to the feed system 110, there remains only a single load provision for charging the main feed conveyor 135.",
"As a result, the control of the feed rate of the main feed conveyor 135 becomes more accurate and more readily executable.",
"FIG. 4 is a side elevation of a soil decontamination apparatus designated generally by the numeral 180, which is an alternate embodiment of the invention.",
"The soil decontamination apparatus 180 shows particular features which enhances the compactness and portability of the apparatus and, hence, has cost advantages in performing the decontamination operation in remote areas.",
"As is the apparatus 100, the apparatus 180 is mounted on a single frame 181 which allows the apparatus to be transported as a semi-trailer.",
"A soil feed system 185 is somewhat modified with respect to the feed system 110.",
"In particular, the comminution apparatus or, as preferred, the hammermill 133 is mounted ahead of a feed hopper 186 of the feed system 185.",
"As in the described feed system 110, the discharge of oversized soil particles from the screen 132 is directly guided into the hammermill 133.",
"Crushed materials from the hammermill 133 are, however, discharged directly onto a main feed conveyor 187 which also includes a weigh cell or weigh bridge 188.",
"A control gate 189 disposed in the direction of travel of the the main feed conveyor 187 may be incrementally adjusted to control and smoothen the feed rate of material into the respective drum drier 112.",
"The main feed conveyor 187 may be operated at a preset constant speed, the weigh cell 188 measuring the feed rate of the conveyor 187 on a real time basis.",
"In such a mode the feed rate of a feed hopper conveyor 191 may be varied in response to a variation from a predetermined material feed rate of the main feed conveyor 187 as determined by the weigh cell 188.",
"In another mode of operation, the speed of the main feed conveyor 187 may be varied to compensate instantaneously to variations in the feed rate determined by the weigh cell 188.",
"In this latter mode the speed of the feed hopper conveyor 191 may also be varied in response to control signals from the control box 145 of the apparatus 180.",
"In either of the two above modes of operation the control gate may not be needed to smoothen the amounts of material on the main feed conveyor 187.",
"A third mode of operation contemplates the use of the control gate 189 to control the material flow rate on the main feed conveyor 187.",
"In such a mode and with the control gate set at a predetermined height above the conveyor 187, the speed of the conveyor may be varied to directly control the feed rate of the conveyor into the drum drier 112.",
"In this latter mode it is contemplated to operate the feed hopper conveyor 191 in a stop and go mode.",
"In such a mode the primary feed onto the conveyor occurs from feed through the crusher 133.",
"When a decrease in the desired feed rate is detected of less than the preset minimum feed rate and the speed of the main feed conveyor can no longer be increased to increase the feed rate of the conveyor 187, at that time the conveyor 191 is activated and feeds material onto the main feed conveyor until the main feed conveyor again is in control of the feed rate into the drum drier 112.",
"The apparatus 180 in FIG. 4 also shows a baghouse filter 195 which straddles the drum drier 112.",
"Hot gases are directly discharged at the material intake end 115 of the drum drier 112 into an exhaust header section 196 of the filter 195.",
"Screw conveyors 197 disposed coaxially with the drum drier 112 on both sides thereof are coupled into the discharge box 123 of the drum drier 112 to discharge the collected fines directly into the discharge box to combine with the decontaminated base material of the soil.",
"An exhaust fan 198 is coupled to an exhaust manifold 199 of the filter 195 and draws the exhaust from the drum drier 112 through the filter.",
"An exhaust duct 201 coupled to the turbo output from the fan 198 may be coupled to an afterburner 202 mounted directly onto the frame 181.",
"Exhaust may then be released after a final treatment in the afterburner 202.",
"FIG. 5 shows the baghouse filter 195 in section, showing particularly an upper exhaust collection chamber 205 which is coupled to the input of the exhaust fan 198.",
"At base extensions 206 on both sides of the drum drier 112, the screw conveyors 197 are disposed within a lowermost trough to collect the filtered dust in an effective manner for direct transfer to the base material at the discharge box 123 as heretofore described.",
"Sloped walls 207 of the inner surface of the filter house 195 guide the collected fines from the filter bags like funnels toward the screw conveyors 197.",
"Various changes and modifications in the structure of the described embodiment are possible without departing from the spirit and scope of the invention as defined by the terms of the claims appended hereto and reasonable equivalents thereof."
] |
This application is a divisional of U.S. Ser. No. 07/888,916, filed May 26, 1992, now abandoned.
The present invention relates to concrete molding machines, and more particularly, to a portable concrete molding machine for mass producing vertically oriented concrete panels having any of a variety of dimensions.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,534,924 discloses a battery mold for molding concrete slabs. The battery mold may include manifold means in fluid communication with the bottom of each cavity formed between adjacent plates, for introducing concrete into each cavity.
U.S. Pat. No. 3,881,856 discloses a plant for the fabrication of parallel molded construction elements. The plant includes a plurality of form panels movable along a pair of support rails. The form panels are provided with vibrator devices and heating conduits. A latching assembly provides for the coupling and uncoupling of adjacent panels. Once the panels are in the desired position, the concrete is poured into the mold.
U.S. Pat. No. 3,844,524 discloses a concrete molding machine wherein concrete is admitted to the open top of a plurality of cavities formed between vertically supported panels. The panels include a hot liquid piping system for decreasing the setting time of the concrete.
U.S. Pat. No. 3,804,361 discloses a plant for manufacturing reinforced concrete construction panels. The plant includes electrically heated forms having a major surface which may be disposed perpendicular to planar vertical partition members to form a mold therebetween. Upon formation of the mold, the concrete is poured into the mold from the upper end of the mold.
While the devices of the prior art provide for mass production of concrete structures, a need exits for the formation of concrete structures having differing dimensions, wherein the structures may be formed in heated cavities either on site, or at a central manufacturing facility. In addition, the need exists for minimizing the size and number of air pockets at the interface of the mold and the concrete in the mold.
SUMMARY OF THE INVENTION
The present invention provides a mobile concrete molding apparatus for forming concrete panels of varying dimensions. Preferably, the molding apparatus is affixed to a trailer bed, so that concrete panels may be formed either on site, or at central manufacturing facilities.
The present invention includes a furnace plenum partially bounded by a pair of fixed walls, such that the fixed walls are thermally coupled to the furnace plenum. A movable wall is cooperatively associated with each fixed wall. Each movable wall includes a planar surface extending parallel to the corresponding fixed wall, and is movable in a direction normal to the corresponding fixed wall.
Preferably, each movable wall includes a concrete inlet for introducing concrete into the lower portion of the mold, such that the concrete substantially fills the mold from the bottom. That is, at least a portion of the concrete introduced through the concrete inlet acts against a pressure head of concrete in the mold. By pumping the concrete into the bottom of the mold, the number and size of the trapped air pockets at the interface of the mold surface and the concrete is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention connected to a concrete supply;
FIG. 2 is a cross sectional view taken along lines 2--2 of FIG. 1;
FIG. 3 is a cross sectional view taken along lines 3--3 of FIG. 1;
FIG. 4 is a cross sectional view taken along lines 4--4 of FIG. 1;
FIG. 5 is a side elevational view of the present invention;
FIG. 6 is a localized perspective view showing a push-off valve in relation to a wall of the mold;
FIG. 7 is a localized perspective showing an actuated push-off valve spaced apart from the surrounding mold wall;
FIG. 8 is an exploded perspective of the valve mechanism in a first open position;
FIG. 9 is an exploded perspective of the valve mechanism showing closed, venting position;
FIG. 10 is a partial cross sectional view taken along lines 10--10 of FIG. 2;
FIG. 11 is a partial cross sectional view taken along lines 11--11 of FIG. 10;
FIG. 12 is a top plan view showing a lower lock assembly; and
FIG. 13 is a partial cross sectional view taken along lines 13--13 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the variable wall molding apparatus 10 includes a trailer 12 having a furnace plenum 40, first and second fixed walls 60,80, and first and second movable walls 120,160.
As shown in FIGS. 1, 2 and 4, the fixed wall 60 and the movable wall 120 are shown in an open position, while the fixed wall 80 and the movable wall 160 are shown in a casting position. Referring to FIGS. 1 and 2, a concrete supply 8 is shown connected to the movable wall 120. As the movable wall 120 is not in a casting position, there is no concrete in the line connecting the concrete supply 8 to the molding apparatus 10.
Trailer
The trailer 12 cooperatively engages a truck tractor (not shown) to permit ready transport of the molding apparatus 10.
As shown in FIG. 2, the trailer 12 includes a pair of parallel I-beams 14,16 extending the length of the trailer. A plurality of transverse channels 18 are affixed to the underside of the I-beams 14,16, and extend perpendicular to the length of the trailer 12. Each channel 18 includes a depending leveler 20 at each end of the channel. The depending leveler 20 selectively displaces the end of the channel 18 relative to the ground to ensure a level orientation of the apparatus 10.
A pair of transverse beams 21,22 is slidably received within each channel 18. Each beam 21,22 includes an inner and outer set of rollers 24,26 for slidably moving the beams 21,22 within the channel 18.
Referring to FIG. 2, the top of the I-beams 14,16 are interconnected by upper panel 28 and the bottom of the I-beams are interconnected by a lower panel 29 to enclose the space between I-beams 14,16 thereby defining a return manifold 30. Each I-beam 14,16 includes a plurality of return ports 31. As shown in FIG. 3, the return ports 31 extend along the length of the return manifold 30.
Fixed Walls
Referring to FIG. 2, the fixed walls 60,80 are attached to the outside of the return manifold 30 to define a substantial portion of the furnace plenum 40. The fixed walls 60,80 are vertically oriented and extend upward from opposite sides of the return manifold 30. Each fixed wall 60,80 includes mold side 61,81 and plenum side 63,83. The mold sides 61,81 form planar vertical surfaces for forming a concrete panel. Preferably, each of the fixed walls 60,80 defines a vertically oriented molding surface having an overall height of approximately 10 feet and a length of approximately 30 feet.
Referring to FIGS. 1, 2 and 4, the fixed walls 60,80 and the movable walls 120,160 are symmetrically oriented about the longitudinal axis of the molding apparatus 10. The fixed walls 60,80 are identical to each other in structure and operation. Similarly, the movable walls 120,160 are identical to each other in structure and operation. Therefore, for purposes of clarity of the disclosure, only the fixed wall 60 and the movable wall 120 will be described in detail. The remaining fixed wall 80 and the movable wall 160 may be taken as having similar structure and function as the corresponding fixed wall 60 and the movable wall 120.
As shown in FIGS. 2 and 4, the fixed wall 60 is formed by a skin plate 62 and a plurality of Z-members 64. The skin plate 62 is 0.25 inch steel, and defines the molding surface against which a portion of the concrete panel is cast. Referring to FIG. 4, the Z-members 64 are vertically oriented and evenly aligned to define channels 65 between the adjacent Z-members. As shown in FIG. 2, the Z-members 64 have a first end welded to a plenum side 63 of the skin plate 62. The lower portion of the second end of the Z-members 64 is affixed to the I-beam 14 such that the channels 65 between adjacent Z-members 64 are in fluid communication with the return ports 31, and hence the return manifold 30.
Referring to FIGS. 1, 2, and 13 the top of the skin plate 62 forms a screeding edge 66. The screeding edge 66 provides a level and accurate surface perpendicular to the plane of the skin plate 62.
Returning to FIG. 2, a core frame 34 is formed between the fixed walls 60,80 above the return manifold 30. The core frame 34 interconnects the Z-members of the fixed walls 60,80. The top of the core frame 34 and top of the Z-members of the fixed walls 60,80 cooperate with an upper deck 36 to enclose the top of the furnace plenum 40. The plenum side of the deck 36 includes insulation 38 such as polyurethane to retain thermal energy within the furnace plenum 40.
The furnace plenum 40 includes substantially the entire area of the skin plate of each fixed wall 60,80. Therefore, approximately one-half of the surface area of the mold is in direct thermal contact with the furnace plenum 40.
Furnace Units
As shown in FIGS. 1 and 3-5, a pair of furnace units 44 are disposed on the trailer 12 such that one furnace unit is fluidly connected to each end of the furnace plenum 40 and the return manifold 30. The remaining area of each end of the furnace plenum 40 is sealed to enclose the furnace plenum. Each furnace unit 44 includes a 60 kilowatt air duct heater such as TDH 60C as Manufactured by Chromalox of Pennsylvania, and a blower having a capacity of approximately 6000 cubic feet per minute. To enhance thermal efficiency, the furnace units 44 and connecting duct work outside of the furnace plenum 40 are encapsulated with insulation.
Referring to FIGS. 2, 3 and 4, a fluid path is defined from the furnace units 44 into the furnace plenum 40, through the channels 65,85 formed by the Z-members 64,84 and the respective skin plate 62,82 of each fixed wall 60,80, through the return ports 31, and the return manifold 30 to the furnace units 44.
Movable Walls
As previously stated, each movable wall 120,160 is identical in terms of relevant structure and function. Therefore, only movable wall 120 will be discussed in detail.
Referring to FIGS. 1, 2, 4 and 10, the movable wall 120 is similar to the fixed walls 60,80 and is formed of a skin plate 122 and Z-members 124. The skin plate 122 is formed of 0.25 inch steel. The first end of each Z-member 124 is welded to the outside of the skin plate 122 so as to retain the skin plate in a substantially planar, vertical orientation. The second end of each Z-member 124 is connected to an adjacent Z-member 124 by framing to provide structural rigidity. Similar to the fixed walls 60 and 80, the Z-members in the movable wall 120 form channels between adjacent Z-members. As shown in FIGS. 2 and 4, the channels in the movable wall 120 are at least partially filled with insulation 125, such as polyurethane.
Referring to FIGS. 2 and 13, the top of the skin plate 122 forms a screeding edge 126 for cooperating with the screeding edge 66 of the fixed wall 60 for leveling the top of the concrete in the mold. FIG. 11 discloses a detail of the top of fixed wall 80 and movable wall 160 showing corresponding screeding edges 86,166.
As shown in FIGS. 1, 2 and 5, the bottom of the movable wall 120 is affixed to a plurality of the transverse beams 21, intermediate of the ends of the beams. Similarly, the bottom of the movable wall 160 is affixed to a plurality of transverse beams 22.
The movable wall 120 is mounted on the transverse beams 21 above the outer set of rollers 26. Struts 130 extend from the outer end of the transverse beams 21 to engage the upper portion of the movable wall 120. The movable wall 120 is thereby fixedly retained relative to the transverse beams 21. Each movable wall 120,160 includes a walkway 132 for accessing the respective screeding edges 66, 126 and 86, 166 and the top of the mold. The movable walls are mounted on the transverse beams to be movable between a first position adjacent the corresponding fixed wall for forming the mold, and a second position approximately 29 inches from the corresponding fixed wall.
Referring to FIG. 5, the bottom of each movable wall 120,160 includes a plurality of depending pads 134. The pads 134 are located intermediate of the transverse channels 18 and depend directly below the movable wall.
Referring to FIGS. 3-5, a plurality of machine screw actuators 136 are coupled between the depending pads 134 and the trailer 12. The machine screw actuators 136 are Model 9010 machine screw actuators manufactured by the Duff-Norton Company of Charlotte, N.C. The actuators 136 are commonly controlled, as well known in the art, to provide simultaneous activation and maintain the parallel orientation of the movable wall and the fixed wall as the movable wall is disposed between the first and the second position.
Referring to FIGS. 1, 2, 3 and 5, the top of each fixed wall 60,80 and corresponding movable wall 120,160 includes a plurality of cooperating upper locks 140 for selectively precluding motion of the walls when in the casting position. The upper locks 140 for each fixed and movable wall pair, includes a capture block 142 on one wall and an adjustable loop 144 on the remaining wall. The adjustable loop 144 permits the upper lock 140 to lock the walls at a variety of distances.
As shown in FIG. 12, the apparatus 10 also includes lower locks 150 for securing the relative position of a pair of fixed and movable walls when in the casting position. Each lower lock 150 includes a U-shaped bracket 152 and adjusting bolt 154 threaded through the closed end of the bracket 152. The outer ends of each transverse channel 18 include a pair of opposing recesses or apertures 19 for cooperatively engaging the open ends of the bracket 152. To lock a transverse beam 21 or 22 with respect to the corresponding channel 18, the open ends of the bracket 152 are engaged with the apertures 19 in the channel 18. The adjusting bolt is threaded until it contacts the outer end of the transverse beam, thereby precluding motion of the movable wall away from the corresponding fixed wall.
As shown in FIGS. 1, 2 and 5, vibrators 158 are attached to the movable walls 120,160 along upper and lower rows. The vibrators are external impact vibrators such as AR 06/460 vibrators manufactured by the Wacker Corporation of Menomnee Fall, Wis. The vibrators 158 consolidate and compact the concrete in the mold to reduce the number and size of the trapped air pockets at the interface of the mold and the concrete. In addition, the vibrators 158 enhance the flow of concrete within the mold during the casting process.
As shown in FIGS. 4 and 5, each of the fixed and movable walls include a plurality of push-off valves 180. Referring to FIGS. 6 and 7, the push-off valves 180 include air actuated poppets 182. In the default position, the poppets 182 are coplanar with the surrounding portion of the skin plate, or mold surface, such that the local area of the poppet and the skin plate define a planar surface. Actuation of the push-off valve 180 disposes the poppet 182 intermediate of the movable wall and fixed wall, that is, within the mold so as to push against a molded concrete structure such as a panel, thereby separating the molded concrete structure from the mold wall.
Concrete Inlets
Referring to FIGS. 1, 2, 5, 10 and 11, each movable wall 120,160 includes a concrete inlet 200 in the lower portion of the wall. As the concrete inlet 200 in each movable wall 120,160 is identical in structure and function, a single concrete inlet will be described in detail.
The concrete inlet 200 includes a tapered transition orifice 202 between the concrete supply line and the mold, such that the larger diameter of the orifice 202 terminates at the mold wall. The transition orifice 202 flares from a diameter of five inches to terminate in the plane of the skin plate at a diameter of seven inches.
Flow through the concrete inlet 200 is controlled by a valve mechanism 210. The valve mechanism 210 controls introduction of concrete into the mold defined between the fixed and movable walls.
Referring to FIGS. 8 and 9, the valve mechanism 210 includes an inlet housing 212 and an outlet housing 214. The inlet housing 212 includes an inlet aperture 213, and the outlet housing 214 includes an outlet aperture 215, wherein the inlet and outlet apertures are of equal size. The inlet and outlet housings 212,214 are separated by lateral spacers 216.
A cutoff blade 218 is slidably disposed between the inlet and outlet housings 212,214 and intermediate of the lateral spacers 216. The cutoff blade 218 includes a central aperture 219 having a size equal to the inlet and outlet apertures 213,215. The cutoff blade 218 also includes vent channels 221 extending from the edge of the blade to terminate within a circumference equal to the circumference of the inlet aperture 213. The terminal ends of the vent channels 221 are spaced from the central aperture 219 by a distance greater than the diameter of the inlet aperture 213.
The cutoff blade 218 is movable relative to the inlet and outlet housings 212, 214, to assume three operative positions. In the first position, the central aperture 219 aligns with the inlet and outlet apertures 213,215 to permit a flow of concrete through the valve mechanism 210. In the second position, the cutoff blade 218 is oriented to preclude fluid communication between the inlet and outlet apertures 213,215. In the third position fluid communication between the inlet and outlet apertures 213,215 is precluded, while the inlet aperture 213 is fluidly connected to atmospheric pressure through the vent channels 221. A hydraulic mechanism 224 is used to move the cutoff blade 218 relative to the housings.
Preferably, the concrete inlets 200 are located such that during filling of the mold, at least a portion of the concrete introduced through the concrete inlet into the mold acts against a pressure head of concrete already in the mold.
Although the concrete inlet 200 may be located at any vertical position in the mold, the concrete inlet is preferably located at the midpoint of the mold, or lower.
While the concrete inlets 200 are shown in the lower portions of the moveable walls 120,160, the concrete inlets may be located in the lower portion of the fixed walls 60,80, bulkheads in the ends of the mold, or the bottom of the mold. Alternatively, the concrete inlets 200 may be entirely eliminated, wherein the concrete is poured into the top of the mold, and the introduced concrete does not act against a pressure head of concrete in the mold.
In the preferred embodiment, the horizontal actuators 136, and the vibrators 158 are selectively actuated through control panels 230 associated with each movable wall. The control panels 230 reduce the number of workers, and safely locate the operator during formation of the concrete panels.
Referring to FIGS. 1, 10 and 11, the molding apparatus 10 may include a divider 260 vertically oriented in the mold. The divider 260 substantially separates the mold into two distinct compartments. The divider 260 is oriented to bisect the length of the mold and bisect the concrete inlet 200. Referring to FIG. 11, the divider 260 is positioned to define an inlet slot 262. The inlet slot 262 extends beyond the diameter of the transition orifice 202. Preferably, the divider 260 cooperates with a lower portion 264 extending across the width of the mold, below the inlet slot 262. Referring to FIG. 10, the divider 260 has a tapered cross section. That is, the divider 260 is narrowest adjacent the movable wall and widest adjacent the fixed wall, wherein the divider flares from a width of approximately 13/16" to a width of approximately 1".
Operation
The present invention provides for the mass production of reinforced vertical concrete panels. The concrete panels may have any length and height which is less than the length and height of the fixed and movable walls. The thickness of the concrete panel is determined by the maximum separation of the movable wall from the fixed wall, such that the maximum separation of the mold walls includes the thickness of the concrete panel and a release space for separating the concrete structure from the mold. The panels may also be formed to include window or door apertures and conduits for electrical and environmental services.
As shown in FIGS. 1, 2 and 4, bulk heads 240, 240a and bottom gauge 242 are disposed relative to the fixed walls 60,80 to define the desired thickness, length and height of the concrete structure to be formed. The bulk heads 240, 240a and bottom gauge 242 space the movable wall from the fixed wall and determine the height, width and length of the structure to be formed when the walls are in the molding position. In addition, the bulk heads 240b (not shown) may be disposed at any location within the mold to define windows, doors or other desired openings in the final product. The surfaces of the mold are treated to enhance subsequent separation of the cured concrete and the mold, as well known in the art. A reinforcing bar frame (not shown) is disposed between the inner and outer walls.
The horizontal actuators 136 are activated to draw the movable wall towards the fixed wall such that the fixed wall, the movable wall, the bulk heads 240, 240a and the bottom gauge 242 form the mold. The upper and lower locks 140,150 are engaged to secure the walls in the molding position.
The furnace units 44 are activated to force hot air in the furnace plenum 40. Referring to FIGS. 2-4, the heated air travels into the furnace plenum and descends between adjacent Z-members, transferring heat to the skin plates of the fixed walls 60,80. The heated air passes through the return ports 31 and into the return manifold 30. The heated air exits the return manifold 30 to be reintroduced into the furnaces 44, reheated and recirculated. The fixed walls 60,80 are heated to a temperature in excess of 100° F. prior to introduction of concrete into the mold. Preferably, the mold cavity is covered with an insulating blanket or board (not shown) to retain the thermal energy in the mold. The insulation on the moveable walls 120, 160 and deck 36 also serves to retain the thermal energy in the mold.
Prior to introduction into the mold, the concrete is preheated to a temperature in excess of 85° F. Upon sufficient heating of the mold cavity and the concrete, the concrete supply line is connected to the valve mechanism 210. The concrete is pumped to a pressure of approximately 400 to 500 psi. The hydraulic mechanism 224 is used to align the central aperture 219 of the cutoff blade 218 with the inlet and outlet apertures 213,215. Concrete then passes into the transition orifice 202 at a flow rate of approximately 75 cubic yards per hour.
As the concrete flows to the larger cross sectional area of the transition orifice 202, the velocity of the flow is reduced. The passage of the concrete to the larger cross sectional area of the concrete inlet 200 reduces frictional losses, thereby promoting flow of concrete into the mold. The concrete enters the mold at a reduced velocity and flows towards the ends of the mold.
The vibrators 158 are activated to enhance flow of concrete within the mold. If the divider 260 is employed, the concrete flows to both sides of the divider. After the desired quantity of concrete is injected into the mold, the valve mechanism 210 is closed by placing the cut-off blade 218 in the second position to preclude further introduction of concrete into the mold and to hold back the fluid pressure head of the concrete in the mold.
Upon closure of the valve mechanism 210, the supply line is full of concrete. To safely disconnect the supply line, the concrete must be drawn back through the supply line. The valve mechanism 210 is moved to the third position, the overdrawn position, to expose the vent channels 221 to the inlet aperture 213 and the supply line. As the concrete is drawn back through the supply line, air passes through the vent channels 221 into the supply line to prevent creation of a vacuum within the line.
The top of the concrete in the mold is screeded along the screeding edges of the fixed and movable walls.
The continued heating of the fixed walls 60,80 by the furnace plenum 40 accelerates curing of the concrete, and reduces the time to realize the heat of hydration. The insulation on the movable walls 120, 160 and deck 36, and insulating blanket on top of the mold cavity increase the thermal retention of the mold cavity.
Upon sufficient curing of the concrete, the actuators 136 and the push-off valves 180 are actuated. The poppets 182 are urged against the concrete, and simultaneously the movable wall is slightly disposed away from the fixed wall by the horizontal actuators 136. The concrete panels are thereby separated from the walls. The cooperation of the push off values 180 and horizontal actuators 136 provide for uniform separation of the concrete panel from the mold. The concrete panels are lifted by a crane and set on to holding stands, or immediately set into place and allowed to cure.
If the divider 260 is employed the only contiguous concrete link between the separate compartments in the mold is the area of the inlet slot 262. As this concrete does not include reinforcing bar, and is still green, the concrete is scored and is easily fractured, thereby producing two separate panels from a single mold.
While one pair of a fixed and movable wall is molding a concrete panel, the remaining pair of walls may be cleared and prepared for molding, thereby reducing down time of the apparatus.
Although a preferred embodiment of the invention has been shown and described with particularity, it will be appreciated that various changes and modifications may suggest themselves to one having ordinary skill in the art upon being apprised of the present invention. It is intended to encompass all such changes and modifications as fall within the scope and spirit of the appended claims. | A portable concrete molding apparatus for forming concrete structures of a predetermined configuration, either on-site or at a central manufacturing facility. The apparatus includes a trailer having furnace plenum bounded by a pair of fixed walls. Each fixed wall cooperates with a movable wall for forming a mold therebetween. Each movable wall includes a concrete inlet for introducing concrete into the bottom portion of the mold. The fixed and movable walls include push-off valves for ensuring separation of a concrete structure from the mold walls, as the mold walls are separated. | Provide a concise summary of the essential information conveyed in the context. | [
"This application is a divisional of U.S. Ser.",
"No. 07/888,916, filed May 26, 1992, now abandoned.",
"The present invention relates to concrete molding machines, and more particularly, to a portable concrete molding machine for mass producing vertically oriented concrete panels having any of a variety of dimensions.",
"BACKGROUND OF THE INVENTION U.S. Pat. No. 4,534,924 discloses a battery mold for molding concrete slabs.",
"The battery mold may include manifold means in fluid communication with the bottom of each cavity formed between adjacent plates, for introducing concrete into each cavity.",
"U.S. Pat. No. 3,881,856 discloses a plant for the fabrication of parallel molded construction elements.",
"The plant includes a plurality of form panels movable along a pair of support rails.",
"The form panels are provided with vibrator devices and heating conduits.",
"A latching assembly provides for the coupling and uncoupling of adjacent panels.",
"Once the panels are in the desired position, the concrete is poured into the mold.",
"U.S. Pat. No. 3,844,524 discloses a concrete molding machine wherein concrete is admitted to the open top of a plurality of cavities formed between vertically supported panels.",
"The panels include a hot liquid piping system for decreasing the setting time of the concrete.",
"U.S. Pat. No. 3,804,361 discloses a plant for manufacturing reinforced concrete construction panels.",
"The plant includes electrically heated forms having a major surface which may be disposed perpendicular to planar vertical partition members to form a mold therebetween.",
"Upon formation of the mold, the concrete is poured into the mold from the upper end of the mold.",
"While the devices of the prior art provide for mass production of concrete structures, a need exits for the formation of concrete structures having differing dimensions, wherein the structures may be formed in heated cavities either on site, or at a central manufacturing facility.",
"In addition, the need exists for minimizing the size and number of air pockets at the interface of the mold and the concrete in the mold.",
"SUMMARY OF THE INVENTION The present invention provides a mobile concrete molding apparatus for forming concrete panels of varying dimensions.",
"Preferably, the molding apparatus is affixed to a trailer bed, so that concrete panels may be formed either on site, or at central manufacturing facilities.",
"The present invention includes a furnace plenum partially bounded by a pair of fixed walls, such that the fixed walls are thermally coupled to the furnace plenum.",
"A movable wall is cooperatively associated with each fixed wall.",
"Each movable wall includes a planar surface extending parallel to the corresponding fixed wall, and is movable in a direction normal to the corresponding fixed wall.",
"Preferably, each movable wall includes a concrete inlet for introducing concrete into the lower portion of the mold, such that the concrete substantially fills the mold from the bottom.",
"That is, at least a portion of the concrete introduced through the concrete inlet acts against a pressure head of concrete in the mold.",
"By pumping the concrete into the bottom of the mold, the number and size of the trapped air pockets at the interface of the mold surface and the concrete is minimized.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the present invention connected to a concrete supply;",
"FIG. 2 is a cross sectional view taken along lines 2--2 of FIG. 1;",
"FIG. 3 is a cross sectional view taken along lines 3--3 of FIG. 1;",
"FIG. 4 is a cross sectional view taken along lines 4--4 of FIG. 1;",
"FIG. 5 is a side elevational view of the present invention;",
"FIG. 6 is a localized perspective view showing a push-off valve in relation to a wall of the mold;",
"FIG. 7 is a localized perspective showing an actuated push-off valve spaced apart from the surrounding mold wall;",
"FIG. 8 is an exploded perspective of the valve mechanism in a first open position;",
"FIG. 9 is an exploded perspective of the valve mechanism showing closed, venting position;",
"FIG. 10 is a partial cross sectional view taken along lines 10--10 of FIG. 2;",
"FIG. 11 is a partial cross sectional view taken along lines 11--11 of FIG. 10;",
"FIG. 12 is a top plan view showing a lower lock assembly;",
"and FIG. 13 is a partial cross sectional view taken along lines 13--13 of FIG. 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1, the variable wall molding apparatus 10 includes a trailer 12 having a furnace plenum 40, first and second fixed walls 60,80, and first and second movable walls 120,160.",
"As shown in FIGS. 1, 2 and 4, the fixed wall 60 and the movable wall 120 are shown in an open position, while the fixed wall 80 and the movable wall 160 are shown in a casting position.",
"Referring to FIGS. 1 and 2, a concrete supply 8 is shown connected to the movable wall 120.",
"As the movable wall 120 is not in a casting position, there is no concrete in the line connecting the concrete supply 8 to the molding apparatus 10.",
"Trailer The trailer 12 cooperatively engages a truck tractor (not shown) to permit ready transport of the molding apparatus 10.",
"As shown in FIG. 2, the trailer 12 includes a pair of parallel I-beams 14,16 extending the length of the trailer.",
"A plurality of transverse channels 18 are affixed to the underside of the I-beams 14,16, and extend perpendicular to the length of the trailer 12.",
"Each channel 18 includes a depending leveler 20 at each end of the channel.",
"The depending leveler 20 selectively displaces the end of the channel 18 relative to the ground to ensure a level orientation of the apparatus 10.",
"A pair of transverse beams 21,22 is slidably received within each channel 18.",
"Each beam 21,22 includes an inner and outer set of rollers 24,26 for slidably moving the beams 21,22 within the channel 18.",
"Referring to FIG. 2, the top of the I-beams 14,16 are interconnected by upper panel 28 and the bottom of the I-beams are interconnected by a lower panel 29 to enclose the space between I-beams 14,16 thereby defining a return manifold 30.",
"Each I-beam 14,16 includes a plurality of return ports 31.",
"As shown in FIG. 3, the return ports 31 extend along the length of the return manifold 30.",
"Fixed Walls Referring to FIG. 2, the fixed walls 60,80 are attached to the outside of the return manifold 30 to define a substantial portion of the furnace plenum 40.",
"The fixed walls 60,80 are vertically oriented and extend upward from opposite sides of the return manifold 30.",
"Each fixed wall 60,80 includes mold side 61,81 and plenum side 63,83.",
"The mold sides 61,81 form planar vertical surfaces for forming a concrete panel.",
"Preferably, each of the fixed walls 60,80 defines a vertically oriented molding surface having an overall height of approximately 10 feet and a length of approximately 30 feet.",
"Referring to FIGS. 1, 2 and 4, the fixed walls 60,80 and the movable walls 120,160 are symmetrically oriented about the longitudinal axis of the molding apparatus 10.",
"The fixed walls 60,80 are identical to each other in structure and operation.",
"Similarly, the movable walls 120,160 are identical to each other in structure and operation.",
"Therefore, for purposes of clarity of the disclosure, only the fixed wall 60 and the movable wall 120 will be described in detail.",
"The remaining fixed wall 80 and the movable wall 160 may be taken as having similar structure and function as the corresponding fixed wall 60 and the movable wall 120.",
"As shown in FIGS. 2 and 4, the fixed wall 60 is formed by a skin plate 62 and a plurality of Z-members 64.",
"The skin plate 62 is 0.25 inch steel, and defines the molding surface against which a portion of the concrete panel is cast.",
"Referring to FIG. 4, the Z-members 64 are vertically oriented and evenly aligned to define channels 65 between the adjacent Z-members.",
"As shown in FIG. 2, the Z-members 64 have a first end welded to a plenum side 63 of the skin plate 62.",
"The lower portion of the second end of the Z-members 64 is affixed to the I-beam 14 such that the channels 65 between adjacent Z-members 64 are in fluid communication with the return ports 31, and hence the return manifold 30.",
"Referring to FIGS. 1, 2, and 13 the top of the skin plate 62 forms a screeding edge 66.",
"The screeding edge 66 provides a level and accurate surface perpendicular to the plane of the skin plate 62.",
"Returning to FIG. 2, a core frame 34 is formed between the fixed walls 60,80 above the return manifold 30.",
"The core frame 34 interconnects the Z-members of the fixed walls 60,80.",
"The top of the core frame 34 and top of the Z-members of the fixed walls 60,80 cooperate with an upper deck 36 to enclose the top of the furnace plenum 40.",
"The plenum side of the deck 36 includes insulation 38 such as polyurethane to retain thermal energy within the furnace plenum 40.",
"The furnace plenum 40 includes substantially the entire area of the skin plate of each fixed wall 60,80.",
"Therefore, approximately one-half of the surface area of the mold is in direct thermal contact with the furnace plenum 40.",
"Furnace Units As shown in FIGS. 1 and 3-5, a pair of furnace units 44 are disposed on the trailer 12 such that one furnace unit is fluidly connected to each end of the furnace plenum 40 and the return manifold 30.",
"The remaining area of each end of the furnace plenum 40 is sealed to enclose the furnace plenum.",
"Each furnace unit 44 includes a 60 kilowatt air duct heater such as TDH 60C as Manufactured by Chromalox of Pennsylvania, and a blower having a capacity of approximately 6000 cubic feet per minute.",
"To enhance thermal efficiency, the furnace units 44 and connecting duct work outside of the furnace plenum 40 are encapsulated with insulation.",
"Referring to FIGS. 2, 3 and 4, a fluid path is defined from the furnace units 44 into the furnace plenum 40, through the channels 65,85 formed by the Z-members 64,84 and the respective skin plate 62,82 of each fixed wall 60,80, through the return ports 31, and the return manifold 30 to the furnace units 44.",
"Movable Walls As previously stated, each movable wall 120,160 is identical in terms of relevant structure and function.",
"Therefore, only movable wall 120 will be discussed in detail.",
"Referring to FIGS. 1, 2, 4 and 10, the movable wall 120 is similar to the fixed walls 60,80 and is formed of a skin plate 122 and Z-members 124.",
"The skin plate 122 is formed of 0.25 inch steel.",
"The first end of each Z-member 124 is welded to the outside of the skin plate 122 so as to retain the skin plate in a substantially planar, vertical orientation.",
"The second end of each Z-member 124 is connected to an adjacent Z-member 124 by framing to provide structural rigidity.",
"Similar to the fixed walls 60 and 80, the Z-members in the movable wall 120 form channels between adjacent Z-members.",
"As shown in FIGS. 2 and 4, the channels in the movable wall 120 are at least partially filled with insulation 125, such as polyurethane.",
"Referring to FIGS. 2 and 13, the top of the skin plate 122 forms a screeding edge 126 for cooperating with the screeding edge 66 of the fixed wall 60 for leveling the top of the concrete in the mold.",
"FIG. 11 discloses a detail of the top of fixed wall 80 and movable wall 160 showing corresponding screeding edges 86,166.",
"As shown in FIGS. 1, 2 and 5, the bottom of the movable wall 120 is affixed to a plurality of the transverse beams 21, intermediate of the ends of the beams.",
"Similarly, the bottom of the movable wall 160 is affixed to a plurality of transverse beams 22.",
"The movable wall 120 is mounted on the transverse beams 21 above the outer set of rollers 26.",
"Struts 130 extend from the outer end of the transverse beams 21 to engage the upper portion of the movable wall 120.",
"The movable wall 120 is thereby fixedly retained relative to the transverse beams 21.",
"Each movable wall 120,160 includes a walkway 132 for accessing the respective screeding edges 66, 126 and 86, 166 and the top of the mold.",
"The movable walls are mounted on the transverse beams to be movable between a first position adjacent the corresponding fixed wall for forming the mold, and a second position approximately 29 inches from the corresponding fixed wall.",
"Referring to FIG. 5, the bottom of each movable wall 120,160 includes a plurality of depending pads 134.",
"The pads 134 are located intermediate of the transverse channels 18 and depend directly below the movable wall.",
"Referring to FIGS. 3-5, a plurality of machine screw actuators 136 are coupled between the depending pads 134 and the trailer 12.",
"The machine screw actuators 136 are Model 9010 machine screw actuators manufactured by the Duff-Norton Company of Charlotte, N.C. The actuators 136 are commonly controlled, as well known in the art, to provide simultaneous activation and maintain the parallel orientation of the movable wall and the fixed wall as the movable wall is disposed between the first and the second position.",
"Referring to FIGS. 1, 2, 3 and 5, the top of each fixed wall 60,80 and corresponding movable wall 120,160 includes a plurality of cooperating upper locks 140 for selectively precluding motion of the walls when in the casting position.",
"The upper locks 140 for each fixed and movable wall pair, includes a capture block 142 on one wall and an adjustable loop 144 on the remaining wall.",
"The adjustable loop 144 permits the upper lock 140 to lock the walls at a variety of distances.",
"As shown in FIG. 12, the apparatus 10 also includes lower locks 150 for securing the relative position of a pair of fixed and movable walls when in the casting position.",
"Each lower lock 150 includes a U-shaped bracket 152 and adjusting bolt 154 threaded through the closed end of the bracket 152.",
"The outer ends of each transverse channel 18 include a pair of opposing recesses or apertures 19 for cooperatively engaging the open ends of the bracket 152.",
"To lock a transverse beam 21 or 22 with respect to the corresponding channel 18, the open ends of the bracket 152 are engaged with the apertures 19 in the channel 18.",
"The adjusting bolt is threaded until it contacts the outer end of the transverse beam, thereby precluding motion of the movable wall away from the corresponding fixed wall.",
"As shown in FIGS. 1, 2 and 5, vibrators 158 are attached to the movable walls 120,160 along upper and lower rows.",
"The vibrators are external impact vibrators such as AR 06/460 vibrators manufactured by the Wacker Corporation of Menomnee Fall, Wis.",
"The vibrators 158 consolidate and compact the concrete in the mold to reduce the number and size of the trapped air pockets at the interface of the mold and the concrete.",
"In addition, the vibrators 158 enhance the flow of concrete within the mold during the casting process.",
"As shown in FIGS. 4 and 5, each of the fixed and movable walls include a plurality of push-off valves 180.",
"Referring to FIGS. 6 and 7, the push-off valves 180 include air actuated poppets 182.",
"In the default position, the poppets 182 are coplanar with the surrounding portion of the skin plate, or mold surface, such that the local area of the poppet and the skin plate define a planar surface.",
"Actuation of the push-off valve 180 disposes the poppet 182 intermediate of the movable wall and fixed wall, that is, within the mold so as to push against a molded concrete structure such as a panel, thereby separating the molded concrete structure from the mold wall.",
"Concrete Inlets Referring to FIGS. 1, 2, 5, 10 and 11, each movable wall 120,160 includes a concrete inlet 200 in the lower portion of the wall.",
"As the concrete inlet 200 in each movable wall 120,160 is identical in structure and function, a single concrete inlet will be described in detail.",
"The concrete inlet 200 includes a tapered transition orifice 202 between the concrete supply line and the mold, such that the larger diameter of the orifice 202 terminates at the mold wall.",
"The transition orifice 202 flares from a diameter of five inches to terminate in the plane of the skin plate at a diameter of seven inches.",
"Flow through the concrete inlet 200 is controlled by a valve mechanism 210.",
"The valve mechanism 210 controls introduction of concrete into the mold defined between the fixed and movable walls.",
"Referring to FIGS. 8 and 9, the valve mechanism 210 includes an inlet housing 212 and an outlet housing 214.",
"The inlet housing 212 includes an inlet aperture 213, and the outlet housing 214 includes an outlet aperture 215, wherein the inlet and outlet apertures are of equal size.",
"The inlet and outlet housings 212,214 are separated by lateral spacers 216.",
"A cutoff blade 218 is slidably disposed between the inlet and outlet housings 212,214 and intermediate of the lateral spacers 216.",
"The cutoff blade 218 includes a central aperture 219 having a size equal to the inlet and outlet apertures 213,215.",
"The cutoff blade 218 also includes vent channels 221 extending from the edge of the blade to terminate within a circumference equal to the circumference of the inlet aperture 213.",
"The terminal ends of the vent channels 221 are spaced from the central aperture 219 by a distance greater than the diameter of the inlet aperture 213.",
"The cutoff blade 218 is movable relative to the inlet and outlet housings 212, 214, to assume three operative positions.",
"In the first position, the central aperture 219 aligns with the inlet and outlet apertures 213,215 to permit a flow of concrete through the valve mechanism 210.",
"In the second position, the cutoff blade 218 is oriented to preclude fluid communication between the inlet and outlet apertures 213,215.",
"In the third position fluid communication between the inlet and outlet apertures 213,215 is precluded, while the inlet aperture 213 is fluidly connected to atmospheric pressure through the vent channels 221.",
"A hydraulic mechanism 224 is used to move the cutoff blade 218 relative to the housings.",
"Preferably, the concrete inlets 200 are located such that during filling of the mold, at least a portion of the concrete introduced through the concrete inlet into the mold acts against a pressure head of concrete already in the mold.",
"Although the concrete inlet 200 may be located at any vertical position in the mold, the concrete inlet is preferably located at the midpoint of the mold, or lower.",
"While the concrete inlets 200 are shown in the lower portions of the moveable walls 120,160, the concrete inlets may be located in the lower portion of the fixed walls 60,80, bulkheads in the ends of the mold, or the bottom of the mold.",
"Alternatively, the concrete inlets 200 may be entirely eliminated, wherein the concrete is poured into the top of the mold, and the introduced concrete does not act against a pressure head of concrete in the mold.",
"In the preferred embodiment, the horizontal actuators 136, and the vibrators 158 are selectively actuated through control panels 230 associated with each movable wall.",
"The control panels 230 reduce the number of workers, and safely locate the operator during formation of the concrete panels.",
"Referring to FIGS. 1, 10 and 11, the molding apparatus 10 may include a divider 260 vertically oriented in the mold.",
"The divider 260 substantially separates the mold into two distinct compartments.",
"The divider 260 is oriented to bisect the length of the mold and bisect the concrete inlet 200.",
"Referring to FIG. 11, the divider 260 is positioned to define an inlet slot 262.",
"The inlet slot 262 extends beyond the diameter of the transition orifice 202.",
"Preferably, the divider 260 cooperates with a lower portion 264 extending across the width of the mold, below the inlet slot 262.",
"Referring to FIG. 10, the divider 260 has a tapered cross section.",
"That is, the divider 260 is narrowest adjacent the movable wall and widest adjacent the fixed wall, wherein the divider flares from a width of approximately 13/16"",
"to a width of approximately 1".",
"Operation The present invention provides for the mass production of reinforced vertical concrete panels.",
"The concrete panels may have any length and height which is less than the length and height of the fixed and movable walls.",
"The thickness of the concrete panel is determined by the maximum separation of the movable wall from the fixed wall, such that the maximum separation of the mold walls includes the thickness of the concrete panel and a release space for separating the concrete structure from the mold.",
"The panels may also be formed to include window or door apertures and conduits for electrical and environmental services.",
"As shown in FIGS. 1, 2 and 4, bulk heads 240, 240a and bottom gauge 242 are disposed relative to the fixed walls 60,80 to define the desired thickness, length and height of the concrete structure to be formed.",
"The bulk heads 240, 240a and bottom gauge 242 space the movable wall from the fixed wall and determine the height, width and length of the structure to be formed when the walls are in the molding position.",
"In addition, the bulk heads 240b (not shown) may be disposed at any location within the mold to define windows, doors or other desired openings in the final product.",
"The surfaces of the mold are treated to enhance subsequent separation of the cured concrete and the mold, as well known in the art.",
"A reinforcing bar frame (not shown) is disposed between the inner and outer walls.",
"The horizontal actuators 136 are activated to draw the movable wall towards the fixed wall such that the fixed wall, the movable wall, the bulk heads 240, 240a and the bottom gauge 242 form the mold.",
"The upper and lower locks 140,150 are engaged to secure the walls in the molding position.",
"The furnace units 44 are activated to force hot air in the furnace plenum 40.",
"Referring to FIGS. 2-4, the heated air travels into the furnace plenum and descends between adjacent Z-members, transferring heat to the skin plates of the fixed walls 60,80.",
"The heated air passes through the return ports 31 and into the return manifold 30.",
"The heated air exits the return manifold 30 to be reintroduced into the furnaces 44, reheated and recirculated.",
"The fixed walls 60,80 are heated to a temperature in excess of 100° F. prior to introduction of concrete into the mold.",
"Preferably, the mold cavity is covered with an insulating blanket or board (not shown) to retain the thermal energy in the mold.",
"The insulation on the moveable walls 120, 160 and deck 36 also serves to retain the thermal energy in the mold.",
"Prior to introduction into the mold, the concrete is preheated to a temperature in excess of 85° F. Upon sufficient heating of the mold cavity and the concrete, the concrete supply line is connected to the valve mechanism 210.",
"The concrete is pumped to a pressure of approximately 400 to 500 psi.",
"The hydraulic mechanism 224 is used to align the central aperture 219 of the cutoff blade 218 with the inlet and outlet apertures 213,215.",
"Concrete then passes into the transition orifice 202 at a flow rate of approximately 75 cubic yards per hour.",
"As the concrete flows to the larger cross sectional area of the transition orifice 202, the velocity of the flow is reduced.",
"The passage of the concrete to the larger cross sectional area of the concrete inlet 200 reduces frictional losses, thereby promoting flow of concrete into the mold.",
"The concrete enters the mold at a reduced velocity and flows towards the ends of the mold.",
"The vibrators 158 are activated to enhance flow of concrete within the mold.",
"If the divider 260 is employed, the concrete flows to both sides of the divider.",
"After the desired quantity of concrete is injected into the mold, the valve mechanism 210 is closed by placing the cut-off blade 218 in the second position to preclude further introduction of concrete into the mold and to hold back the fluid pressure head of the concrete in the mold.",
"Upon closure of the valve mechanism 210, the supply line is full of concrete.",
"To safely disconnect the supply line, the concrete must be drawn back through the supply line.",
"The valve mechanism 210 is moved to the third position, the overdrawn position, to expose the vent channels 221 to the inlet aperture 213 and the supply line.",
"As the concrete is drawn back through the supply line, air passes through the vent channels 221 into the supply line to prevent creation of a vacuum within the line.",
"The top of the concrete in the mold is screeded along the screeding edges of the fixed and movable walls.",
"The continued heating of the fixed walls 60,80 by the furnace plenum 40 accelerates curing of the concrete, and reduces the time to realize the heat of hydration.",
"The insulation on the movable walls 120, 160 and deck 36, and insulating blanket on top of the mold cavity increase the thermal retention of the mold cavity.",
"Upon sufficient curing of the concrete, the actuators 136 and the push-off valves 180 are actuated.",
"The poppets 182 are urged against the concrete, and simultaneously the movable wall is slightly disposed away from the fixed wall by the horizontal actuators 136.",
"The concrete panels are thereby separated from the walls.",
"The cooperation of the push off values 180 and horizontal actuators 136 provide for uniform separation of the concrete panel from the mold.",
"The concrete panels are lifted by a crane and set on to holding stands, or immediately set into place and allowed to cure.",
"If the divider 260 is employed the only contiguous concrete link between the separate compartments in the mold is the area of the inlet slot 262.",
"As this concrete does not include reinforcing bar, and is still green, the concrete is scored and is easily fractured, thereby producing two separate panels from a single mold.",
"While one pair of a fixed and movable wall is molding a concrete panel, the remaining pair of walls may be cleared and prepared for molding, thereby reducing down time of the apparatus.",
"Although a preferred embodiment of the invention has been shown and described with particularity, it will be appreciated that various changes and modifications may suggest themselves to one having ordinary skill in the art upon being apprised of the present invention.",
"It is intended to encompass all such changes and modifications as fall within the scope and spirit of the appended claims."
] |
BACKGROUND OF INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a system for managing wireless communication between two or more devices, and more specifically, to the automatic establishment of security provisions when transferring information from one wireless communication device to another.
[0003] 2. Description of Prior Art
[0004] Modern society has quickly adopted, and become reliant upon, handheld devices for wireless communication. For example, cellular telephones continue to proliferate in the global marketplace due to technological improvements in both the quality of the communication and the functionality of the devices. These wireless communication devices (WCDs) have become commonplace for both personal and business use, allowing users to transmit and receive voice, text and graphical data from a multitude of geographic locations. The communication networks utilized by these devices span different frequencies and cover different transmission distances, each having strengths desirable for various applications.
[0005] Cellular networks facilitate WCD communication over large geographic areas. These network technologies have commonly been divided by generations, starting in the late 1970s to early 1980s with first generation (1G) analog cellular telephones that provided baseline voice communication, to modem digital cellular telephones. GSM is an example of a widely employed 2G digital cellular network communicating in the 900 MHZ/1.8 GHZ bands in Europe and at 850 MHz and 1.9 GHZ in the United States. This network provides voice communication and also supports the transmission of textual data via the Short Messaging Service (SMS). SMS allows a WCD to transmit and receive text messages of up to 160 characters, while providing data transfer to packet networks, ISDN and POTS users at 9.6 Kbps. The Multimedia Messaging Service (MMS), an enhanced messaging system allowing for the transmission of sound, graphics and video files in addition to simple text, has also become available in certain devices. Soon emerging technologies such as Digital Video Broadcasting for Handheld Devices (DVB-H) will make streaming digital video, and other similar content, available via direct transmission to a WCD. While long-range communication networks like GSM are a well-accepted means for transmitting and receiving data, due to cost, traffic and legislative concerns, these networks may not be appropriate for all data applications.
[0006] Short-range wireless networks provide communication solutions that avoid some of the problems seen in large cellular networks. Bluetooth™ is an example of a short-range wireless technology quickly gaining acceptance in the marketplace. A Bluetooth™ enabled WCD transmits and receives data at a rate of 720 Kbps within a range of 10 meters, and may transmit up to 100 meters with additional power boosting. A user does not actively instigate a Bluetooth™ network. Instead, a plurality of devices within operating range of each other will automatically form a network group called a “piconet”. Any device may promote itself to the master of the piconet, allowing it to control data exchanges with up to seven “active” slaves and 255 “parked” slaves. Active slaves exchange data based on the clock timing of the master. Parked slaves monitor a beacon signal in order to stay synchronized with the master, and wait for an active slot to become available. These devices continually switch between various active communication and power saving modes in order to transmit data to other piconet members. In addition to Bluetooth™, other popular short-range wireless networks include WLAN (of which “Wi-Fi” local access points communicating in accordance with the IEEE 802.11 standard, is an example), WUSB, UWB, ZigBee (802.15.4, 802.15.4a), and UHF RFID. All of these wireless mediums have features and advantages that make them appropriate for various applications.
[0007] More recently, manufacturers have also begun to incorporate various resources for providing enhanced functionality in WCDs (e.g., components and software for performing close-proximity wireless information exchanges). Sensors and/or readers may be used to read visual or electronic information into a device. A transaction may involve a user holding their WCD in proximity to a target, aiming their WCD at an object (e.g., to take a picture) or sweeping the device over a printed tag or document. Machine-readable technologies such as radio frequency identification (RFID), Infra-red (IR) communication, optical character recognition (OCR) and various other types of visual, electronic and magnetic scanning are used to quickly input desired information into the WCD without the need for manual entry by a user.
[0008] Device manufacturers are continuing to incorporate as many of the previously identified exemplary communication features as possible into wireless communication devices in an attempt to bring powerful, “do-all” devices to market. Devices incorporating long-range, short-range and machine readable communication resources also often include multiple wireless mediums or radio protocols for each category. For example, a user may utilize a multifunction WCD to replace traditional tools such as individual phones, facsimile machines, computers, storage media, etc. which tend to be more cumbersome to both integrate and transport.
[0009] With the incorporation of so many functions into a single device, the wireless exchange of information from one device to another has become commonplace. For example, desired information may be exchanged in a standardized format, such as the vCard file format utilized for exchanging electronic business card information and the vCalendar format (now superseded by the iCalendar format) for appointment scheduling. These standard information formats allow a multitude of devices running different applications to quickly share information.
[0010] However, the convenience realized by these standard protocols may, in some instances, also lead to problems. Many of these protocols for exchanging wireless information may be enhanced with security features, such as encryption, but often these security features are optional. Security enforcement may not be required because in many cases, for example two professionals wirelessly exchanging contact information saved in their mobile devices, the need to manually enable/disable security, enter a password, etc. could be both inconvenient and possibly embarrassing in certain business situations. The result of not requiring security measures like encryption is that frequently no security is implemented in these transactions. Unsecured information being transmitted wirelessly may be intercepted by an unknown third party. The intercepted information could be used for malicious purposes, or may be altered and retransmitted before getting to its target, such as in the case of a man-in-the-middle attack.
[0011] What is therefore needed is a system and method for automatically enabling security measures when transferring data. The enablement of these security measures should be premised on whether a secure connection can be established with little or no manual intervention from either party involved in the transaction. If security can be enabled under these conditions, then security is enforced. Otherwise, the transaction proceeds without security (e.g., encryption).
SUMMARY OF INVENTION
[0012] The present invention includes at least a system and method for automatically controlling the enforcement of security in a wireless transaction. In a short-range wireless medium, such as Bluetooth™, a device (e.g., client) may transmit information to another device (e.g., a server) over a wireless connection. If circumstances permit, security may be automatically enabled, or a request to enable security may automatically be issued, so that the information is exchanged in a secure manner.
[0013] In at least one embodiment of the present invention as it pertains to short-range wireless communication mediums like Bluetooth™, a connection may be negotiated between at least a server device and a client device. When information is pushed from server to client, a determination is made whether the devices were previously known to each other (e.g., linked in trusted pair). If these two devices were previously paired, and as a result specific link keys exist in one or both devices, then encryption may automatically be enabled in the wireless transaction. If the devices were not previously paired, then the transaction may proceed without encryption.
[0014] Further, if the at least two devices are known to each other and were previously linked as a trusted pair, an inquiry may be issued in one or both of the devices involved in the transaction. The inquiry may include a message on the user interface of a WCD announcing that security is available and asking whether to enable security for the transaction. One or both of the users may then respond. If either response requests security to be enabled, then the wireless transaction may be encrypted. Otherwise, security will not be activated in the wireless exchange.
DESCRIPTION OF DRAWINGS
[0015] The invention will be further understood from the following detailed description of a preferred embodiment, taken in conjunction with appended drawings, in which:
[0016] FIG. 1 discloses an exemplary wireless operational environment, including wireless communication mediums of different effective range.
[0017] FIG. 2 discloses a modular description of an exemplary wireless communication device usable with at least one embodiment of the present invention.
[0018] FIG. 3 discloses an exemplary structural description of the wireless communication device previously described in FIG. 2 .
[0019] FIG. 4 discloses an exemplary operational description of a wireless communication device including further detail regarding a Bluetooth™ protocol stack in accordance with at least one embodiment of the present invention.
[0020] FIG. 5 discloses additional detail regarding the Bluetooth™ Profiles section of the exemplary Bluetooth™ protocol stack disclosed in FIG. 4 in accordance with at least one embodiment of the present invention.
[0021] FIG. 6A discloses an exemplary Object Push Profile transaction in accordance with at least one embodiment of the present invention.
[0022] FIG. 6B discloses additional detail regarding the exemplary Object Push Profile transaction of FIG. 6A in accordance with at least one embodiment of the present invention.
[0023] FIG. 7 discloses an example of an alternative Object Push Profile transaction in accordance with at least one embodiment of the present invention.
[0024] FIG. 8 discloses a flow chart for an exemplary communication transaction process in accordance with at least one embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0025] While the invention has been described in preferred embodiments, various changes can be made therein without departing from the spirit and scope of the invention, as described in the appended claims.
I. Wireless Communication Over Different Communication Networks
[0026] A WCD may both transmit and receive information over a wide array of wireless communication networks, each with different advantages regarding speed, range, quality (error correction), security (encoding), etc. These characteristics will dictate the amount of information that may be transferred to a receiving device, and the duration of the information transfer. FIG. 1 includes a diagram of a WCD and how it interacts with various types of wireless networks.
[0027] In the example pictured in FIG. 1 , user 110 possesses WCD 100 . This device may be anything from a basic cellular handset to a more complex device such as a wirelessly enabled palmtop or laptop computer. Near Field Communication (NFC) 130 includes various transponder-type interactions wherein normally only the scanning device requires its own power source. WCD 100 scans source 120 via short-range communication. A transponder in source 120 may use the energy and/or clock signal contained within the scanning signal, as in the case of RFID communication, to respond with data stored in the transponder. These types of technologies usually have an effective transmission range on the order of ten feet, and may be able to deliver stored data in amounts from 96 bits to over a megabit (or 125 Kbytes) relatively quickly. These features make such technologies well suited for identification purposes, such as to receive an account number for a public transportation provider, a key code for an automatic electronic door lock, an account number for a credit or debit transaction, etc.
[0028] The transmission range between two devices may be extended if both devices are capable of performing powered communication. Short-range active communication 140 includes applications wherein the sending and receiving devices are both active. An exemplary situation would include user 110 coming within effective transmission range of a Bluetooth™, WLAN, UWB, WUSB, etc. access point. In the case of Wibree™, a network may automatically be established to transmit information to WCD 100 possessed by user 110 . Wibree™ may be used for battery-powered devices, such as wireless sensors, since its power consumption is low. A Wibree™ device may use the advertisement mode to more rapidly establish the initial connection to WCD 100 . This data may include information of an informative, educational or entertaining nature. The amount of information to be conveyed is unlimited, except that it must all be transferred in the time when user 110 is within effective transmission range of the access point. This duration may be extremely limited if the user is, for example, strolling through a shopping mall or walking down a street. Due to the higher complexity of these wireless networks, additional time is also required to establish the initial connection to WCD 100 , which may be increased if many devices are queued for service in the area proximate to the access point. The effective transmission range of these networks depends on the technology, and may be from some 30 ft. to over 300 ft. with additional power boosting.
[0029] Long-range networks 150 are used to provide virtually uninterrupted communication coverage for WCD 100 . Land-based radio stations or satellites are used to relay various communication transactions worldwide. While these systems are extremely functional, the use of these systems is often charged on a per-minute basis to user 110 , not including additional charges for data transfer (e.g., wireless Internet access). Further, the regulations covering these systems may cause additional overhead for both the users and providers, making the use of these systems more cumbersome.
II. Wireless Communication Device
[0030] As previously described, the present invention may be implemented using a variety of wireless communication equipment. Therefore, it is important to understand the communication tools available to user 110 before exploring the present invention. For example, in the case of a cellular telephone or other handheld wireless devices, the integrated data handling capabilities of the device play an important role in facilitating transactions between the transmitting and receiving devices.
[0031] FIG. 2 discloses an exemplary modular layout for a wireless communication device usable with the present invention. WCD 100 is broken down into modules representing the functional aspects of the device. These functions may be performed by the various combinations of software and/or hardware components discussed below.
[0032] Control module 210 regulates the operation of the device. Inputs may be received from various other modules included within WCD 100 . For example, interference sensing module 220 may use various techniques known in the art to sense sources of environmental interference within the effective transmission range of the wireless communication device. Control module 210 interprets these data inputs, and in response, may issue control commands to the other modules in WCD 100 .
[0033] Communications module 230 incorporates all of the communication aspects of WCD 100 . As shown in FIG. 2 , communications module 230 may include, for example, long-range communications module 232 , short-range communications module 234 and machine-readable data module 236 (e.g., for NFC). Communications module 230 utilizes at least these sub-modules to receive a multitude of different types of communication from both local and long distance sources, and to transmit data to recipient devices within the transmission range of WCD 100 . Communications module 230 may be triggered by control module 210 , or by control resources local to the module responding to sensed messages, environmental influences and/or other devices in proximity to WCD 100 .
[0034] User interface module 240 includes visual, audible and tactile elements which allow the user 110 to receive data from, and enter data into, the device. The data entered by user 110 may be interpreted by control module 210 to affect the behavior of WCD 100 . User-inputted data may also be transmitted by communications module 230 to other devices within effective transmission range. Other devices in transmission range may also send information to WCD 100 via communications module 230 , and control module 210 may cause this information to be transferred to user interface module 240 for presentment to the user.
[0035] Applications module 250 incorporates all other hardware and/or software applications on WCD 100 . These applications may include sensors, interfaces, utilities, interpreters, data applications, etc., and may be invoked by control module 210 to read information provided by the various modules and in turn supply information to requesting modules in WCD 100 .
[0036] FIG. 3 discloses an exemplary structural layout of WCD 100 according to an embodiment of the present invention that may be used to implement the functionality of the modular system previously described in FIG. 2 . Processor 300 controls overall device operation. As shown in FIG. 3 , processor 300 is coupled to at least communications sections 310 , 320 and 340 . Processor 300 may be implemented with one or more microprocessors that are each capable of executing software instructions stored in memory 330 .
[0037] Memory 330 may include random access memory (RAM), read only memory (ROM), and/or flash memory, and stores information in the form of data and software components (also referred to herein as modules). The data stored by memory 330 may be associated with particular software components. In addition, this data may be associated with databases, such as a bookmark database or a business database for scheduling, email, etc.
[0038] The software components stored by memory 330 include instructions that can be executed by processor 300 . Various types of software components may be stored in memory 330 . For instance, memory 330 may store software components that control the operation of communication sections 310 , 320 and 340 . Memory 330 may also store software components including a firewall, a service guide manager, a bookmark database, user interface manager, and any communication utilities modules required to support WCD 100 .
[0039] Long-range communications 310 performs functions related to the exchange of information over large geographic areas (such as cellular networks) via an antenna. These communication methods include technologies from the previously described 1G to 3G. In addition to basic voice communication (e.g., via GSM), long-range communications 310 may operate to establish data communication sessions, such as General Packet Radio Service (GPRS) sessions and/or Universal Mobile Telecommunications System (UMTS) sessions. Also, long-range communications 310 may operate to transmit and receive messages, such as short messaging service (SMS) messages and/or multimedia messaging service (MMS) messages.
[0040] As a subset of long-range communications 310 , or alternatively operating as an independent module separately connected to processor 300 , transmission receiver 312 allows WCD 100 to receive transmission messages via mediums such as Digital Video Broadcast for Handheld Devices (DVB-H). These transmissions may be encoded so that only certain designated receiving devices may access the transmission content, and may contain text, audio or video information. In at least one example, WCD 100 may receive these transmissions and use information contained within the transmission signal to determine if the device is permitted to view the received content.
[0041] Short-range communications 320 is responsible for functions involving the exchange of information across short-range wireless networks. As described above and depicted in FIG. 3 , examples of such short-range communications 320 are not limited to Bluetooth™, Wibree™, WLAN, UWB and Wireless USB connections. Accordingly, short-range communications 320 performs functions related to the establishment of short-range connections, as well as processing related to the transmission and reception of information via such connections.
[0042] Short-range input device 340 , also depicted in FIG. 3 , may provide functionality related to the short-range scanning of machine-readable data (e.g., for NFC). For example, processor 300 may control short-range input device 340 to generate RF signals for activating an RFID transponder, and may in turn control the reception of signals from an RFID transponder. Other short-range scanning methods for reading machine-readable data that may be supported by short-range input device 340 are not limited to IR communication, linear and 2-D (e.g., QR) bar code readers (including processes related to interpreting UPC labels), and optical character recognition devices for reading magnetic, UV, conductive or other types of coded data that may be provided in a tag using suitable ink. In order for short-range input device 340 to scan the aforementioned types of machine-readable data, the input device may include optical detectors, magnetic detectors, CCDs or other sensors known in the art for interpreting machine-readable information.
[0043] As further shown in FIG. 3 , user interface 350 is also coupled to processor 300 . User interface 350 facilitates the exchange of information with a user. FIG. 3 shows that user interface 350 includes a user input 360 and a user output 370 . User input 360 may include one or more components that allow a user to input information. Examples of such components include keypads, touch screens, and microphones. User output 370 allows a user to receive information from the device. Thus, user output portion 370 may include various components, such as a display, light emitting diodes (LED), tactile emitters and one or more audio speakers. Exemplary displays include liquid crystal displays (LCDs), and other video displays.
[0044] WCD 100 may also include one or more transponders 380 . This is essentially a passive device that may be programmed by processor 300 with information to be delivered in response to a scan from an outside source. For example, an RFID reader mounted in an entryway may continuously emit radio frequency waves. When a person with a device containing transponder 380 walks through the door, the transponder is energized and may respond with information identifying the device, the person, etc. In addition, a reader may be mounted (e.g., as discussed above with regard to examples of short-range input device 340 ) in WCD 100 so that it can read information from other transponders in the vicinity.
[0045] Hardware corresponding to communications sections 310 , 312 , 320 and 340 provide for the transmission and reception of signals. Accordingly, these portions may include components (e.g., electronics) that perform functions, such as modulation, demodulation, amplification, and filtering. These portions may be locally controlled, or controlled by processor 300 in accordance with software communication components stored in memory 330 .
[0046] The elements shown in FIG. 3 may be constituted and coupled according to various techniques in order to produce the functionality described in FIG. 2 . One such technique involves coupling separate hardware components corresponding to processor 300 , communications sections 310 , 312 and 320 , memory 330 , short-range input device 340 , user interface 350 , transponder 380 , etc. through one or more bus interfaces (which may be wired or wireless bus interfaces). Alternatively, any and/or all of the individual components may be replaced by an integrated circuit in the form of a programmable logic device, gate array, ASIC, multi-chip module, etc. programmed to replicate the functions of the stand-alone devices. In addition, each of these components is coupled to a power source, such as a removable and/or rechargeable battery (not shown).
[0047] The user interface 350 may interact with a communication utilities software component, also contained in memory 330 , which provides for the establishment of service sessions using long-range communications 310 and/or short-range communications 320 . The communication utilities component may include various routines that allow the reception of services from remote devices according to mediums such as the Wireless Application Medium (WAP), Hypertext Markup Language (HTML) variants like Compact HTML (CHTML), etc.
III. Basic Profiles for Wireless Communication.
[0048] FIG. 4 discloses a stack approach to understanding the operation of a WCD in accordance with at least one embodiment of the present invention. At the top level 400 , user 110 interacts with WCD 100 . The interaction involves user 110 entering information via user input 360 and receiving information from user output 370 in order to activate functionality in application level 410 . In the application level, programs related to specific functionality within the device interact with both the user and the system level. These programs include applications for visual information (e.g., web browser, DVB-H receiver, etc.), audio information (e.g., cellular telephone, voice mail, conferencing software, DAB or analog radio receiver, etc.), recording information (e.g., digital photography software, word processing, scheduling, etc.) or other information processing. Actions initiated at application level 410 may require information to be sent from or received into WCD 100 . In the example of FIG. 4 , data is requested to be sent to a recipient device via Bluetooth™ communication. As a result, application level 410 may then call resources in the system level to initiate the required processing and routing of data.
[0049] System level 420 processes data requests and routes the data for transmission. Processing may include, for example, calculation, translation, conversion and/or packetizing the data. The information may then be routed to an appropriate communication resource in the service level. If the desired communication resource is active and available in the service level 430 , the packets may be routed to a radio modem for delivery via wireless transmission. There may be a plurality of modems operating using different wireless mediums. For example, in FIG. 4 , modem 4 is activated and able to send packets using Bluetooth™ communication. However, a radio modem (as a hardware resource) need not be dedicated only to a specific wireless medium, and may be used for different types of communication depending on the requirements of the wireless medium and the hardware characteristics of the radio modem.
[0050] More specifically, a radio modem operating in service level 430 may, when operating using Bluetooth™, utilize a protocol stack such as further depicted in FIG. 4 . The protocol stack includes elements that may convey information from a system level to a physical layer where it may be transmitted wirelessly to another device. At the top level, Bluetooth™ Profiles 432 may include definitions which describe, for example, known peripheral devices which may be connected wirelessly to WCD 100 , or standards by which applications may utilize Bluetooth™ in order to engage in wireless communication with a peripheral device. Bluetooth™ profiles of other devices may be established through a pairing procedure, wherein identification and connection information for a peripheral device may be received by WCD 100 through a polling process and then saved in order to expedite the connection to the device at a later time. After the application and/or target peripheral device (or devices) is established, any information to be sent must be prepared for transmission. L2CAP level 434 includes at least a logical link controller and adaptation protocol. This protocol supports higher level protocol multiplexing packet segmentation and reassembly, and the conveying of quality of service information. The information prepared by L2CAP level 434 may then be passed to an application-optional host controller interface (HCI) 436 . This layer may provide a command interface to the lower link manager protocol (LMP) layers, link manager (LM) 438 and link controller (LC) 440 . LM 438 may establish the link setup, authentication, link configuration and other protocols related to establishing a wireless link between two or more devices. Further, LC 440 may manage active links between two or more devices by handling low-level baseband protocols. Wireless communication may then be established and conducted using the hardware (modem, antenna, etc.) making up physical layer (PHY) 442 . The Bluetooth™ protocol stack layers may also be utilized in an order reversed from that disclosed above in order to receive wireless transmissions.
[0051] FIG. 5 discloses further detail regarding Bluetooth™ profiles layer 432 . The profiles 502 - 522 define various standardized tasks that may be completed via Bluetooth™ communication. For example, developers may use these profiles in order to make sure that their application will interface correctly with the Bluetooth™. The profiles are organized in a hierarchy, wherein each subsequent profile relies on the definitions in the profile from which it depends. General access profile (GAP) 502 provides the basis for all other profiles and defines a consistent means with which to establish a wireless link between devices (e.g., the device requirements and procedures needed to link the devices, etc.) Under GAP 502 exist basic profiles utilized to establish transactions between two or more devices. Service discovery profile (SDP) 504 delineates how a device should discover services in another device. Serial port profile (SPP) 506 defines how to establish a virtual serial port between two devices. Human interface device profile (HID) 508 defines how various pointing and other user interface devices will wirelessly interact with WCD 100 . Generic object exchange profile (GOEP) 510 is the general profile that dictates how objects may be transferred from one device to another, and Hardcopy cable replacement profile (HCRP) 512 defines how driver-based printing is done over a wireless link.
[0052] The aforementioned exemplary Bluetooth™ Profiles 423 may be further broken down into more specialized functions. For example, SPP 506 may further incorporate dial-up networking profile (DUN) 514 and headset profile (HSP) 516 . DUN 514 may be utilized for accessing the Internet using Bluetooth™ while HSP 516 defines how a Bluetooth™-enabled headset should communicate with WCD 100 . Profiles included under GEOP 510 include file transfer profile (FTP) 518 , object push profile (OPP) 520 , synchronization profile (SYNC) 522 and Basic Printing Profile (BPP) 524 . These profiles are all used to define specific instances wherein information is transferred from one device to another device. This information may include files, folders, calendar information, email information, virtual business cards and various other types of electronic information. The information may be pushed to/pulled from a device.
III. Basic Profiles for Wireless Communication.
[0053] It is important to realize that as wireless mediums like Bluetooth™ evolve, that older profiles may be altered and new profiles may evolve based on consumer demand. The profiles previously set forth represent only a small portion of the profiles generally available for interfacing with the wireless medium. Further, the discussion in the present disclosure will be focused on OPP 520 . While OPP 520 is a Bluetooth™ profile that may be used with the present invention, the present invention is not specifically limited to only this profile/medium. The present invention may be applicable to any wireless transaction between at least two devices.
[0054] OPP 520 may define the roles of a push server device and a push client device. These roles are analogous to, and must interoperate with, the server and client device roles that are previously defined by GOEP 510 . It is called “push” because the transfers are always instigated by the sender (client), not the receiver (server). OPP 520 focuses on a narrow range of object formats to maximize interoperability. The most common acceptable format is the vCard. OPP 520 may also be used for sending objects such as pictures, appointment details, etc.
[0055] FIG. 6A discloses an exemplary transaction as defined by OPP 520 . Device A 600 (hereafter, “client 600 ”) may transmit or “push” a data object to Device B 602 (hereafter, “server 602 ”). Client 600 and server 602 may be, for example, communication devices similar to WCD 100 . Client 600 , after a connection is established, may push an object (e.g., a vCard or iCalendar information) to server 602 . In a push transaction, client 600 may both initiate the connection with the server and then push the object to the server. The object, if in accordance with a standard format, may then be quickly assimilated into applications running on client 600 .
[0056] FIG. 6B follows the example given in FIG. 6A and offers additional detail. Client 600 is pushing information to server 602 in accordance with OPP 520 . However, this example specifies that no security is required (e.g., no encryption). Each profile defines some security requirements, but there is no “property” in a transaction to dictate whether a link should be secure. Instead, each device in the transaction is free to initiate the enabling of a secure link.
[0057] The implications of this transaction are that information is transmitted without any security measures in place, allowing the information to be intercepted by other listening wireless devices within transmission range of server 602 . A third party receiving this information could possibly use it for malicious intent. For example, if the information is sensitive or confidential, such as personal identification information, billing information, credit card information, etc., the third party could use it to impersonate the sending party or possibly to purchase items with their credit card. This situation is also a good scenario for a “man-in-the-middle” attack, wherein the wireless communication device of the third party could intercept, change and rebroadcast the information before it reaches client 600 . The attack results in client 600 receiving erroneous or fraudulent information from the third party device instead of the expected object pushed from server 602 . With these examples in mind, enabling security whenever possible seems beneficial.
[0058] Now referring to FIG. 7 , the previously set forth data transaction is improved in accordance with at least one embodiment of the present invention. In this example employing OPP 520 , client 600 is again pushing information to server 602 . However, in this scenario client 600 is also attempting to determine if security is available, such as encrypting the object push message. Encryption may be available, for example, when the devices have been previously paired. When two devices have already been established as a pair, passkeys and/or other authenticating means have already been used in initially establishing a connection and generating the corresponding link key or association information. This reusable information may be retained on the devices so that client 600 and server 602 may quickly authenticate to each other and encrypt the link during subsequent connections. In this example, after client 600 determines that the devices have been previously paired, the devices may both activate stronger security by encrypting the object push message so that only server 600 may interpret it. Alternatively, if the devices have not been previously paired, and no other security measures are available, the transaction may proceed as requested without any encryption being implemented.
[0059] FIG. 8 further discloses an exemplary process flow diagram in accordance with at least one embodiment of the present invention. In step 800 a connection is established between client 600 and server 602 . This connection may be a new connection (e.g., the devices are encountering each other for the first time) or the devices may have previously been paired. After the connection is established, client 600 may initiate a transaction to push a data object to server 602 in step 802 . If these devices have not been paired before (as determined in step 804 ) then the transaction may proceed without any security provisions (provided that the higher layers do not enforce security provisions for this connection) in step 806 , which results in the object being pushed from the server to the client in step 808 .
[0060] If in step 804 it is determined that these devices have been paired previously, then an optional step 810 may occur. In this optional step a message is displayed on the user interface of one or both client 600 and server 602 that alerts the users of these devices that security (e.g., encryption) is available and inquires whether to implement it for this transaction. If either user replies affirmatively (to require encryption) then security may be activated in step 810 . Otherwise, the transaction may proceed as previously discussed with respect to step 806 . If either user requests encryption, or if step 810 is not utilized so that encryption may occur automatically when available, then in step 812 established link key information may be used to encrypt the OPP 520 transaction and push the object from server to client (step 814 ).
[0061] The present invention is an improvement over existing systems in at least one benefit that may be realized in automatically enabling security in a wireless transaction when information required for message encryption/decryption already exists. In this way a transaction may be secured, if possible, without inconveniencing and/or possibly even embarrassing a user of a wireless communication device.
[0062] Accordingly, it will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A system and method for automatically controlling the enforcement of security in a wireless transaction. In a short-range wireless medium, such as Bluetooth™, a device (e.g., a client) may transmit information to another device (e.g., a server) over a wireless connection. If circumstances permit, security may be automatically enabled, or a request to enable security may automatically be issued, so that the information is exchanged in a secure manner. | Briefly describe the main idea outlined in the provided context. | [
"BACKGROUND OF INVENTION [0001] 1.",
"Field of Invention [0002] The present invention relates to a system for managing wireless communication between two or more devices, and more specifically, to the automatic establishment of security provisions when transferring information from one wireless communication device to another.",
"[0003] 2.",
"Description of Prior Art [0004] Modern society has quickly adopted, and become reliant upon, handheld devices for wireless communication.",
"For example, cellular telephones continue to proliferate in the global marketplace due to technological improvements in both the quality of the communication and the functionality of the devices.",
"These wireless communication devices (WCDs) have become commonplace for both personal and business use, allowing users to transmit and receive voice, text and graphical data from a multitude of geographic locations.",
"The communication networks utilized by these devices span different frequencies and cover different transmission distances, each having strengths desirable for various applications.",
"[0005] Cellular networks facilitate WCD communication over large geographic areas.",
"These network technologies have commonly been divided by generations, starting in the late 1970s to early 1980s with first generation (1G) analog cellular telephones that provided baseline voice communication, to modem digital cellular telephones.",
"GSM is an example of a widely employed 2G digital cellular network communicating in the 900 MHZ/1.8 GHZ bands in Europe and at 850 MHz and 1.9 GHZ in the United States.",
"This network provides voice communication and also supports the transmission of textual data via the Short Messaging Service (SMS).",
"SMS allows a WCD to transmit and receive text messages of up to 160 characters, while providing data transfer to packet networks, ISDN and POTS users at 9.6 Kbps.",
"The Multimedia Messaging Service (MMS), an enhanced messaging system allowing for the transmission of sound, graphics and video files in addition to simple text, has also become available in certain devices.",
"Soon emerging technologies such as Digital Video Broadcasting for Handheld Devices (DVB-H) will make streaming digital video, and other similar content, available via direct transmission to a WCD.",
"While long-range communication networks like GSM are a well-accepted means for transmitting and receiving data, due to cost, traffic and legislative concerns, these networks may not be appropriate for all data applications.",
"[0006] Short-range wireless networks provide communication solutions that avoid some of the problems seen in large cellular networks.",
"Bluetooth™ is an example of a short-range wireless technology quickly gaining acceptance in the marketplace.",
"A Bluetooth™ enabled WCD transmits and receives data at a rate of 720 Kbps within a range of 10 meters, and may transmit up to 100 meters with additional power boosting.",
"A user does not actively instigate a Bluetooth™ network.",
"Instead, a plurality of devices within operating range of each other will automatically form a network group called a “piconet.”",
"Any device may promote itself to the master of the piconet, allowing it to control data exchanges with up to seven “active”",
"slaves and 255 “parked”",
"slaves.",
"Active slaves exchange data based on the clock timing of the master.",
"Parked slaves monitor a beacon signal in order to stay synchronized with the master, and wait for an active slot to become available.",
"These devices continually switch between various active communication and power saving modes in order to transmit data to other piconet members.",
"In addition to Bluetooth™, other popular short-range wireless networks include WLAN (of which “Wi-Fi”",
"local access points communicating in accordance with the IEEE 802.11 standard, is an example), WUSB, UWB, ZigBee (802.15.4, 802.15.4a), and UHF RFID.",
"All of these wireless mediums have features and advantages that make them appropriate for various applications.",
"[0007] More recently, manufacturers have also begun to incorporate various resources for providing enhanced functionality in WCDs (e.g., components and software for performing close-proximity wireless information exchanges).",
"Sensors and/or readers may be used to read visual or electronic information into a device.",
"A transaction may involve a user holding their WCD in proximity to a target, aiming their WCD at an object (e.g., to take a picture) or sweeping the device over a printed tag or document.",
"Machine-readable technologies such as radio frequency identification (RFID), Infra-red (IR) communication, optical character recognition (OCR) and various other types of visual, electronic and magnetic scanning are used to quickly input desired information into the WCD without the need for manual entry by a user.",
"[0008] Device manufacturers are continuing to incorporate as many of the previously identified exemplary communication features as possible into wireless communication devices in an attempt to bring powerful, “do-all”",
"devices to market.",
"Devices incorporating long-range, short-range and machine readable communication resources also often include multiple wireless mediums or radio protocols for each category.",
"For example, a user may utilize a multifunction WCD to replace traditional tools such as individual phones, facsimile machines, computers, storage media, etc.",
"which tend to be more cumbersome to both integrate and transport.",
"[0009] With the incorporation of so many functions into a single device, the wireless exchange of information from one device to another has become commonplace.",
"For example, desired information may be exchanged in a standardized format, such as the vCard file format utilized for exchanging electronic business card information and the vCalendar format (now superseded by the iCalendar format) for appointment scheduling.",
"These standard information formats allow a multitude of devices running different applications to quickly share information.",
"[0010] However, the convenience realized by these standard protocols may, in some instances, also lead to problems.",
"Many of these protocols for exchanging wireless information may be enhanced with security features, such as encryption, but often these security features are optional.",
"Security enforcement may not be required because in many cases, for example two professionals wirelessly exchanging contact information saved in their mobile devices, the need to manually enable/disable security, enter a password, etc.",
"could be both inconvenient and possibly embarrassing in certain business situations.",
"The result of not requiring security measures like encryption is that frequently no security is implemented in these transactions.",
"Unsecured information being transmitted wirelessly may be intercepted by an unknown third party.",
"The intercepted information could be used for malicious purposes, or may be altered and retransmitted before getting to its target, such as in the case of a man-in-the-middle attack.",
"[0011] What is therefore needed is a system and method for automatically enabling security measures when transferring data.",
"The enablement of these security measures should be premised on whether a secure connection can be established with little or no manual intervention from either party involved in the transaction.",
"If security can be enabled under these conditions, then security is enforced.",
"Otherwise, the transaction proceeds without security (e.g., encryption).",
"SUMMARY OF INVENTION [0012] The present invention includes at least a system and method for automatically controlling the enforcement of security in a wireless transaction.",
"In a short-range wireless medium, such as Bluetooth™, a device (e.g., client) may transmit information to another device (e.g., a server) over a wireless connection.",
"If circumstances permit, security may be automatically enabled, or a request to enable security may automatically be issued, so that the information is exchanged in a secure manner.",
"[0013] In at least one embodiment of the present invention as it pertains to short-range wireless communication mediums like Bluetooth™, a connection may be negotiated between at least a server device and a client device.",
"When information is pushed from server to client, a determination is made whether the devices were previously known to each other (e.g., linked in trusted pair).",
"If these two devices were previously paired, and as a result specific link keys exist in one or both devices, then encryption may automatically be enabled in the wireless transaction.",
"If the devices were not previously paired, then the transaction may proceed without encryption.",
"[0014] Further, if the at least two devices are known to each other and were previously linked as a trusted pair, an inquiry may be issued in one or both of the devices involved in the transaction.",
"The inquiry may include a message on the user interface of a WCD announcing that security is available and asking whether to enable security for the transaction.",
"One or both of the users may then respond.",
"If either response requests security to be enabled, then the wireless transaction may be encrypted.",
"Otherwise, security will not be activated in the wireless exchange.",
"DESCRIPTION OF DRAWINGS [0015] The invention will be further understood from the following detailed description of a preferred embodiment, taken in conjunction with appended drawings, in which: [0016] FIG. 1 discloses an exemplary wireless operational environment, including wireless communication mediums of different effective range.",
"[0017] FIG. 2 discloses a modular description of an exemplary wireless communication device usable with at least one embodiment of the present invention.",
"[0018] FIG. 3 discloses an exemplary structural description of the wireless communication device previously described in FIG. 2 .",
"[0019] FIG. 4 discloses an exemplary operational description of a wireless communication device including further detail regarding a Bluetooth™ protocol stack in accordance with at least one embodiment of the present invention.",
"[0020] FIG. 5 discloses additional detail regarding the Bluetooth™ Profiles section of the exemplary Bluetooth™ protocol stack disclosed in FIG. 4 in accordance with at least one embodiment of the present invention.",
"[0021] FIG. 6A discloses an exemplary Object Push Profile transaction in accordance with at least one embodiment of the present invention.",
"[0022] FIG. 6B discloses additional detail regarding the exemplary Object Push Profile transaction of FIG. 6A in accordance with at least one embodiment of the present invention.",
"[0023] FIG. 7 discloses an example of an alternative Object Push Profile transaction in accordance with at least one embodiment of the present invention.",
"[0024] FIG. 8 discloses a flow chart for an exemplary communication transaction process in accordance with at least one embodiment of the present invention.",
"DESCRIPTION OF PREFERRED EMBODIMENT [0025] While the invention has been described in preferred embodiments, various changes can be made therein without departing from the spirit and scope of the invention, as described in the appended claims.",
"I. Wireless Communication Over Different Communication Networks [0026] A WCD may both transmit and receive information over a wide array of wireless communication networks, each with different advantages regarding speed, range, quality (error correction), security (encoding), etc.",
"These characteristics will dictate the amount of information that may be transferred to a receiving device, and the duration of the information transfer.",
"FIG. 1 includes a diagram of a WCD and how it interacts with various types of wireless networks.",
"[0027] In the example pictured in FIG. 1 , user 110 possesses WCD 100 .",
"This device may be anything from a basic cellular handset to a more complex device such as a wirelessly enabled palmtop or laptop computer.",
"Near Field Communication (NFC) 130 includes various transponder-type interactions wherein normally only the scanning device requires its own power source.",
"WCD 100 scans source 120 via short-range communication.",
"A transponder in source 120 may use the energy and/or clock signal contained within the scanning signal, as in the case of RFID communication, to respond with data stored in the transponder.",
"These types of technologies usually have an effective transmission range on the order of ten feet, and may be able to deliver stored data in amounts from 96 bits to over a megabit (or 125 Kbytes) relatively quickly.",
"These features make such technologies well suited for identification purposes, such as to receive an account number for a public transportation provider, a key code for an automatic electronic door lock, an account number for a credit or debit transaction, etc.",
"[0028] The transmission range between two devices may be extended if both devices are capable of performing powered communication.",
"Short-range active communication 140 includes applications wherein the sending and receiving devices are both active.",
"An exemplary situation would include user 110 coming within effective transmission range of a Bluetooth™, WLAN, UWB, WUSB, etc.",
"access point.",
"In the case of Wibree™, a network may automatically be established to transmit information to WCD 100 possessed by user 110 .",
"Wibree™ may be used for battery-powered devices, such as wireless sensors, since its power consumption is low.",
"A Wibree™ device may use the advertisement mode to more rapidly establish the initial connection to WCD 100 .",
"This data may include information of an informative, educational or entertaining nature.",
"The amount of information to be conveyed is unlimited, except that it must all be transferred in the time when user 110 is within effective transmission range of the access point.",
"This duration may be extremely limited if the user is, for example, strolling through a shopping mall or walking down a street.",
"Due to the higher complexity of these wireless networks, additional time is also required to establish the initial connection to WCD 100 , which may be increased if many devices are queued for service in the area proximate to the access point.",
"The effective transmission range of these networks depends on the technology, and may be from some 30 ft.",
"to over 300 ft.",
"with additional power boosting.",
"[0029] Long-range networks 150 are used to provide virtually uninterrupted communication coverage for WCD 100 .",
"Land-based radio stations or satellites are used to relay various communication transactions worldwide.",
"While these systems are extremely functional, the use of these systems is often charged on a per-minute basis to user 110 , not including additional charges for data transfer (e.g., wireless Internet access).",
"Further, the regulations covering these systems may cause additional overhead for both the users and providers, making the use of these systems more cumbersome.",
"II.",
"Wireless Communication Device [0030] As previously described, the present invention may be implemented using a variety of wireless communication equipment.",
"Therefore, it is important to understand the communication tools available to user 110 before exploring the present invention.",
"For example, in the case of a cellular telephone or other handheld wireless devices, the integrated data handling capabilities of the device play an important role in facilitating transactions between the transmitting and receiving devices.",
"[0031] FIG. 2 discloses an exemplary modular layout for a wireless communication device usable with the present invention.",
"WCD 100 is broken down into modules representing the functional aspects of the device.",
"These functions may be performed by the various combinations of software and/or hardware components discussed below.",
"[0032] Control module 210 regulates the operation of the device.",
"Inputs may be received from various other modules included within WCD 100 .",
"For example, interference sensing module 220 may use various techniques known in the art to sense sources of environmental interference within the effective transmission range of the wireless communication device.",
"Control module 210 interprets these data inputs, and in response, may issue control commands to the other modules in WCD 100 .",
"[0033] Communications module 230 incorporates all of the communication aspects of WCD 100 .",
"As shown in FIG. 2 , communications module 230 may include, for example, long-range communications module 232 , short-range communications module 234 and machine-readable data module 236 (e.g., for NFC).",
"Communications module 230 utilizes at least these sub-modules to receive a multitude of different types of communication from both local and long distance sources, and to transmit data to recipient devices within the transmission range of WCD 100 .",
"Communications module 230 may be triggered by control module 210 , or by control resources local to the module responding to sensed messages, environmental influences and/or other devices in proximity to WCD 100 .",
"[0034] User interface module 240 includes visual, audible and tactile elements which allow the user 110 to receive data from, and enter data into, the device.",
"The data entered by user 110 may be interpreted by control module 210 to affect the behavior of WCD 100 .",
"User-inputted data may also be transmitted by communications module 230 to other devices within effective transmission range.",
"Other devices in transmission range may also send information to WCD 100 via communications module 230 , and control module 210 may cause this information to be transferred to user interface module 240 for presentment to the user.",
"[0035] Applications module 250 incorporates all other hardware and/or software applications on WCD 100 .",
"These applications may include sensors, interfaces, utilities, interpreters, data applications, etc.",
", and may be invoked by control module 210 to read information provided by the various modules and in turn supply information to requesting modules in WCD 100 .",
"[0036] FIG. 3 discloses an exemplary structural layout of WCD 100 according to an embodiment of the present invention that may be used to implement the functionality of the modular system previously described in FIG. 2 .",
"Processor 300 controls overall device operation.",
"As shown in FIG. 3 , processor 300 is coupled to at least communications sections 310 , 320 and 340 .",
"Processor 300 may be implemented with one or more microprocessors that are each capable of executing software instructions stored in memory 330 .",
"[0037] Memory 330 may include random access memory (RAM), read only memory (ROM), and/or flash memory, and stores information in the form of data and software components (also referred to herein as modules).",
"The data stored by memory 330 may be associated with particular software components.",
"In addition, this data may be associated with databases, such as a bookmark database or a business database for scheduling, email, etc.",
"[0038] The software components stored by memory 330 include instructions that can be executed by processor 300 .",
"Various types of software components may be stored in memory 330 .",
"For instance, memory 330 may store software components that control the operation of communication sections 310 , 320 and 340 .",
"Memory 330 may also store software components including a firewall, a service guide manager, a bookmark database, user interface manager, and any communication utilities modules required to support WCD 100 .",
"[0039] Long-range communications 310 performs functions related to the exchange of information over large geographic areas (such as cellular networks) via an antenna.",
"These communication methods include technologies from the previously described 1G to 3G.",
"In addition to basic voice communication (e.g., via GSM), long-range communications 310 may operate to establish data communication sessions, such as General Packet Radio Service (GPRS) sessions and/or Universal Mobile Telecommunications System (UMTS) sessions.",
"Also, long-range communications 310 may operate to transmit and receive messages, such as short messaging service (SMS) messages and/or multimedia messaging service (MMS) messages.",
"[0040] As a subset of long-range communications 310 , or alternatively operating as an independent module separately connected to processor 300 , transmission receiver 312 allows WCD 100 to receive transmission messages via mediums such as Digital Video Broadcast for Handheld Devices (DVB-H).",
"These transmissions may be encoded so that only certain designated receiving devices may access the transmission content, and may contain text, audio or video information.",
"In at least one example, WCD 100 may receive these transmissions and use information contained within the transmission signal to determine if the device is permitted to view the received content.",
"[0041] Short-range communications 320 is responsible for functions involving the exchange of information across short-range wireless networks.",
"As described above and depicted in FIG. 3 , examples of such short-range communications 320 are not limited to Bluetooth™, Wibree™, WLAN, UWB and Wireless USB connections.",
"Accordingly, short-range communications 320 performs functions related to the establishment of short-range connections, as well as processing related to the transmission and reception of information via such connections.",
"[0042] Short-range input device 340 , also depicted in FIG. 3 , may provide functionality related to the short-range scanning of machine-readable data (e.g., for NFC).",
"For example, processor 300 may control short-range input device 340 to generate RF signals for activating an RFID transponder, and may in turn control the reception of signals from an RFID transponder.",
"Other short-range scanning methods for reading machine-readable data that may be supported by short-range input device 340 are not limited to IR communication, linear and 2-D (e.g., QR) bar code readers (including processes related to interpreting UPC labels), and optical character recognition devices for reading magnetic, UV, conductive or other types of coded data that may be provided in a tag using suitable ink.",
"In order for short-range input device 340 to scan the aforementioned types of machine-readable data, the input device may include optical detectors, magnetic detectors, CCDs or other sensors known in the art for interpreting machine-readable information.",
"[0043] As further shown in FIG. 3 , user interface 350 is also coupled to processor 300 .",
"User interface 350 facilitates the exchange of information with a user.",
"FIG. 3 shows that user interface 350 includes a user input 360 and a user output 370 .",
"User input 360 may include one or more components that allow a user to input information.",
"Examples of such components include keypads, touch screens, and microphones.",
"User output 370 allows a user to receive information from the device.",
"Thus, user output portion 370 may include various components, such as a display, light emitting diodes (LED), tactile emitters and one or more audio speakers.",
"Exemplary displays include liquid crystal displays (LCDs), and other video displays.",
"[0044] WCD 100 may also include one or more transponders 380 .",
"This is essentially a passive device that may be programmed by processor 300 with information to be delivered in response to a scan from an outside source.",
"For example, an RFID reader mounted in an entryway may continuously emit radio frequency waves.",
"When a person with a device containing transponder 380 walks through the door, the transponder is energized and may respond with information identifying the device, the person, etc.",
"In addition, a reader may be mounted (e.g., as discussed above with regard to examples of short-range input device 340 ) in WCD 100 so that it can read information from other transponders in the vicinity.",
"[0045] Hardware corresponding to communications sections 310 , 312 , 320 and 340 provide for the transmission and reception of signals.",
"Accordingly, these portions may include components (e.g., electronics) that perform functions, such as modulation, demodulation, amplification, and filtering.",
"These portions may be locally controlled, or controlled by processor 300 in accordance with software communication components stored in memory 330 .",
"[0046] The elements shown in FIG. 3 may be constituted and coupled according to various techniques in order to produce the functionality described in FIG. 2 .",
"One such technique involves coupling separate hardware components corresponding to processor 300 , communications sections 310 , 312 and 320 , memory 330 , short-range input device 340 , user interface 350 , transponder 380 , etc.",
"through one or more bus interfaces (which may be wired or wireless bus interfaces).",
"Alternatively, any and/or all of the individual components may be replaced by an integrated circuit in the form of a programmable logic device, gate array, ASIC, multi-chip module, etc.",
"programmed to replicate the functions of the stand-alone devices.",
"In addition, each of these components is coupled to a power source, such as a removable and/or rechargeable battery (not shown).",
"[0047] The user interface 350 may interact with a communication utilities software component, also contained in memory 330 , which provides for the establishment of service sessions using long-range communications 310 and/or short-range communications 320 .",
"The communication utilities component may include various routines that allow the reception of services from remote devices according to mediums such as the Wireless Application Medium (WAP), Hypertext Markup Language (HTML) variants like Compact HTML (CHTML), etc.",
"III.",
"Basic Profiles for Wireless Communication.",
"[0048] FIG. 4 discloses a stack approach to understanding the operation of a WCD in accordance with at least one embodiment of the present invention.",
"At the top level 400 , user 110 interacts with WCD 100 .",
"The interaction involves user 110 entering information via user input 360 and receiving information from user output 370 in order to activate functionality in application level 410 .",
"In the application level, programs related to specific functionality within the device interact with both the user and the system level.",
"These programs include applications for visual information (e.g., web browser, DVB-H receiver, etc.), audio information (e.g., cellular telephone, voice mail, conferencing software, DAB or analog radio receiver, etc.), recording information (e.g., digital photography software, word processing, scheduling, etc.) or other information processing.",
"Actions initiated at application level 410 may require information to be sent from or received into WCD 100 .",
"In the example of FIG. 4 , data is requested to be sent to a recipient device via Bluetooth™ communication.",
"As a result, application level 410 may then call resources in the system level to initiate the required processing and routing of data.",
"[0049] System level 420 processes data requests and routes the data for transmission.",
"Processing may include, for example, calculation, translation, conversion and/or packetizing the data.",
"The information may then be routed to an appropriate communication resource in the service level.",
"If the desired communication resource is active and available in the service level 430 , the packets may be routed to a radio modem for delivery via wireless transmission.",
"There may be a plurality of modems operating using different wireless mediums.",
"For example, in FIG. 4 , modem 4 is activated and able to send packets using Bluetooth™ communication.",
"However, a radio modem (as a hardware resource) need not be dedicated only to a specific wireless medium, and may be used for different types of communication depending on the requirements of the wireless medium and the hardware characteristics of the radio modem.",
"[0050] More specifically, a radio modem operating in service level 430 may, when operating using Bluetooth™, utilize a protocol stack such as further depicted in FIG. 4 .",
"The protocol stack includes elements that may convey information from a system level to a physical layer where it may be transmitted wirelessly to another device.",
"At the top level, Bluetooth™ Profiles 432 may include definitions which describe, for example, known peripheral devices which may be connected wirelessly to WCD 100 , or standards by which applications may utilize Bluetooth™ in order to engage in wireless communication with a peripheral device.",
"Bluetooth™ profiles of other devices may be established through a pairing procedure, wherein identification and connection information for a peripheral device may be received by WCD 100 through a polling process and then saved in order to expedite the connection to the device at a later time.",
"After the application and/or target peripheral device (or devices) is established, any information to be sent must be prepared for transmission.",
"L2CAP level 434 includes at least a logical link controller and adaptation protocol.",
"This protocol supports higher level protocol multiplexing packet segmentation and reassembly, and the conveying of quality of service information.",
"The information prepared by L2CAP level 434 may then be passed to an application-optional host controller interface (HCI) 436 .",
"This layer may provide a command interface to the lower link manager protocol (LMP) layers, link manager (LM) 438 and link controller (LC) 440 .",
"LM 438 may establish the link setup, authentication, link configuration and other protocols related to establishing a wireless link between two or more devices.",
"Further, LC 440 may manage active links between two or more devices by handling low-level baseband protocols.",
"Wireless communication may then be established and conducted using the hardware (modem, antenna, etc.) making up physical layer (PHY) 442 .",
"The Bluetooth™ protocol stack layers may also be utilized in an order reversed from that disclosed above in order to receive wireless transmissions.",
"[0051] FIG. 5 discloses further detail regarding Bluetooth™ profiles layer 432 .",
"The profiles 502 - 522 define various standardized tasks that may be completed via Bluetooth™ communication.",
"For example, developers may use these profiles in order to make sure that their application will interface correctly with the Bluetooth™.",
"The profiles are organized in a hierarchy, wherein each subsequent profile relies on the definitions in the profile from which it depends.",
"General access profile (GAP) 502 provides the basis for all other profiles and defines a consistent means with which to establish a wireless link between devices (e.g., the device requirements and procedures needed to link the devices, etc.) Under GAP 502 exist basic profiles utilized to establish transactions between two or more devices.",
"Service discovery profile (SDP) 504 delineates how a device should discover services in another device.",
"Serial port profile (SPP) 506 defines how to establish a virtual serial port between two devices.",
"Human interface device profile (HID) 508 defines how various pointing and other user interface devices will wirelessly interact with WCD 100 .",
"Generic object exchange profile (GOEP) 510 is the general profile that dictates how objects may be transferred from one device to another, and Hardcopy cable replacement profile (HCRP) 512 defines how driver-based printing is done over a wireless link.",
"[0052] The aforementioned exemplary Bluetooth™ Profiles 423 may be further broken down into more specialized functions.",
"For example, SPP 506 may further incorporate dial-up networking profile (DUN) 514 and headset profile (HSP) 516 .",
"DUN 514 may be utilized for accessing the Internet using Bluetooth™ while HSP 516 defines how a Bluetooth™-enabled headset should communicate with WCD 100 .",
"Profiles included under GEOP 510 include file transfer profile (FTP) 518 , object push profile (OPP) 520 , synchronization profile (SYNC) 522 and Basic Printing Profile (BPP) 524 .",
"These profiles are all used to define specific instances wherein information is transferred from one device to another device.",
"This information may include files, folders, calendar information, email information, virtual business cards and various other types of electronic information.",
"The information may be pushed to/pulled from a device.",
"III.",
"Basic Profiles for Wireless Communication.",
"[0053] It is important to realize that as wireless mediums like Bluetooth™ evolve, that older profiles may be altered and new profiles may evolve based on consumer demand.",
"The profiles previously set forth represent only a small portion of the profiles generally available for interfacing with the wireless medium.",
"Further, the discussion in the present disclosure will be focused on OPP 520 .",
"While OPP 520 is a Bluetooth™ profile that may be used with the present invention, the present invention is not specifically limited to only this profile/medium.",
"The present invention may be applicable to any wireless transaction between at least two devices.",
"[0054] OPP 520 may define the roles of a push server device and a push client device.",
"These roles are analogous to, and must interoperate with, the server and client device roles that are previously defined by GOEP 510 .",
"It is called “push”",
"because the transfers are always instigated by the sender (client), not the receiver (server).",
"OPP 520 focuses on a narrow range of object formats to maximize interoperability.",
"The most common acceptable format is the vCard.",
"OPP 520 may also be used for sending objects such as pictures, appointment details, etc.",
"[0055] FIG. 6A discloses an exemplary transaction as defined by OPP 520 .",
"Device A 600 (hereafter, “client 600 ”) may transmit or “push”",
"a data object to Device B 602 (hereafter, “server 602 ”).",
"Client 600 and server 602 may be, for example, communication devices similar to WCD 100 .",
"Client 600 , after a connection is established, may push an object (e.g., a vCard or iCalendar information) to server 602 .",
"In a push transaction, client 600 may both initiate the connection with the server and then push the object to the server.",
"The object, if in accordance with a standard format, may then be quickly assimilated into applications running on client 600 .",
"[0056] FIG. 6B follows the example given in FIG. 6A and offers additional detail.",
"Client 600 is pushing information to server 602 in accordance with OPP 520 .",
"However, this example specifies that no security is required (e.g., no encryption).",
"Each profile defines some security requirements, but there is no “property”",
"in a transaction to dictate whether a link should be secure.",
"Instead, each device in the transaction is free to initiate the enabling of a secure link.",
"[0057] The implications of this transaction are that information is transmitted without any security measures in place, allowing the information to be intercepted by other listening wireless devices within transmission range of server 602 .",
"A third party receiving this information could possibly use it for malicious intent.",
"For example, if the information is sensitive or confidential, such as personal identification information, billing information, credit card information, etc.",
", the third party could use it to impersonate the sending party or possibly to purchase items with their credit card.",
"This situation is also a good scenario for a “man-in-the-middle”",
"attack, wherein the wireless communication device of the third party could intercept, change and rebroadcast the information before it reaches client 600 .",
"The attack results in client 600 receiving erroneous or fraudulent information from the third party device instead of the expected object pushed from server 602 .",
"With these examples in mind, enabling security whenever possible seems beneficial.",
"[0058] Now referring to FIG. 7 , the previously set forth data transaction is improved in accordance with at least one embodiment of the present invention.",
"In this example employing OPP 520 , client 600 is again pushing information to server 602 .",
"However, in this scenario client 600 is also attempting to determine if security is available, such as encrypting the object push message.",
"Encryption may be available, for example, when the devices have been previously paired.",
"When two devices have already been established as a pair, passkeys and/or other authenticating means have already been used in initially establishing a connection and generating the corresponding link key or association information.",
"This reusable information may be retained on the devices so that client 600 and server 602 may quickly authenticate to each other and encrypt the link during subsequent connections.",
"In this example, after client 600 determines that the devices have been previously paired, the devices may both activate stronger security by encrypting the object push message so that only server 600 may interpret it.",
"Alternatively, if the devices have not been previously paired, and no other security measures are available, the transaction may proceed as requested without any encryption being implemented.",
"[0059] FIG. 8 further discloses an exemplary process flow diagram in accordance with at least one embodiment of the present invention.",
"In step 800 a connection is established between client 600 and server 602 .",
"This connection may be a new connection (e.g., the devices are encountering each other for the first time) or the devices may have previously been paired.",
"After the connection is established, client 600 may initiate a transaction to push a data object to server 602 in step 802 .",
"If these devices have not been paired before (as determined in step 804 ) then the transaction may proceed without any security provisions (provided that the higher layers do not enforce security provisions for this connection) in step 806 , which results in the object being pushed from the server to the client in step 808 .",
"[0060] If in step 804 it is determined that these devices have been paired previously, then an optional step 810 may occur.",
"In this optional step a message is displayed on the user interface of one or both client 600 and server 602 that alerts the users of these devices that security (e.g., encryption) is available and inquires whether to implement it for this transaction.",
"If either user replies affirmatively (to require encryption) then security may be activated in step 810 .",
"Otherwise, the transaction may proceed as previously discussed with respect to step 806 .",
"If either user requests encryption, or if step 810 is not utilized so that encryption may occur automatically when available, then in step 812 established link key information may be used to encrypt the OPP 520 transaction and push the object from server to client (step 814 ).",
"[0061] The present invention is an improvement over existing systems in at least one benefit that may be realized in automatically enabling security in a wireless transaction when information required for message encryption/decryption already exists.",
"In this way a transaction may be secured, if possible, without inconveniencing and/or possibly even embarrassing a user of a wireless communication device.",
"[0062] Accordingly, it will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention.",
"The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents."
] |
CROSS REFERENCES TO CO-PENDING APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a safety rail system for providing a protective barrier for blocking access to a hazardous area or for preventing falls from an elevated area.
2. Description of the Prior Art
Prior art safety rail systems required the user to secure components of the systems by some type of securing method, such as by using anchor bolts or by welding pieces together. One similar prior art system to this invention utilizes cast bases and rail sections. This system uses two post receivers on each cast base to support only two rail sections. In each post receiver are four cast holes spaced 90 degrees from one another. These holes are used to secure the rail sections to the base with some type of securing pin. In contrast, the present invention utilizes a plurality of offset slots instead of holes to provide for infinite positioning.
A common prior art system has toe board receiver slots cast into the perimeter of the base itself, creating protrusions. These protrusions could extend up to six inches from the base surface. In contrast, this invention uses removable toe board adapters. By utilizing the adapter method, potential hazards due to protrusions extending from the base are eliminated. One hazard is a potential tip-over of a forklift driving over the protrusion. Another potential hazard is human injury should someone trip over the protrusion and fall. These protrusions also become a nuisance when toe boards are not in use.
No known system allows for infinite positioning and in addition has locking gates and removable toe board adapters. The present invention provides for all three of these features inclusive or independent.
SUMMARY OF THE INVENTION
The general purpose of the present invention is to provide a safety rail system which is intended to be used to cordon off work areas and the like where human safety is an issue. When the cast iron base is coupled to the rail and/or gate sections, it has enough weight, mass and strength to withstand tipping. Thus, the system provides a safe means of protection should one fall against it. It also meets and exceeds OSHA regulations for permanent safety railings. When used on an elevated work surface, optional toe board adapters are added. These adapters enable the system to be in accordance with OSHA regulations pertaining to elevated work areas.
The base is the vital component of this invention and enables the system to be as versatile as it is described herein. The base has four post receivers so as to enable as many as four rail sections, latching posts, or gate posts to be incorporated at any one time. Thus, the system has the versatility to have up to four quadrants of work areas to be defined by the base placement. The base also incorporates four symmetrically positioned holes to enable a permanent mount to a surface, via some form of anchor bolts, if desired.
Designed into each of the post receivers are strategically positioned slots. These slots will align with two vertically spaced holes in the vertical posts of the rail sections. This alignment will enable the rail sections to be secured to the base at infinite positions along a 360° rotation with some type of locking pin.
The rail sections used in this invention come in varying lengths and are comprised of iron tubing with a sufficient wall thickness to withstand the potential force that could be exerted when a person falls against a rail section. It is to be understood that aluminum or another appropriate material may be used in the rail section construction. The rail sections include a rail-locking system that adds additional strength to the entire system, preventing tipping. The vertical posts of each rail section have doughnut-shaped metal pieces (securing rings) welded at equal heights from the bottoms of the posts. The securing rings have precise internal cutouts that enable each rail section to be secured to each other with some type of securing means. A carabiner or locking safety chain would be sufficient to additionally secure the rail sections together. The internal cutouts enable the rail sections to be secured to one another at infinite directions of any rail section that is incorporated in the base at any one time.
This invention incorporates a derivative of the rail section. It is a gate assembly that is utilized to access a work area without having to remove locking pins and a rail section to gain access. A coupler is designed to attach and lock a gate post to a base post receiver. This feature is important so it can lock the angle of assembly of the gate post to the base. Without the coupler, the gate post would move within the post receiver slots and then would not align with the gate latching post after moving from its original installation position.
When this invention is used on an elevated work surface, as defined by OSHA regulations, an adapter or receiver for required toe boards is available. Toe boards are intended to keep objects from being kicked over the elevated work surface that may cause injury to someone below. These toe board adapters or receivers slide onto the lower ends of the vertical posts of each rail section and then are lowered onto the toe board. After positioning onto the toe board, the adapters are secured to the rail section with a securing bolt or knob of one's choice. The toe boards are then secured to the adapter by nails or by a locking pin that is similar to or the same as that used to secure the rail section to the base. Because these adapters are designed to rotate on the vertical post before being locked into place, they can be positioned in any direction so that they follow the in-line path of the rail section itself.
This invention comes with an optional number of horizontal cross members or vertical posts that can be welded to the rail sections. This feature enables this portable system to be used in a variety of markets. One example of this feature is the agricultural market. One could specify the requirements of spacing between the horizontal/vertical spacing of the cross members so that animals could not escape from a livestock pen created using this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 illustrates a perspective view of a safety rail system, the present invention;
FIG. 2 illustrates a top view of a base;
FIG. 3 illustrates a side view of the base;
FIG. 4 illustrates a front view of two rail sections connected together using rail lock donuts and a securing chain;
FIG. 5 illustrates a front view of a gate assembly including a gate section in conjunction with a latching post and a gate post;
FIG. 6 illustrates a front view of a gate post and gate section where a locking coupler secures the gate post to a post receiver of a base;
FIG. 7 illustrates a cross sectional view of the locking coupler;
FIG. 8 illustrates a top view of a rail lock donut;
FIG. 9 illustrates a front view of a rail section supported by two bases and incorporating a toe board secured in place by toe board receivers;
FIG. 10 illustrates a front view of a toe board receiver;
FIG. 11 illustrates a side view of a toe board receiver;
FIG. 12 illustrates a perspective view of the safety rail system configured for use in a manufacturing facility;
FIG. 13 illustrates a perspective view of the safety rail system constructed around a construction dig site; and,
FIG. 14 illustrates a perspective view of a base and rail section depicting how each post receiver has a 360° rotation capacity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a perspective view of a safety rail system 10 , the present invention. This illustration shows the safety rail system 10 assembled on a rooftop in a random configuration. The safety rail system 10 is comprised of a plurality of rail sections 12 a - 12 n, a plurality of bases 14 a - 14 n, a plurality of rail lock donuts 16 a - 16 n, a plurality of securing chains 18 a - 18 n, and a plurality of toe boards 20 a - 20 n used in conjunction with a plurality of toe board receivers 22 a - 22 n. Each component will be later described in detail with reference to the following figures.
FIG. 2 illustrates a top view of a base 14 a, and FIG. 3 illustrates a side view of base 14 a. The bases 14 a - 14 n weigh between 100-120 lbs. and are cast iron or welded plate and tube to support rail sections 12 a - 12 n without tipping. Each base 14 a - 14 n is constructed in the same manner having identical parts including a planar portion 42 with cutouts 40 a - 40 d on four opposing sides creating built-in handles for transporting it. There is also a centrally located lifting bar 46 which allows the user to hook the bases 14 a - 14 n to a pulley or a dolly to more easily move the heavy bases 14 a - 14 n. There are provided holes 38 a - 38 d which accommodate anchor bolts for securing the bases 14 a - 14 n to a work surface such as a concrete floor or roof top if permanent mounting is desired. The key feature of the bases 14 a - 14 n is four post receivers 36 a - 36 d which extend perpendicularly upward from planar portion 42 . Rail sections 12 a - 12 n are identical and each includes any number of horizontal rails 23 a - 23 n connected at their ends to vertical posts 24 a - 24 b. The vertical posts 24 a - 24 b are positioned in the post receivers 36 a - 36 n allowing the rail sections 12 a - 12 n to be positioned in any position in a 360° range. Each of these post receivers 36 a - 36 d includes a plurality of slots 44 a - 44 n; and the vertical posts 24 a - 24 b of the rail sections 12 a - 12 n incorporate a plurality of corresponding holes 48 a - 48 n, as shown in FIG. 4, for receiving locking pins 30 (FIGS. 9) to hold the rail sections 12 a - 12 n in place in the bases 14 a - 14 n once the desired position is acquired. Once the rail sections 12 a - 12 n are secured to bases 14 a - 14 n at each end, the slots will allow the rail sections 12 a - 12 n to pivot. Each base 14 a - 14 n may accommodate a maximum of four rail sections 12 a - 12 n which can be locked in any position within their range of motion. It is to be understood that the slots 44 a - 44 n may be substituted with multiple holes at different heights, but holes will not allow the infinite 360° range at which the rail sections 12 a - 12 n may be locked. The post receivers 36 a - 36 d can also accommodate a latching post and/or a gate post which will be described with reference to FIGS. 4 and 5.
FIG. 4 illustrates a front view of two rail sections 12 a - 12 n connected together using rail lock donuts 16 a - 16 n and a securing chain 18 a, and FIG. 5 illustrates a front view of a gate assembly which includes a gate section 32 a in conjunction with a latching post 28 a and a gate post 34 a. Each gate section 32 a - 32 n includes any number of horizontal rails 25 a - 25 n connected at their ends to vertical posts 26 a - 26 b. A plurality of latching posts 28 a - 28 n and a plurality of gate posts 34 a - 34 n may be used in any configuration. Illustrated in these figures are the holes 48 a - 48 n which were mentioned in connection with the previous figures. The latching post 28 a and the gate post 34 a also incorporate holes 48 a - 48 n identical to those in the vertical posts 24 a - 24 b of the rail sections 12 a - 12 n and these holes serve the same purpose. Also illustrated are hinges 50 a - 50 n which are secured to the gate post 34 a in at least two positions. The opposite ends of hinges 50 a - 50 n secure to the vertical post 26 b of gate section 32 a, creating a pivoting gate. The gate section 32 a also has a gate latch 52 secured on the vertical post 26 a opposite hinges 50 a - 50 n. The gate latch 52 provides a locking means for the gate section 32 a. In the configuration illustrated in FIG. 5, only the gate post 34 a and the latching post 28 a are secured to bases 14 a - 14 n (not illustrated) and gate section 32 a is suspended between them, creating the operational gate. Both the latching post 28 a and the gate post 34 a are locked in position using a locking coupler 54 which will be described with reference to FIGS. 6 and 7. It is necessary to lock the gate post 34 a in position using the locking coupler 54 to prevent pivoting, keeping hinges 50 a - 50 n in position.
FIG. 6 illustrates a front view of a gate post 34 a and gate section 32 a where locking coupler 54 secures gate post 34 a to post receiver 36 a of base 14 a, and FIG. 7 illustrates a cross sectional view of locking coupler 54 . Illustrated in particular is the configuration of the safety rail system 10 components when a gate is needed and the locking coupler 54 is used. Also illustrated are a set of holes 56 a and 56 b which lock the gate post 34 a to the locking coupler 54 and a hole 58 which allows the locking coupler 54 to be secured to post receiver 36 a of base 14 a by a securing knob, bolt or other suitable device.
FIG. 8 illustrates a top view of a rail lock donut 16 a. Illustrated in particular is a hole 60 whereby the rail lock donut 16 a is secured to vertical post 24 a or 24 b of rail section 12 a, and slots 62 a - 62 b which accommodate securing chains 18 a - 18 n, as illustrated in FIGS. 1 and 4.
FIG. 9 illustrates a front view of a rail section 12 a supported by two bases 14 a - 14 n and incorporating a toe board 20 a secured in place by toe board receivers 22 a - 22 n, where all numerals correspond to those elements previously described. With further reference to FIGS. 10 and 11, the use of the toe board will now be described in detail.
FIG. 10 illustrates a front view of a toe board receiver 22 a, and FIG. 11 illustrates a side view of a toe board receiver 22 a. Each toe board receiver 22 a - 22 n includes a sleeve 64 which is slid upwardly over and about the bottom of vertical post 24 a or 24 b of rail section 12 a prior to securing rail section 12 a to base 14 a. Each sleeve 64 has a nut 74 welded to the outside over a hole, not illustrated, in the sleeve 64 , where an L-bolt 76 or the like is screwed through the sleeve 64 and frictionally engages vertical post 24 a or 24 b. The sleeve 64 may also be bolted or welded, if necessary or so desired. There is a board receiver bracket 66 connected at an angle to the sleeve 64 by shaft 68 . The board receiver bracket 66 is straddled over toe board 20 a and appropriately secured thereto through holes 70 a and 70 b by a bolt, securing pin or other appropriate means. Each rail section 12 a - 12 n should include two toe board receivers 22 a - 22 n and one toe board 20 a - 20 n, as illustrated, to prevent materials from being kicked off an elevated work area using the safety rail system 10 .
FIG. 12 illustrates a perspective view of the safety rail system 10 configured for use in a manufacturing facility, where all numerals correspond to those elements previously described. It defines the use for the four post receivers 36 a - 36 d that are incorporated into the bases 14 a - 14 n. Unlimited work areas can be defined with this set-up or one similar to it. Also illustrated is how the gate sections 32 a - 32 n are used in conjunction with the rail sections 12 a - 12 n. These gate sections 32 a - 32 n allow access to the work areas by workers or a forklift, for example. When the gate sections 32 a - 32 n are not in use, they are closed. When closed, these gate sections 32 a - 32 n create a safe barrier just as the solid rail sections 12 a - 12 n would. This illustration shows work areas configured in squares, but it is to be understood that the safety rail system 10 can be configured in any shape needed.
FIG. 13 illustrates a perspective view of the safety rail system 10 constructed around a construction dig site 78 . This configuration allows the safety rail system 10 to follow the various angles that are created by the edge of the dig site 78 and still be secured in position by the locking pins 30 (FIG. 9) at any of the angles shown, as well as an infinite number of angles not shown.
FIG. 14 illustrates a perspective view of a base 14 a and rail section 12 a depicting how each post receiver 36 a - 36 d has the capability to be secured by a locking pin 30 (FIG. 9) to a rail section 12 a - 12 d in a 360° range when utilizing the slots 44 a - 44 n in the post receivers 36 a - 36 d. A plurality of holes at different horizontal planes may be substituted for the plurality of slots 44 a - 44 n, but the holes would limit the direction the rail sections 12 a - 12 n could be positioned and not allow the infinite positioning that slots 44 a - 44 n provide.
MODE OF OPERATION
With reference to FIGS. 1-14, the mode of operation is now described, where all numerals correspond to those elements previously described. The portable safety rail system 10 is comprised of a number of components. The rail sections 12 a - 12 n come in varying lengths. Secured to the vertical posts 24 a - 24 b of a rail section 12 a is a rail-lock donut 16 a - 16 n. These rail lock donuts 16 a - 16 n are secured at equal heights on all rail sections 12 a - 12 n by welding or other appropriate means. When the rail sections 12 a - 12 n are secured in position and the rail lock donuts 16 a - 16 n are coupled with a securing chain 18 a - 18 n, added strength is given to the system should a rail section 12 a - 12 n start to tip over. A carabiner or other suitable device may be substituted for the securing chains 18 a - 18 n. The tipped-over rail section 12 a - 12 n would then try to drag the next attached rail section 12 a - 12 n with it and so on. The overall weight will prevent the safety rail system from tipping over. The rail lock donut 16 a - 16 n is designed so it too can accommodate the infinite directions available to the rail sections 12 a - 12 n as they are turned in the post receivers 36 a - 36 d of bases 14 a - 14 n.
The gate assemblies for the safety rail system 10 are unique in design. A gate assembly is comprised of four major components: namely, one of the gate sections 32 a - 32 n, one of the latching posts 28 a - 28 n, one of the gate posts 34 a - 34 n, and a locking coupler 54 . The latching post 28 a is where a gate latch 52 will secure the gate section 32 a so to not swing to and fro. The gate section 32 a connects via hinges 50 a - 50 n to the gate post 34 a. The gate sections 32 a - 32 n also have the capability to have infinite positions for placement and when the desired direction is found, the locking couplers 54 can easily lock the gate sections 32 a - 32 n into position so they will not move. The locking coupler 54 is made of a lightweight metal such as aluminum. It is machined half way through to be the outside diameter of a gate post 34 a - 34 n . The locking coupler 54 has holes 56 a - 56 b for a securing means such as a spring pin or bolt that can be installed on the gate post 34 a - 34 n so that the gate post 34 a - 34 n cannot be removed. The lower interior of the locking coupler 54 is machined tapered to fit the tapered post receiver 36 a - 36 d, or if tubing is used, it would not need to be tapered. It also has a hole 58 so that a knob can be screwed into the hole and against the post receiver so that the gate post 34 a - 34 n will not rotate when mounted into position.
Although this invention was designed for manufacturing facilities, construction sites, and animal pens, it can be used on elevated work surfaces and meets or exceeds OSHA's regulations for fall protection on an elevated work surface. This invention has optional toe board receivers 22 a - 22 n which are slid over and about the bottoms of each of the vertical posts 24 a - 24 b of the rail sections 12 a - 12 n. A toe board 20 a - 20 n, that meets OSHA'S standards, can be secured to the board receiver bracket 66 and secured with a screw, bolt or locking pin. Once in place, the toe board receiver 22 a - 22 n can be secured to the rail section by tightening the L-bolt 76 against the post receivers 36 a - 36 d of bases 14 a - 14 n. This device was also designed to have infinite directional movement before securement. No matter what position the base 14 a - 14 n is in when the rail section 12 a - 12 n is installed and secured, the toe board receivers 22 a - 22 n will always be able to follow the run of the rail sections 12 a - 12 n.
The bases 14 a - 14 n are of a cast iron design or welded design to meet the weight requirements. They have enough weight that when varying lengths of rail sections 12 a - 12 n or gate sections 32 a - 32 n are secured to the post receivers 36 a - 36 d, the safety rail system 10 can withstand a minimum of 250 pounds of pressure from any angle. This feature allows the system to be in compliance with OSHA's Fall Protection Regulations. Each of the bases 14 a - 14 n has four post receivers 36 a - 36 d which allow the bases 14 a - 14 n to accommodate as many rail sections 12 a - 12 n, thus creating a maximum of four quadrants emanating from each base 14 a - 14 n. The post receivers 36 a - 36 d have strategically positioned slots 44 a - 44 n that enable the rail section 12 a - 12 n to be positioned in infinite directions while setting up another base 14 a - 14 n at the end of the rail section 12 a - 12 n. When the rail section 12 a - 12 n is placed into the desired position, bolts or locking pins 30 are installed through the slots 44 a - 44 n, into the holes 48 a - 48 n on the vertical posts 24 a - 24 b of rail sections 12 a - 12 n. One type of locking pin is a clevis pin with a hole at one end for a lynch pin with a ball detent. A double ring with a lanyard can connect between a top of the clevis pin and the lynch pin for operator convenience. This secures the rail sections 12 a - 12 n in place.
Various modifications can be made to the present invention without departing from the apparent scope hereof.
SAFETY RAIL SYSTEM
PARTS LIST
10 safety rail system
12 a-n rail sections
14 a-n bases
16 a-n rail lock donut
18 a-n securing chain
20 a-n toe boards
22 a-n toe board receivers
23 a-n horizontal rails (of rail sections)
24 a-b vertical posts (of rail sections)
25 a-n horizontal rails (of gate sections)
26 a-b vertical posts (of gate sections)
28 a-n latching posts
30 locking pin
32 a-n gate sections
34 a-n gate posts
36 a-d post receivers
38 a-d holes
40 a-d cutouts
42 planar portion
44 a-n slots
46 lifting bar
48 a-n holes
50 a-n hinges
52 gate latch
54 locking coupler
56 a-b holes
58 hole
60 hole
62 a-b slots
64 sleeve
66 board receiver bracket
68 shaft
70 a-b holes
74 nut
76 L-bolt
78 dig site | An improved portable safety guardrail system which utilizes cast iron bases or welded bases and tubular guardrail sections and gates. The system is designed to meet and exceed OSHA Fall Protection Regulations while having the appeal of being modular and portable with no need for anchoring devices (i.e., anchor bolts, etc.). This invention allows for infinite configuration of a guardrail system to suit the needs of the user. | Identify and summarize the most critical features from the given passage. | [
"CROSS REFERENCES TO CO-PENDING APPLICATIONS None.",
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention pertains to a safety rail system for providing a protective barrier for blocking access to a hazardous area or for preventing falls from an elevated area.",
"Description of the Prior Art Prior art safety rail systems required the user to secure components of the systems by some type of securing method, such as by using anchor bolts or by welding pieces together.",
"One similar prior art system to this invention utilizes cast bases and rail sections.",
"This system uses two post receivers on each cast base to support only two rail sections.",
"In each post receiver are four cast holes spaced 90 degrees from one another.",
"These holes are used to secure the rail sections to the base with some type of securing pin.",
"In contrast, the present invention utilizes a plurality of offset slots instead of holes to provide for infinite positioning.",
"A common prior art system has toe board receiver slots cast into the perimeter of the base itself, creating protrusions.",
"These protrusions could extend up to six inches from the base surface.",
"In contrast, this invention uses removable toe board adapters.",
"By utilizing the adapter method, potential hazards due to protrusions extending from the base are eliminated.",
"One hazard is a potential tip-over of a forklift driving over the protrusion.",
"Another potential hazard is human injury should someone trip over the protrusion and fall.",
"These protrusions also become a nuisance when toe boards are not in use.",
"No known system allows for infinite positioning and in addition has locking gates and removable toe board adapters.",
"The present invention provides for all three of these features inclusive or independent.",
"SUMMARY OF THE INVENTION The general purpose of the present invention is to provide a safety rail system which is intended to be used to cordon off work areas and the like where human safety is an issue.",
"When the cast iron base is coupled to the rail and/or gate sections, it has enough weight, mass and strength to withstand tipping.",
"Thus, the system provides a safe means of protection should one fall against it.",
"It also meets and exceeds OSHA regulations for permanent safety railings.",
"When used on an elevated work surface, optional toe board adapters are added.",
"These adapters enable the system to be in accordance with OSHA regulations pertaining to elevated work areas.",
"The base is the vital component of this invention and enables the system to be as versatile as it is described herein.",
"The base has four post receivers so as to enable as many as four rail sections, latching posts, or gate posts to be incorporated at any one time.",
"Thus, the system has the versatility to have up to four quadrants of work areas to be defined by the base placement.",
"The base also incorporates four symmetrically positioned holes to enable a permanent mount to a surface, via some form of anchor bolts, if desired.",
"Designed into each of the post receivers are strategically positioned slots.",
"These slots will align with two vertically spaced holes in the vertical posts of the rail sections.",
"This alignment will enable the rail sections to be secured to the base at infinite positions along a 360° rotation with some type of locking pin.",
"The rail sections used in this invention come in varying lengths and are comprised of iron tubing with a sufficient wall thickness to withstand the potential force that could be exerted when a person falls against a rail section.",
"It is to be understood that aluminum or another appropriate material may be used in the rail section construction.",
"The rail sections include a rail-locking system that adds additional strength to the entire system, preventing tipping.",
"The vertical posts of each rail section have doughnut-shaped metal pieces (securing rings) welded at equal heights from the bottoms of the posts.",
"The securing rings have precise internal cutouts that enable each rail section to be secured to each other with some type of securing means.",
"A carabiner or locking safety chain would be sufficient to additionally secure the rail sections together.",
"The internal cutouts enable the rail sections to be secured to one another at infinite directions of any rail section that is incorporated in the base at any one time.",
"This invention incorporates a derivative of the rail section.",
"It is a gate assembly that is utilized to access a work area without having to remove locking pins and a rail section to gain access.",
"A coupler is designed to attach and lock a gate post to a base post receiver.",
"This feature is important so it can lock the angle of assembly of the gate post to the base.",
"Without the coupler, the gate post would move within the post receiver slots and then would not align with the gate latching post after moving from its original installation position.",
"When this invention is used on an elevated work surface, as defined by OSHA regulations, an adapter or receiver for required toe boards is available.",
"Toe boards are intended to keep objects from being kicked over the elevated work surface that may cause injury to someone below.",
"These toe board adapters or receivers slide onto the lower ends of the vertical posts of each rail section and then are lowered onto the toe board.",
"After positioning onto the toe board, the adapters are secured to the rail section with a securing bolt or knob of one's choice.",
"The toe boards are then secured to the adapter by nails or by a locking pin that is similar to or the same as that used to secure the rail section to the base.",
"Because these adapters are designed to rotate on the vertical post before being locked into place, they can be positioned in any direction so that they follow the in-line path of the rail section itself.",
"This invention comes with an optional number of horizontal cross members or vertical posts that can be welded to the rail sections.",
"This feature enables this portable system to be used in a variety of markets.",
"One example of this feature is the agricultural market.",
"One could specify the requirements of spacing between the horizontal/vertical spacing of the cross members so that animals could not escape from a livestock pen created using this invention.",
"BRIEF DESCRIPTION OF THE DRAWINGS Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein: FIG. 1 illustrates a perspective view of a safety rail system, the present invention;",
"FIG. 2 illustrates a top view of a base;",
"FIG. 3 illustrates a side view of the base;",
"FIG. 4 illustrates a front view of two rail sections connected together using rail lock donuts and a securing chain;",
"FIG. 5 illustrates a front view of a gate assembly including a gate section in conjunction with a latching post and a gate post;",
"FIG. 6 illustrates a front view of a gate post and gate section where a locking coupler secures the gate post to a post receiver of a base;",
"FIG. 7 illustrates a cross sectional view of the locking coupler;",
"FIG. 8 illustrates a top view of a rail lock donut;",
"FIG. 9 illustrates a front view of a rail section supported by two bases and incorporating a toe board secured in place by toe board receivers;",
"FIG. 10 illustrates a front view of a toe board receiver;",
"FIG. 11 illustrates a side view of a toe board receiver;",
"FIG. 12 illustrates a perspective view of the safety rail system configured for use in a manufacturing facility;",
"FIG. 13 illustrates a perspective view of the safety rail system constructed around a construction dig site;",
"and, FIG. 14 illustrates a perspective view of a base and rail section depicting how each post receiver has a 360° rotation capacity.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 illustrates a perspective view of a safety rail system 10 , the present invention.",
"This illustration shows the safety rail system 10 assembled on a rooftop in a random configuration.",
"The safety rail system 10 is comprised of a plurality of rail sections 12 a - 12 n, a plurality of bases 14 a - 14 n, a plurality of rail lock donuts 16 a - 16 n, a plurality of securing chains 18 a - 18 n, and a plurality of toe boards 20 a - 20 n used in conjunction with a plurality of toe board receivers 22 a - 22 n. Each component will be later described in detail with reference to the following figures.",
"FIG. 2 illustrates a top view of a base 14 a, and FIG. 3 illustrates a side view of base 14 a. The bases 14 a - 14 n weigh between 100-120 lbs.",
"and are cast iron or welded plate and tube to support rail sections 12 a - 12 n without tipping.",
"Each base 14 a - 14 n is constructed in the same manner having identical parts including a planar portion 42 with cutouts 40 a - 40 d on four opposing sides creating built-in handles for transporting it.",
"There is also a centrally located lifting bar 46 which allows the user to hook the bases 14 a - 14 n to a pulley or a dolly to more easily move the heavy bases 14 a - 14 n. There are provided holes 38 a - 38 d which accommodate anchor bolts for securing the bases 14 a - 14 n to a work surface such as a concrete floor or roof top if permanent mounting is desired.",
"The key feature of the bases 14 a - 14 n is four post receivers 36 a - 36 d which extend perpendicularly upward from planar portion 42 .",
"Rail sections 12 a - 12 n are identical and each includes any number of horizontal rails 23 a - 23 n connected at their ends to vertical posts 24 a - 24 b. The vertical posts 24 a - 24 b are positioned in the post receivers 36 a - 36 n allowing the rail sections 12 a - 12 n to be positioned in any position in a 360° range.",
"Each of these post receivers 36 a - 36 d includes a plurality of slots 44 a - 44 n;",
"and the vertical posts 24 a - 24 b of the rail sections 12 a - 12 n incorporate a plurality of corresponding holes 48 a - 48 n, as shown in FIG. 4, for receiving locking pins 30 (FIGS.",
"9) to hold the rail sections 12 a - 12 n in place in the bases 14 a - 14 n once the desired position is acquired.",
"Once the rail sections 12 a - 12 n are secured to bases 14 a - 14 n at each end, the slots will allow the rail sections 12 a - 12 n to pivot.",
"Each base 14 a - 14 n may accommodate a maximum of four rail sections 12 a - 12 n which can be locked in any position within their range of motion.",
"It is to be understood that the slots 44 a - 44 n may be substituted with multiple holes at different heights, but holes will not allow the infinite 360° range at which the rail sections 12 a - 12 n may be locked.",
"The post receivers 36 a - 36 d can also accommodate a latching post and/or a gate post which will be described with reference to FIGS. 4 and 5.",
"FIG. 4 illustrates a front view of two rail sections 12 a - 12 n connected together using rail lock donuts 16 a - 16 n and a securing chain 18 a, and FIG. 5 illustrates a front view of a gate assembly which includes a gate section 32 a in conjunction with a latching post 28 a and a gate post 34 a. Each gate section 32 a - 32 n includes any number of horizontal rails 25 a - 25 n connected at their ends to vertical posts 26 a - 26 b. A plurality of latching posts 28 a - 28 n and a plurality of gate posts 34 a - 34 n may be used in any configuration.",
"Illustrated in these figures are the holes 48 a - 48 n which were mentioned in connection with the previous figures.",
"The latching post 28 a and the gate post 34 a also incorporate holes 48 a - 48 n identical to those in the vertical posts 24 a - 24 b of the rail sections 12 a - 12 n and these holes serve the same purpose.",
"Also illustrated are hinges 50 a - 50 n which are secured to the gate post 34 a in at least two positions.",
"The opposite ends of hinges 50 a - 50 n secure to the vertical post 26 b of gate section 32 a, creating a pivoting gate.",
"The gate section 32 a also has a gate latch 52 secured on the vertical post 26 a opposite hinges 50 a - 50 n. The gate latch 52 provides a locking means for the gate section 32 a. In the configuration illustrated in FIG. 5, only the gate post 34 a and the latching post 28 a are secured to bases 14 a - 14 n (not illustrated) and gate section 32 a is suspended between them, creating the operational gate.",
"Both the latching post 28 a and the gate post 34 a are locked in position using a locking coupler 54 which will be described with reference to FIGS. 6 and 7.",
"It is necessary to lock the gate post 34 a in position using the locking coupler 54 to prevent pivoting, keeping hinges 50 a - 50 n in position.",
"FIG. 6 illustrates a front view of a gate post 34 a and gate section 32 a where locking coupler 54 secures gate post 34 a to post receiver 36 a of base 14 a, and FIG. 7 illustrates a cross sectional view of locking coupler 54 .",
"Illustrated in particular is the configuration of the safety rail system 10 components when a gate is needed and the locking coupler 54 is used.",
"Also illustrated are a set of holes 56 a and 56 b which lock the gate post 34 a to the locking coupler 54 and a hole 58 which allows the locking coupler 54 to be secured to post receiver 36 a of base 14 a by a securing knob, bolt or other suitable device.",
"FIG. 8 illustrates a top view of a rail lock donut 16 a. Illustrated in particular is a hole 60 whereby the rail lock donut 16 a is secured to vertical post 24 a or 24 b of rail section 12 a, and slots 62 a - 62 b which accommodate securing chains 18 a - 18 n, as illustrated in FIGS. 1 and 4.",
"FIG. 9 illustrates a front view of a rail section 12 a supported by two bases 14 a - 14 n and incorporating a toe board 20 a secured in place by toe board receivers 22 a - 22 n, where all numerals correspond to those elements previously described.",
"With further reference to FIGS. 10 and 11, the use of the toe board will now be described in detail.",
"FIG. 10 illustrates a front view of a toe board receiver 22 a, and FIG. 11 illustrates a side view of a toe board receiver 22 a. Each toe board receiver 22 a - 22 n includes a sleeve 64 which is slid upwardly over and about the bottom of vertical post 24 a or 24 b of rail section 12 a prior to securing rail section 12 a to base 14 a. Each sleeve 64 has a nut 74 welded to the outside over a hole, not illustrated, in the sleeve 64 , where an L-bolt 76 or the like is screwed through the sleeve 64 and frictionally engages vertical post 24 a or 24 b. The sleeve 64 may also be bolted or welded, if necessary or so desired.",
"There is a board receiver bracket 66 connected at an angle to the sleeve 64 by shaft 68 .",
"The board receiver bracket 66 is straddled over toe board 20 a and appropriately secured thereto through holes 70 a and 70 b by a bolt, securing pin or other appropriate means.",
"Each rail section 12 a - 12 n should include two toe board receivers 22 a - 22 n and one toe board 20 a - 20 n, as illustrated, to prevent materials from being kicked off an elevated work area using the safety rail system 10 .",
"FIG. 12 illustrates a perspective view of the safety rail system 10 configured for use in a manufacturing facility, where all numerals correspond to those elements previously described.",
"It defines the use for the four post receivers 36 a - 36 d that are incorporated into the bases 14 a - 14 n. Unlimited work areas can be defined with this set-up or one similar to it.",
"Also illustrated is how the gate sections 32 a - 32 n are used in conjunction with the rail sections 12 a - 12 n. These gate sections 32 a - 32 n allow access to the work areas by workers or a forklift, for example.",
"When the gate sections 32 a - 32 n are not in use, they are closed.",
"When closed, these gate sections 32 a - 32 n create a safe barrier just as the solid rail sections 12 a - 12 n would.",
"This illustration shows work areas configured in squares, but it is to be understood that the safety rail system 10 can be configured in any shape needed.",
"FIG. 13 illustrates a perspective view of the safety rail system 10 constructed around a construction dig site 78 .",
"This configuration allows the safety rail system 10 to follow the various angles that are created by the edge of the dig site 78 and still be secured in position by the locking pins 30 (FIG.",
"9) at any of the angles shown, as well as an infinite number of angles not shown.",
"FIG. 14 illustrates a perspective view of a base 14 a and rail section 12 a depicting how each post receiver 36 a - 36 d has the capability to be secured by a locking pin 30 (FIG.",
"9) to a rail section 12 a - 12 d in a 360° range when utilizing the slots 44 a - 44 n in the post receivers 36 a - 36 d. A plurality of holes at different horizontal planes may be substituted for the plurality of slots 44 a - 44 n, but the holes would limit the direction the rail sections 12 a - 12 n could be positioned and not allow the infinite positioning that slots 44 a - 44 n provide.",
"MODE OF OPERATION With reference to FIGS. 1-14, the mode of operation is now described, where all numerals correspond to those elements previously described.",
"The portable safety rail system 10 is comprised of a number of components.",
"The rail sections 12 a - 12 n come in varying lengths.",
"Secured to the vertical posts 24 a - 24 b of a rail section 12 a is a rail-lock donut 16 a - 16 n. These rail lock donuts 16 a - 16 n are secured at equal heights on all rail sections 12 a - 12 n by welding or other appropriate means.",
"When the rail sections 12 a - 12 n are secured in position and the rail lock donuts 16 a - 16 n are coupled with a securing chain 18 a - 18 n, added strength is given to the system should a rail section 12 a - 12 n start to tip over.",
"A carabiner or other suitable device may be substituted for the securing chains 18 a - 18 n. The tipped-over rail section 12 a - 12 n would then try to drag the next attached rail section 12 a - 12 n with it and so on.",
"The overall weight will prevent the safety rail system from tipping over.",
"The rail lock donut 16 a - 16 n is designed so it too can accommodate the infinite directions available to the rail sections 12 a - 12 n as they are turned in the post receivers 36 a - 36 d of bases 14 a - 14 n. The gate assemblies for the safety rail system 10 are unique in design.",
"A gate assembly is comprised of four major components: namely, one of the gate sections 32 a - 32 n, one of the latching posts 28 a - 28 n, one of the gate posts 34 a - 34 n, and a locking coupler 54 .",
"The latching post 28 a is where a gate latch 52 will secure the gate section 32 a so to not swing to and fro.",
"The gate section 32 a connects via hinges 50 a - 50 n to the gate post 34 a. The gate sections 32 a - 32 n also have the capability to have infinite positions for placement and when the desired direction is found, the locking couplers 54 can easily lock the gate sections 32 a - 32 n into position so they will not move.",
"The locking coupler 54 is made of a lightweight metal such as aluminum.",
"It is machined half way through to be the outside diameter of a gate post 34 a - 34 n .",
"The locking coupler 54 has holes 56 a - 56 b for a securing means such as a spring pin or bolt that can be installed on the gate post 34 a - 34 n so that the gate post 34 a - 34 n cannot be removed.",
"The lower interior of the locking coupler 54 is machined tapered to fit the tapered post receiver 36 a - 36 d, or if tubing is used, it would not need to be tapered.",
"It also has a hole 58 so that a knob can be screwed into the hole and against the post receiver so that the gate post 34 a - 34 n will not rotate when mounted into position.",
"Although this invention was designed for manufacturing facilities, construction sites, and animal pens, it can be used on elevated work surfaces and meets or exceeds OSHA's regulations for fall protection on an elevated work surface.",
"This invention has optional toe board receivers 22 a - 22 n which are slid over and about the bottoms of each of the vertical posts 24 a - 24 b of the rail sections 12 a - 12 n. A toe board 20 a - 20 n, that meets OSHA'S standards, can be secured to the board receiver bracket 66 and secured with a screw, bolt or locking pin.",
"Once in place, the toe board receiver 22 a - 22 n can be secured to the rail section by tightening the L-bolt 76 against the post receivers 36 a - 36 d of bases 14 a - 14 n. This device was also designed to have infinite directional movement before securement.",
"No matter what position the base 14 a - 14 n is in when the rail section 12 a - 12 n is installed and secured, the toe board receivers 22 a - 22 n will always be able to follow the run of the rail sections 12 a - 12 n. The bases 14 a - 14 n are of a cast iron design or welded design to meet the weight requirements.",
"They have enough weight that when varying lengths of rail sections 12 a - 12 n or gate sections 32 a - 32 n are secured to the post receivers 36 a - 36 d, the safety rail system 10 can withstand a minimum of 250 pounds of pressure from any angle.",
"This feature allows the system to be in compliance with OSHA's Fall Protection Regulations.",
"Each of the bases 14 a - 14 n has four post receivers 36 a - 36 d which allow the bases 14 a - 14 n to accommodate as many rail sections 12 a - 12 n, thus creating a maximum of four quadrants emanating from each base 14 a - 14 n. The post receivers 36 a - 36 d have strategically positioned slots 44 a - 44 n that enable the rail section 12 a - 12 n to be positioned in infinite directions while setting up another base 14 a - 14 n at the end of the rail section 12 a - 12 n. When the rail section 12 a - 12 n is placed into the desired position, bolts or locking pins 30 are installed through the slots 44 a - 44 n, into the holes 48 a - 48 n on the vertical posts 24 a - 24 b of rail sections 12 a - 12 n. One type of locking pin is a clevis pin with a hole at one end for a lynch pin with a ball detent.",
"A double ring with a lanyard can connect between a top of the clevis pin and the lynch pin for operator convenience.",
"This secures the rail sections 12 a - 12 n in place.",
"Various modifications can be made to the present invention without departing from the apparent scope hereof.",
"SAFETY RAIL SYSTEM PARTS LIST 10 safety rail system 12 a-n rail sections 14 a-n bases 16 a-n rail lock donut 18 a-n securing chain 20 a-n toe boards 22 a-n toe board receivers 23 a-n horizontal rails (of rail sections) 24 a-b vertical posts (of rail sections) 25 a-n horizontal rails (of gate sections) 26 a-b vertical posts (of gate sections) 28 a-n latching posts 30 locking pin 32 a-n gate sections 34 a-n gate posts 36 a-d post receivers 38 a-d holes 40 a-d cutouts 42 planar portion 44 a-n slots 46 lifting bar 48 a-n holes 50 a-n hinges 52 gate latch 54 locking coupler 56 a-b holes 58 hole 60 hole 62 a-b slots 64 sleeve 66 board receiver bracket 68 shaft 70 a-b holes 74 nut 76 L-bolt 78 dig site"
] |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 09/539,094, filed Mar. 30, 2000, pending, which is a continuation of application Ser. No. 09/287,502, filed Apr. 7, 1999, now U.S. Pat. No. 6,062,133, issued May 16, 2000, which is a continuation of application Ser. No. 08/761,630, filed Dec. 6, 1996, now U.S. Pat. No. 5,967,030, issued Oct. 19, 1999, which is a divisional of application Ser. No. 08/560,552, filed Nov. 17, 1995, abandoned.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to creating planar surfaces on a substrate. More particularly, the present invention relates to global planarization methods and apparatuses designed to produce a microscopically smooth surface on a semiconductor wafer.
[0004] 2. Background of Related Art
[0005] Integrated circuits are typically constructed by depositing layers of predetermined materials to form the circuit components on a wafer shaped semiconductor substrate. The formation of the circuit components in each layer produces a rough, or planar topography on the surface of the wafer. The resulting nonplanar surface must be made smooth and planar to provide a proper surface for the formation of subsequent layers of the integrated circuitry. Planarization of the outermost surface of the wafer is performed locally over small regions of the wafers and globally over the entire surface. Typically, a layer of oxide is deposited over the exposed circuit layer to provide an insulating layer for the circuit and to locally planarize regions. A thicker layer is then deposited on top of the insulating layer to provide a surface that can be globally planarized without damaging the deposited circuitry. The thick outer layer is generally composed of an oxide or a polymer material. Spin coating is a commonly used technique to form the thick polymer layers on a wafer. Thick oxide layers can be deposited using conventional deposition techniques. While those techniques are useful in producing uniform thickness layers, neither technique is particularly effective at producing a planar surface when applied to a nonplanar surface. As such, additional surface preparation is generally required prior to forming additional circuit layers on the wafer.
[0006] Conventional methods for globally planarizing the outermost surface of the wafer include chemical etching and chemical mechanical polishing (CMP) of the surface. In chemical etching, a thick layer is produced over the circuit layer as described above and the thick layer is chemically etched back to planarize the surface. Global planarization by this technique is iterative in that following the etching step, if the surface was not sufficiently smooth, a new layer of polymer or oxide must be formed and subsequently etched back. This process is time consuming, lacks predictability due to the iterative procedure for obtaining a planarized surface and consumes significant amounts of oxides and/or polymers in the process.
[0007] In the CMP technique, a reactive chemical slurry is used in conjunction with a polishing pad to planarize the surface of the wafer. Two problems associated with the CMP techniques are that the chemicals may become unevenly distributed in the pad, and particulates removed from the substrate during the polishing process may become lodged in the pad, both of which result in nonuniformity in the substrate surface. As a result, CMP techniques are generally less desirable since the process is often time consuming, exposes the wafers to aggressive chemicals and may not yield the desired results in terms of final surface quality.
[0008] An alternative to the above techniques is the use of a press planarization technique to globally planarize the surface of the wafer. In global press planarization, a deformable layer is deposited on the surface of the wafer containing the circuit components by conventional processes known in the art, such as by spin coating. The surface of the deformable layer, which is usually an uncured polymer, is pressed against a surface having surface characteristics which are desired for the surface of the wafer. The deformable layer is typically then cured while under pressure to harden the deformable layer to produce a planarized outermost surface of the desired surface quality.
[0009] Apparatuses used to perform the global press planarization are known in the art, such as those disclosed in U.S. Pat. No. 5,434,107 to Paranjpe. A problem with those global planarization apparatuses is encountered due to the need to apply a uniform force to the deformable layers while providing an apparatus to be used in production scale operations. For instance, the pressing surfaces of such apparatuses contain holes to allow loading fingers to pass through the surface and lift the wafer; these holes will invariably lead to nonuniform pressure distributions across the surface of the wafer and in the surface of the deformable layer. Additionally, the force used to planarize is applied directly to the surface of the wafer; therefore, any nonuniformities in the application of the force will be directly propagated to the surface layer resulting in less than optimal surface characteristics. The Paranjpe patent suggests a possible solution to the potential direct application of a nonuniform force through the use of direct fluid contact with the wafer and the application of the planarizing force to the wafer by pressurizing the fluid. However, the use of pressurized fluid contact results in substantial complications involved with handling pressurized fluid, as well as exposing the wafer to the fluid and the necessary addition of drying steps to the process. The aforementioned difficulties result in increased throughput time, require precise production controls and a higher potential for damage to the wafers during processing.
[0010] It is therefore an object of the present invention to provide a method and an apparatus for global process planarization of the surface layer of a semiconductor wafer that is conducive to automated handling and provides for a uniform distribution of force to planarize the surface.
SUMMARY OF THE INVENTION
[0011] The above objects and others are accomplished by a global planarization method and apparatus in accordance with the present invention. The apparatus includes a chamber having a pressing surface and containing a rigid plate and a flexible pressing member or “puck” disposed between the rigid plate and the pressing surface. A semiconductor wafer having a deformable outermost layer is placed on the flexible pressing member so the surface of the deformable layer of the wafer is directly opposite and parallel to the pressing surface. Force is applied to the rigid plate which propagates through the flexible pressing member to press the surface of the wafer against the pressing surface. Preferably, a bellows arrangement is used to further ensure a uniformly applied force to the rigid plate. The flexible puck serves to provide a self adjusting mode of uniformly distributing the applied force to the wafer ensuring the formation of a high quality planar surface. The surface of the wafer assumes the shape of the pressing surface and is cured in a suitable manner while under pressure so that the surface of the wafer maintains the shape of the pressing surface after processing to produce a globally planarized surface on the wafer. After the force is removed from the rigid plate, lift pins are slidably inserted through the rigid plate and the flexible pressing member to lift the wafer off the surface of the flexible pressing member.
[0012] Accordingly, the present invention provides an effective solution to problems associated with planarizing the surfaces of semiconductor wafers on a production scale. These advantages and others will become apparent from the following detailed description of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The preferred embodiment of the present invention will be described in greater detail with reference to the accompanying drawings, wherein like members bear like reference numerals and wherein:
[0014] [0014]FIG. 1 is a side view of a preferred embodiment of the present invention in a first position; and
[0015] [0015]FIG. 2 is a side view of a preferred embodiment of the present invention in a second position.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The operation of the global planarization apparatus 10 will be described generally with reference to the drawings for the purpose of illustrating presently preferred embodiments of the invention only and not for purposes of limiting the same. The global planarization apparatus 10 of the present invention serves to press the surface of a semiconductor wafer 20 having multiple layers including a deformable outermost layer 22 against a fixed pressing surface 32 . The surface of deformable layer 22 will assume the shape and surface characteristics of the pressing surface 32 under the application of a force to the wafer 20 . The deformable layer 22 can then be cured in a suitable manner while pressed against the pressing surface 32 so that the surface of the wafer maintains the surface characteristics corresponding to the pressing surface 32 . FIGS. 1 and 2 show one embodiment of the global planarization apparatus 10 in the rest and pressing modes, respectively. While preferred embodiments of the invention will be discussed with respect to producing a globally planarized highly smooth surface, one skilled in the art will appreciate that the invention can be suitably modified to produce a curved or a textured surface on the wafer 20 .
[0017] In a preferred embodiment, the global planarization apparatus 10 includes a fully enclosed apparatus having a hollow cylindrical chamber body 12 formed from a rigid material, such as aluminum, other metals or hard composites, and having open top and bottom ends, 13 and 14 , respectively, an interior surface 16 and an evacuation port 11 . A base plate 18 having an inner surface 17 is attached to the bottom end 14 of chamber body 12 , by conventional means, such as bolts 94 shown in FIGS. 1 and 2. A press plate 30 is removably mounted to the top end 13 of chamber body 12 with pressing surface 32 facing base plate 18 . The interior surface 16 of chamber body 12 , the pressing surface 32 of press plate 30 and the inner surface 17 of base plate 18 define a sealable chamber. It will be appreciated that evacuation port 11 can be positioned through any surface defining the sealed chamber but not used to engage wafer 20 , such as through base plate 18 , and not solely through chamber body 12 .
[0018] The press plate 30 has a pressing surface 32 with dimensions greater than that of the wafers 20 and is of a sufficient thickness to withstand applied pressures. Press plate 30 is formed from non-adhering material capable of being highly polished, preferably with surface variations less than 500 Angstroms, so that pressing surface 32 will impart the desired smooth and flat surface quality to the surface of the deformable layer 22 on wafer 20 . In a preferred embodiment, the press plate 30 is a disc shaped quartz optical flat. However, material selection for the press plate 30 can be specifically tailored to meet process requirements by considering factors such as the range of applied pressures and the method of hardening the deformable layer, such as heat or radiation (UV, IR, etc.), as well as whether the surface of deformable layer 22 of the wafer 20 will be planar, curved or textured.
[0019] A rigid plate 50 having top and bottom surfaces 52 and 54 , respectively, and lift pin penetrations 56 therethrough is disposed within chamber body 12 with the top surface 52 substantially parallel to and facing the pressing surface 32 . In the case where the surface of wafer 20 is to be curved, the term parallel is understood to mean that all points of the top surface 52 of rigid plate 50 are equidistant from the corresponding points on pressing surface 32 . The rigid plate 50 is constructed from a material of sufficient rigidity, such as aluminum, to transfer a load under an applied force with minimal deformation.
[0020] In a preferred embodiment, a uniform force is applied to the bottom surface 54 of rigid plate 50 through the use of a bellows arrangement 40 and relatively pressurized gas to drive rigid plate 50 toward pressing surface 32 . Such relative pressure can be achieved by supplying gas under pressure or, if the chamber body 12 is under vacuum, allowing atmospheric pressure gas into bellows 40 . The bellows 40 is attached at one end to the bottom surface 54 of rigid plate 50 and to the inner surface 17 of base plate 18 with a bolted mounting plate 15 to form a pressure containment that is relatively pressurized through port 19 in base plate 18 . As shown in FIG. 2, when the bellows 40 is relatively pressurized, a force will be applied on the bottom surface 54 driving the rigid plate 50 toward the pressing surface 32 . As shown in FIG. 1, one or more stand off brackets 42 are mounted to the inner surface 17 of the base plate 18 to limit the motion toward base plate 18 of the rigid plate 50 , when the bellows 40 is not relatively pressurized. The application of force through the use of a relatively pressurized gas ensures the uniform application of force to the bottom surface 54 of rigid plate 50 . The use of rigid plate 50 will serve to propagate the uniform pressure field with minimal distortion. Alternatively, the bellows 40 can be replaced with any other suitable means for consistently delivering a uniform force such as hydraulic and pneumatic linear drives or mechanical or electrical linear displacement mechanisms.
[0021] In a preferred embodiment, a flexible pressing member or “puck” 60 is provided having upper and lower surfaces 62 and 64 , respectively, which are substantially parallel to the top surface 52 of rigid plate 50 and pressing surface 32 . Lift pin penetrations 66 are provided through the puck 60 . The flexible puck 60 is positioned with its lower surface 64 in contact with the top surface 52 of rigid plate 50 and lift pin penetrations 66 aligned with lift pin penetrations 56 in rigid plate 50 . The upper surface 62 of the flexible puck 60 is directly opposite and substantially parallel to the pressing surface 32 of press plate 30 . The flexible puck 60 is formed from a material, such as 30 durometer silicone or other materials of similar low viscosity, that will deform under an applied force to close lift pin penetrations 66 and uniformly distribute the applied force to the wafer, even when the top surface 52 , the upper surface 62 and/or the lower surface 64 is not completely parallel to the pressing surface 32 or when thickness variations exist in the wafer 20 , rigid plate 50 or puck 60 , as well as other sources that result in nonuniformities in the applied force. It is also preferred that puck 60 is formed from a material that is thermally resistant in the temperature ranges of interest.
[0022] In a preferred embodiment, lift pins 70 are slidably disposable through lift pin penetrations, 56 and 66 , respectively, in the form of apertures, to contact the bottom surface 26 of wafer 20 for lifting the wafer 20 off of the top surface 62 of flexible puck 60 . Movement of the lift pins 70 is controlled by a lift pin drive assembly 72 , which is mounted on the inner surface 17 of the base plate 18 . The lift pin drive assembly 72 can provide for either manual or automatic control of the lift pins 70 through the use of pneumatic, hydraulic or other conventional drive means as is known in the art. Lift pins 70 and lift pin drive assembly 72 are preferably positioned outside of the pressure boundary defined by the bellows 40 to minimize the number of pressure boundary penetrations. However, the lift pin 70 and lift pin drive assembly 72 can alternatively be located within the pressure boundary when used in conjunction with vacuum seals in the lift pin penetrations 56 , as is known in the art to maintain the pressure boundary.
[0023] In a preferred embodiment, a multi-piece assembly consisting of lower lid 80 , middle lid 82 , top lid 84 , gasket 86 and top clamp ring 88 is used to secure the press plate 30 to the top end 13 of chamber body 12 . The ring-shaped lower lid 80 is mounted to the top end 13 of chamber body 12 and has a portion with an inner ring dimension smaller than press plate 30 , so that press plate 30 can be seated on lower lid 80 as shown in FIGS. 1 and 2. Middle lid 82 and top lid 84 are ring-shaped members of an inner ring dimension greater than press plate 30 and are disposed around press plate 30 . Middle lid 82 is affixed between lower lid 80 and top lid 84 . A gasket 86 and top clamp ring 88 are ring-shaped members with an inner ring dimension less than press plate 30 and are seated on the surface of press plate 30 external to the chamber. Conventional means, such as bolts 94 shown in FIGS. 1 and 2, are used to secure the press plate 30 to the chamber body 12 . While a multi-piece assembly is used to secure press plate 30 , one skilled in the art will appreciate that other suitable attachment designs are possible, including providing access to the interior chamber through any surface defining the chamber not used to engage wafer 20 .
[0024] In a preferred embodiment, heating elements 90 and thermocouples 92 are provided to control the temperature of the flexible puck 60 . However, it can be appreciated that additional heating elements 90 and thermocouples 92 can be added to the press plate 30 and/or to rigid plate 50 . In a preferred embodiment, any conventional means, such as a vacuum pump, for evacuating the chamber body 12 prior to pressing the wafer 20 against the pressing surface 32 can be used with the present invention.
[0025] In the operation of the present invention, the top clamp ring 88 , gasket 86 , upper lid 84 and middle lid 82 are removed from the chamber body 12 and the press plate 30 is lifted from lower lid 80 . At this stage, the bellows 40 is deflated and rigid plate 50 is seated on stand off brackets 42 . The wafer 20 is then placed on the flexible puck 60 with the side of the wafer 20 opposite the deformable layer 22 in contact with flexible puck 60 . Thereafter, the press plate 30 is returned to its position on the lower lid 80 , and the middle lid 82 and upper lid 84 are reinstalled and tightened down using gasket 86 and top clamp ring 88 thereby sealing press plate 30 between top clamp ring 88 and lower lid 80 . If desirable, the temperatures of flexible puck 60 , press plate 30 and rigid plate 50 can be adjusted through the use of heating elements 90 and monitored by thermocouples 92 to vary the deformation characteristics of the outermost deformable layer 22 of wafer 20 . Preferably, chamber body 12 is then evacuated through port 19 to a pressure of approximately 50 millitorr.
[0026] A pressure differential is established between the interior and exterior of the bellows 40 , either by pressurizing or by venting when the chamber body 12 has been evacuated, to drive rigid plate 50 , puck 60 and wafer 20 toward press plate 30 and bring deformable layer 22 of wafer 20 into engagement with pressing surface 32 of press plate 30 . Upon engagement of the wafer 20 with the press plate 30 , the continued application of force will deform the flexible pressing member 60 which serves to close lift pin penetrations 66 and to distribute the force to ensure the wafer 20 experiences a uniform pressure on its deformable layer 22 . After the wafer 20 has been in engagement with pressing surface 32 for a sufficient time to cause its deformable layer 22 to correspond to the pressing surface 32 , the deformable layer 22 may be cured, if necessary, in any conventional manner, such as radiation or heat, so that the deformable layer 22 of the wafer 20 maintains the shape and surface characteristics corresponding to the pressing surface 32 . The air pressure is then released from the bellows 40 thereby retracting wafer 20 , puck 60 and rigid plate 50 from the press plate 30 . The downward movement of rigid plate 50 will be terminated by its engagement with stand off offset brackets 42 .
[0027] Once the rigid plate 50 is fully retracted, the vacuum is released in chamber body 12 . Lift pins 70 are moved through lift pin penetrations 56 in the rigid plate 50 and lift pin penetrations 66 in the flexible puck 60 to lift wafer 20 off of the flexible puck 60 . The top clamp ring 88 , gasket 86 , top lid 84 , middle lid 82 and press plate 30 are removed and the wafer 20 is removed off of lift pins 70 for further processing.
[0028] A specific example is provided to further illustrate the method and operation of the apparatus. A wafer 20 having a nominal 1-5 micron thick deformable layer 22 consisting of a UV curable epoxy resin is placed on the flexible puck 60 within chamber body 12 . Chamber body 12 is evacuated to a pressure of approximately 50 millitorr. A pressure differential is established across the bellows 40 by venting the bellows 40 to atmosphere to drive wafer 20 against press plate 30 . A pressure of 100 psi is then applied to the wafer 20 for 1 minute at a temperature of approximately 50° C. to shape the surface of the epoxy resin to correspond to that of the pressing surface 32 . The deformable layer 22 is then cured while in contact with press plate 30 by the application of ultraviolet radiation for approximately 15-30 seconds through a quartz optical flat used as press plate 30 .
[0029] Those of ordinary skill in the art will appreciate that the present invention provides great advantages over other options for planarizing deformable surface layers. In particular, the subject invention is designed such that the pressure boundary does not have to be breached to operate the apparatus as is true with prior art designs. The subject invention also eliminates the need to use a pressure boundary as the supporting surface for the wafers. Also, the subject invention has the advantage of providing for the automated handling of the wafers, which was not present in the prior art. Thus, the present invention provides a significant reduction in the overall cost associated with the production of semiconductor wafers. While the subject invention provides these and other advantages over other planarization apparatuses, it will be understood, however, that various changes in the details, materials and arrangements of parts which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. | An apparatus for performing a global planarization of a surface of a deformable layer of a wafer on a production scale. The apparatus includes a chamber having a pressing surface and containing a rigid plate and a flexible pressing member or “puck” disposed between the rigid plate and the pressing surface. A wafer having a deformable outermost layer is placed on the flexible pressing member so the deformable layer of the wafer is directly opposite and substantially parallel to the pressing surface. Force is applied to the rigid plate which propagates through the flexible pressing member to press the deformable layer of the wafer against the pressing surface. Preferably, a bellows arrangement is used to ensure a uniformly applied force to the rigid plate. The flexible puck serves to provide a self adjusting mode of uniformly distributing the applied force to the wafer, ensuring the formation of a high quality planar surface. The surface of the wafer assumes the shape of the pressing surface and is hardened in a suitable manner while under pressure to produce a globally planarized surface on the wafer. After the force is removed from the rigid plate, lift pins are slidably inserted through the rigid plate and the flexible pressing member to lift the wafer off of the surface of the flexible pressing member. | Briefly describe the main invention outlined in the provided context. | [
"CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of application Ser.",
"No. 09/539,094, filed Mar. 30, 2000, pending, which is a continuation of application Ser.",
"No. 09/287,502, filed Apr. 7, 1999, now U.S. Pat. No. 6,062,133, issued May 16, 2000, which is a continuation of application Ser.",
"No. 08/761,630, filed Dec. 6, 1996, now U.S. Pat. No. 5,967,030, issued Oct. 19, 1999, which is a divisional of application Ser.",
"No. 08/560,552, filed Nov. 17, 1995, abandoned.",
"BACKGROUND OF THE INVENTION [0002] 1.",
"Field of the Invention [0003] The present invention relates to creating planar surfaces on a substrate.",
"More particularly, the present invention relates to global planarization methods and apparatuses designed to produce a microscopically smooth surface on a semiconductor wafer.",
"[0004] 2.",
"Background of Related Art [0005] Integrated circuits are typically constructed by depositing layers of predetermined materials to form the circuit components on a wafer shaped semiconductor substrate.",
"The formation of the circuit components in each layer produces a rough, or planar topography on the surface of the wafer.",
"The resulting nonplanar surface must be made smooth and planar to provide a proper surface for the formation of subsequent layers of the integrated circuitry.",
"Planarization of the outermost surface of the wafer is performed locally over small regions of the wafers and globally over the entire surface.",
"Typically, a layer of oxide is deposited over the exposed circuit layer to provide an insulating layer for the circuit and to locally planarize regions.",
"A thicker layer is then deposited on top of the insulating layer to provide a surface that can be globally planarized without damaging the deposited circuitry.",
"The thick outer layer is generally composed of an oxide or a polymer material.",
"Spin coating is a commonly used technique to form the thick polymer layers on a wafer.",
"Thick oxide layers can be deposited using conventional deposition techniques.",
"While those techniques are useful in producing uniform thickness layers, neither technique is particularly effective at producing a planar surface when applied to a nonplanar surface.",
"As such, additional surface preparation is generally required prior to forming additional circuit layers on the wafer.",
"[0006] Conventional methods for globally planarizing the outermost surface of the wafer include chemical etching and chemical mechanical polishing (CMP) of the surface.",
"In chemical etching, a thick layer is produced over the circuit layer as described above and the thick layer is chemically etched back to planarize the surface.",
"Global planarization by this technique is iterative in that following the etching step, if the surface was not sufficiently smooth, a new layer of polymer or oxide must be formed and subsequently etched back.",
"This process is time consuming, lacks predictability due to the iterative procedure for obtaining a planarized surface and consumes significant amounts of oxides and/or polymers in the process.",
"[0007] In the CMP technique, a reactive chemical slurry is used in conjunction with a polishing pad to planarize the surface of the wafer.",
"Two problems associated with the CMP techniques are that the chemicals may become unevenly distributed in the pad, and particulates removed from the substrate during the polishing process may become lodged in the pad, both of which result in nonuniformity in the substrate surface.",
"As a result, CMP techniques are generally less desirable since the process is often time consuming, exposes the wafers to aggressive chemicals and may not yield the desired results in terms of final surface quality.",
"[0008] An alternative to the above techniques is the use of a press planarization technique to globally planarize the surface of the wafer.",
"In global press planarization, a deformable layer is deposited on the surface of the wafer containing the circuit components by conventional processes known in the art, such as by spin coating.",
"The surface of the deformable layer, which is usually an uncured polymer, is pressed against a surface having surface characteristics which are desired for the surface of the wafer.",
"The deformable layer is typically then cured while under pressure to harden the deformable layer to produce a planarized outermost surface of the desired surface quality.",
"[0009] Apparatuses used to perform the global press planarization are known in the art, such as those disclosed in U.S. Pat. No. 5,434,107 to Paranjpe.",
"A problem with those global planarization apparatuses is encountered due to the need to apply a uniform force to the deformable layers while providing an apparatus to be used in production scale operations.",
"For instance, the pressing surfaces of such apparatuses contain holes to allow loading fingers to pass through the surface and lift the wafer;",
"these holes will invariably lead to nonuniform pressure distributions across the surface of the wafer and in the surface of the deformable layer.",
"Additionally, the force used to planarize is applied directly to the surface of the wafer;",
"therefore, any nonuniformities in the application of the force will be directly propagated to the surface layer resulting in less than optimal surface characteristics.",
"The Paranjpe patent suggests a possible solution to the potential direct application of a nonuniform force through the use of direct fluid contact with the wafer and the application of the planarizing force to the wafer by pressurizing the fluid.",
"However, the use of pressurized fluid contact results in substantial complications involved with handling pressurized fluid, as well as exposing the wafer to the fluid and the necessary addition of drying steps to the process.",
"The aforementioned difficulties result in increased throughput time, require precise production controls and a higher potential for damage to the wafers during processing.",
"[0010] It is therefore an object of the present invention to provide a method and an apparatus for global process planarization of the surface layer of a semiconductor wafer that is conducive to automated handling and provides for a uniform distribution of force to planarize the surface.",
"SUMMARY OF THE INVENTION [0011] The above objects and others are accomplished by a global planarization method and apparatus in accordance with the present invention.",
"The apparatus includes a chamber having a pressing surface and containing a rigid plate and a flexible pressing member or “puck”",
"disposed between the rigid plate and the pressing surface.",
"A semiconductor wafer having a deformable outermost layer is placed on the flexible pressing member so the surface of the deformable layer of the wafer is directly opposite and parallel to the pressing surface.",
"Force is applied to the rigid plate which propagates through the flexible pressing member to press the surface of the wafer against the pressing surface.",
"Preferably, a bellows arrangement is used to further ensure a uniformly applied force to the rigid plate.",
"The flexible puck serves to provide a self adjusting mode of uniformly distributing the applied force to the wafer ensuring the formation of a high quality planar surface.",
"The surface of the wafer assumes the shape of the pressing surface and is cured in a suitable manner while under pressure so that the surface of the wafer maintains the shape of the pressing surface after processing to produce a globally planarized surface on the wafer.",
"After the force is removed from the rigid plate, lift pins are slidably inserted through the rigid plate and the flexible pressing member to lift the wafer off the surface of the flexible pressing member.",
"[0012] Accordingly, the present invention provides an effective solution to problems associated with planarizing the surfaces of semiconductor wafers on a production scale.",
"These advantages and others will become apparent from the following detailed description of the present invention.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0013] The preferred embodiment of the present invention will be described in greater detail with reference to the accompanying drawings, wherein like members bear like reference numerals and wherein: [0014] [0014 ]FIG. 1 is a side view of a preferred embodiment of the present invention in a first position;",
"and [0015] [0015 ]FIG. 2 is a side view of a preferred embodiment of the present invention in a second position.",
"DETAILED DESCRIPTION OF THE INVENTION [0016] The operation of the global planarization apparatus 10 will be described generally with reference to the drawings for the purpose of illustrating presently preferred embodiments of the invention only and not for purposes of limiting the same.",
"The global planarization apparatus 10 of the present invention serves to press the surface of a semiconductor wafer 20 having multiple layers including a deformable outermost layer 22 against a fixed pressing surface 32 .",
"The surface of deformable layer 22 will assume the shape and surface characteristics of the pressing surface 32 under the application of a force to the wafer 20 .",
"The deformable layer 22 can then be cured in a suitable manner while pressed against the pressing surface 32 so that the surface of the wafer maintains the surface characteristics corresponding to the pressing surface 32 .",
"FIGS. 1 and 2 show one embodiment of the global planarization apparatus 10 in the rest and pressing modes, respectively.",
"While preferred embodiments of the invention will be discussed with respect to producing a globally planarized highly smooth surface, one skilled in the art will appreciate that the invention can be suitably modified to produce a curved or a textured surface on the wafer 20 .",
"[0017] In a preferred embodiment, the global planarization apparatus 10 includes a fully enclosed apparatus having a hollow cylindrical chamber body 12 formed from a rigid material, such as aluminum, other metals or hard composites, and having open top and bottom ends, 13 and 14 , respectively, an interior surface 16 and an evacuation port 11 .",
"A base plate 18 having an inner surface 17 is attached to the bottom end 14 of chamber body 12 , by conventional means, such as bolts 94 shown in FIGS. 1 and 2.",
"A press plate 30 is removably mounted to the top end 13 of chamber body 12 with pressing surface 32 facing base plate 18 .",
"The interior surface 16 of chamber body 12 , the pressing surface 32 of press plate 30 and the inner surface 17 of base plate 18 define a sealable chamber.",
"It will be appreciated that evacuation port 11 can be positioned through any surface defining the sealed chamber but not used to engage wafer 20 , such as through base plate 18 , and not solely through chamber body 12 .",
"[0018] The press plate 30 has a pressing surface 32 with dimensions greater than that of the wafers 20 and is of a sufficient thickness to withstand applied pressures.",
"Press plate 30 is formed from non-adhering material capable of being highly polished, preferably with surface variations less than 500 Angstroms, so that pressing surface 32 will impart the desired smooth and flat surface quality to the surface of the deformable layer 22 on wafer 20 .",
"In a preferred embodiment, the press plate 30 is a disc shaped quartz optical flat.",
"However, material selection for the press plate 30 can be specifically tailored to meet process requirements by considering factors such as the range of applied pressures and the method of hardening the deformable layer, such as heat or radiation (UV, IR, etc.), as well as whether the surface of deformable layer 22 of the wafer 20 will be planar, curved or textured.",
"[0019] A rigid plate 50 having top and bottom surfaces 52 and 54 , respectively, and lift pin penetrations 56 therethrough is disposed within chamber body 12 with the top surface 52 substantially parallel to and facing the pressing surface 32 .",
"In the case where the surface of wafer 20 is to be curved, the term parallel is understood to mean that all points of the top surface 52 of rigid plate 50 are equidistant from the corresponding points on pressing surface 32 .",
"The rigid plate 50 is constructed from a material of sufficient rigidity, such as aluminum, to transfer a load under an applied force with minimal deformation.",
"[0020] In a preferred embodiment, a uniform force is applied to the bottom surface 54 of rigid plate 50 through the use of a bellows arrangement 40 and relatively pressurized gas to drive rigid plate 50 toward pressing surface 32 .",
"Such relative pressure can be achieved by supplying gas under pressure or, if the chamber body 12 is under vacuum, allowing atmospheric pressure gas into bellows 40 .",
"The bellows 40 is attached at one end to the bottom surface 54 of rigid plate 50 and to the inner surface 17 of base plate 18 with a bolted mounting plate 15 to form a pressure containment that is relatively pressurized through port 19 in base plate 18 .",
"As shown in FIG. 2, when the bellows 40 is relatively pressurized, a force will be applied on the bottom surface 54 driving the rigid plate 50 toward the pressing surface 32 .",
"As shown in FIG. 1, one or more stand off brackets 42 are mounted to the inner surface 17 of the base plate 18 to limit the motion toward base plate 18 of the rigid plate 50 , when the bellows 40 is not relatively pressurized.",
"The application of force through the use of a relatively pressurized gas ensures the uniform application of force to the bottom surface 54 of rigid plate 50 .",
"The use of rigid plate 50 will serve to propagate the uniform pressure field with minimal distortion.",
"Alternatively, the bellows 40 can be replaced with any other suitable means for consistently delivering a uniform force such as hydraulic and pneumatic linear drives or mechanical or electrical linear displacement mechanisms.",
"[0021] In a preferred embodiment, a flexible pressing member or “puck”",
"60 is provided having upper and lower surfaces 62 and 64 , respectively, which are substantially parallel to the top surface 52 of rigid plate 50 and pressing surface 32 .",
"Lift pin penetrations 66 are provided through the puck 60 .",
"The flexible puck 60 is positioned with its lower surface 64 in contact with the top surface 52 of rigid plate 50 and lift pin penetrations 66 aligned with lift pin penetrations 56 in rigid plate 50 .",
"The upper surface 62 of the flexible puck 60 is directly opposite and substantially parallel to the pressing surface 32 of press plate 30 .",
"The flexible puck 60 is formed from a material, such as 30 durometer silicone or other materials of similar low viscosity, that will deform under an applied force to close lift pin penetrations 66 and uniformly distribute the applied force to the wafer, even when the top surface 52 , the upper surface 62 and/or the lower surface 64 is not completely parallel to the pressing surface 32 or when thickness variations exist in the wafer 20 , rigid plate 50 or puck 60 , as well as other sources that result in nonuniformities in the applied force.",
"It is also preferred that puck 60 is formed from a material that is thermally resistant in the temperature ranges of interest.",
"[0022] In a preferred embodiment, lift pins 70 are slidably disposable through lift pin penetrations, 56 and 66 , respectively, in the form of apertures, to contact the bottom surface 26 of wafer 20 for lifting the wafer 20 off of the top surface 62 of flexible puck 60 .",
"Movement of the lift pins 70 is controlled by a lift pin drive assembly 72 , which is mounted on the inner surface 17 of the base plate 18 .",
"The lift pin drive assembly 72 can provide for either manual or automatic control of the lift pins 70 through the use of pneumatic, hydraulic or other conventional drive means as is known in the art.",
"Lift pins 70 and lift pin drive assembly 72 are preferably positioned outside of the pressure boundary defined by the bellows 40 to minimize the number of pressure boundary penetrations.",
"However, the lift pin 70 and lift pin drive assembly 72 can alternatively be located within the pressure boundary when used in conjunction with vacuum seals in the lift pin penetrations 56 , as is known in the art to maintain the pressure boundary.",
"[0023] In a preferred embodiment, a multi-piece assembly consisting of lower lid 80 , middle lid 82 , top lid 84 , gasket 86 and top clamp ring 88 is used to secure the press plate 30 to the top end 13 of chamber body 12 .",
"The ring-shaped lower lid 80 is mounted to the top end 13 of chamber body 12 and has a portion with an inner ring dimension smaller than press plate 30 , so that press plate 30 can be seated on lower lid 80 as shown in FIGS. 1 and 2.",
"Middle lid 82 and top lid 84 are ring-shaped members of an inner ring dimension greater than press plate 30 and are disposed around press plate 30 .",
"Middle lid 82 is affixed between lower lid 80 and top lid 84 .",
"A gasket 86 and top clamp ring 88 are ring-shaped members with an inner ring dimension less than press plate 30 and are seated on the surface of press plate 30 external to the chamber.",
"Conventional means, such as bolts 94 shown in FIGS. 1 and 2, are used to secure the press plate 30 to the chamber body 12 .",
"While a multi-piece assembly is used to secure press plate 30 , one skilled in the art will appreciate that other suitable attachment designs are possible, including providing access to the interior chamber through any surface defining the chamber not used to engage wafer 20 .",
"[0024] In a preferred embodiment, heating elements 90 and thermocouples 92 are provided to control the temperature of the flexible puck 60 .",
"However, it can be appreciated that additional heating elements 90 and thermocouples 92 can be added to the press plate 30 and/or to rigid plate 50 .",
"In a preferred embodiment, any conventional means, such as a vacuum pump, for evacuating the chamber body 12 prior to pressing the wafer 20 against the pressing surface 32 can be used with the present invention.",
"[0025] In the operation of the present invention, the top clamp ring 88 , gasket 86 , upper lid 84 and middle lid 82 are removed from the chamber body 12 and the press plate 30 is lifted from lower lid 80 .",
"At this stage, the bellows 40 is deflated and rigid plate 50 is seated on stand off brackets 42 .",
"The wafer 20 is then placed on the flexible puck 60 with the side of the wafer 20 opposite the deformable layer 22 in contact with flexible puck 60 .",
"Thereafter, the press plate 30 is returned to its position on the lower lid 80 , and the middle lid 82 and upper lid 84 are reinstalled and tightened down using gasket 86 and top clamp ring 88 thereby sealing press plate 30 between top clamp ring 88 and lower lid 80 .",
"If desirable, the temperatures of flexible puck 60 , press plate 30 and rigid plate 50 can be adjusted through the use of heating elements 90 and monitored by thermocouples 92 to vary the deformation characteristics of the outermost deformable layer 22 of wafer 20 .",
"Preferably, chamber body 12 is then evacuated through port 19 to a pressure of approximately 50 millitorr.",
"[0026] A pressure differential is established between the interior and exterior of the bellows 40 , either by pressurizing or by venting when the chamber body 12 has been evacuated, to drive rigid plate 50 , puck 60 and wafer 20 toward press plate 30 and bring deformable layer 22 of wafer 20 into engagement with pressing surface 32 of press plate 30 .",
"Upon engagement of the wafer 20 with the press plate 30 , the continued application of force will deform the flexible pressing member 60 which serves to close lift pin penetrations 66 and to distribute the force to ensure the wafer 20 experiences a uniform pressure on its deformable layer 22 .",
"After the wafer 20 has been in engagement with pressing surface 32 for a sufficient time to cause its deformable layer 22 to correspond to the pressing surface 32 , the deformable layer 22 may be cured, if necessary, in any conventional manner, such as radiation or heat, so that the deformable layer 22 of the wafer 20 maintains the shape and surface characteristics corresponding to the pressing surface 32 .",
"The air pressure is then released from the bellows 40 thereby retracting wafer 20 , puck 60 and rigid plate 50 from the press plate 30 .",
"The downward movement of rigid plate 50 will be terminated by its engagement with stand off offset brackets 42 .",
"[0027] Once the rigid plate 50 is fully retracted, the vacuum is released in chamber body 12 .",
"Lift pins 70 are moved through lift pin penetrations 56 in the rigid plate 50 and lift pin penetrations 66 in the flexible puck 60 to lift wafer 20 off of the flexible puck 60 .",
"The top clamp ring 88 , gasket 86 , top lid 84 , middle lid 82 and press plate 30 are removed and the wafer 20 is removed off of lift pins 70 for further processing.",
"[0028] A specific example is provided to further illustrate the method and operation of the apparatus.",
"A wafer 20 having a nominal 1-5 micron thick deformable layer 22 consisting of a UV curable epoxy resin is placed on the flexible puck 60 within chamber body 12 .",
"Chamber body 12 is evacuated to a pressure of approximately 50 millitorr.",
"A pressure differential is established across the bellows 40 by venting the bellows 40 to atmosphere to drive wafer 20 against press plate 30 .",
"A pressure of 100 psi is then applied to the wafer 20 for 1 minute at a temperature of approximately 50° C. to shape the surface of the epoxy resin to correspond to that of the pressing surface 32 .",
"The deformable layer 22 is then cured while in contact with press plate 30 by the application of ultraviolet radiation for approximately 15-30 seconds through a quartz optical flat used as press plate 30 .",
"[0029] Those of ordinary skill in the art will appreciate that the present invention provides great advantages over other options for planarizing deformable surface layers.",
"In particular, the subject invention is designed such that the pressure boundary does not have to be breached to operate the apparatus as is true with prior art designs.",
"The subject invention also eliminates the need to use a pressure boundary as the supporting surface for the wafers.",
"Also, the subject invention has the advantage of providing for the automated handling of the wafers, which was not present in the prior art.",
"Thus, the present invention provides a significant reduction in the overall cost associated with the production of semiconductor wafers.",
"While the subject invention provides these and other advantages over other planarization apparatuses, it will be understood, however, that various changes in the details, materials and arrangements of parts which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims."
] |
BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention generally relates to semiconductor manufacturing equipment and, more particularly, to the controlled delivery of source gas.
[0003] 2. Description of Related Art
[0004] Advanced thin film materials are increasingly important in the manufacture of microelectronic devices. In contrast to traditional thin films, future thin films require new source materials that have low vapor pressures and that are often near their decomposition temperature when heated to achieve an appropriate vapor pressure. Some of the precursors, having both intrinsically low vapor pressure and low thermal decomposition temperature, are considered the best choices for deposition of films of tantalum oxide, tantalum nitride, titanium nitride, copper, and aluminum. For such applications, it is essential that the film morphology and composition be closely controllable. This in turn requires highly reliable and efficient means and methods for delivery of source reagents to the area of film formation.
[0005] In some cases, the delivery of reagents into the reactor in the vapor phase has proven difficult because of problems of premature decomposition or stoichiometry control. Examples include the deposition of tantalum oxide from the liquid precursor tantalum pentaethoxide (TAETO) and the deposition of titanium nitride from bis(dialkylamide)titanium reagents.
[0006] A precursor is the source of a vapor to be used in forming a thin film. Additionally, precursors often contain impurities, and the presence of those impurities can cause undesirable thermally activated chemical reactions at the vaporization zone, also resulting in formation of involatile solids and liquids at that location. For example, a variety of precursors, such as TAETO, are water-sensitive and hydrolysis can occur at the heated vaporizer zone forming tantalum oxide particulates that may be incorporated into the growing tantalum oxide film with deleterious effects.
[0007] Various source reagent delivery systems have been commonly employed to introduce vapors of source reagents to chemical vapor deposition (CVD) reactors. These include bubbler-based systems, liquid mass flow control systems, and liquid metering by pump systems. The use of CVD reactors is well known for thin film deposition and other thermal process steps required in the manufacture of integrated circuits.
[0008] [0008]FIG. 1A illustrates a typical bubbler-based delivery system, which includes an enclosed precursor chamber 10 at least partially submerged in the liquid of a heating bath 20 . The temperature of the bath may be adjusted to heat or cool precursor chamber 10 . In operation, precursor chamber 10 contains a precursor liquid. An inert carrier gas travels to precursor chamber 10 along a first pipe 30 . The open end of first pipe 30 is located in the precursor liquid. The carrier gas exits the pipe and bubbles to the surface of the precursor liquid. Contained within precursor chamber 10 above the surface of the precursor liquid is a space 40 . An input end for a second pipe 50 is located in space 40 above the surface of the precursor liquid. As the stream of the inert gas passes through the liquid precursor and bubbles to the liquid surface, precursor vapor attains its equilibrium vapor pressure more quickly. A “sparger” (a cap with multiple small perforations) is sometimes added to the end of first pipe 30 to ensure formation of small bubbles and rapid equilibration. The carrier gas and precursor vapor enter second pipe 50 and flow to a processing chamber, where the precursor vapor reacts upon a surface of a heated substrate. The temperature of pipe 50 is controlled by heating elements, such as heating coils 55 , surrounding second pipe 50 to keep the precursor vapor from condensing during transport to the processing chamber.
[0009] The performance of bubbler-based delivery systems is complicated by the exponential dependence of liquid vapor pressure on temperature. Small changes in temperature can cause large changes in reagent delivery rate, leading to poor process control. Lower temperatures and/or higher flow rates of the bubbled carrier gas tend to lower vapor pressure. Therefore, fluctuations in carrier gas temperature and flow rate can cause the vapor pressure of the precursor liquid to fluctuate. Accordingly, the precursor vapor will not always be saturated, leading to fluctuating concentrations of the source reagent. Further, vapor concentration in the bubbler-based system is a function of carrier gas contact time in the fluid as the carrier gas bubbles to the surface. Thus, vapor concentration fluctuates over time as the level of precursor liquid in the precursor chamber changes with use.
[0010] [0010]FIG. 1B illustrates another common delivery system using a liquid mass flow controller (LMFC) to measure and control the flow rate of liquid precursor to a vaporizer. An enclosed precursor chamber 10 includes a precursor liquid. An inert gas travels to precursor chamber 10 along a first pipe 30 . The open end of the pipe is located above the surface of the precursor liquid. Inert gas exits first pipe 30 and pressurizes the precursor liquid within precursor chamber 10 . An input end for second pipe 50 is located in the precursor liquid. When the inert gas enters precursor chamber 10 , the space above the precursor liquid becomes pressurized such that the level of the precursor liquid within precursor chamber 10 is lowered. Precursor liquid enters second pipe 50 and is transported to a LMFC 60 . The precursor liquid exits LMFC 60 and is transported to a vaporizer 70 . The precursor liquid is vaporized and is then typically entrained in a carrier gas which delivers it to the heated substrate. Gas exits the vaporizer through a heated pipe 90 . The temperature of the pipe is controlled by heating elements, such as heating coils 95 , surrounding the pipe.
[0011] Disadvantageously, liquid mass flow controllers present a number of drawbacks. LMFCs are extremely sensitive to particles and dissolved gases in the liquid precursor. LMFCs are also sensitive to variations in the temperature of the liquid precursor. Further, most LMFCs cannot operate at temperatures above 40° C., a temperature below which some precursor liquids, such as TAETO, have high viscosity. Another drawback with LMFC-based systems can be attributed to the “dead volume” (e.g. piping) between the LFMC and the vaporizer. Any amount of liquid that remains in the dead volume can contribute in making an inaccurate delivery of source reagent to the vaporizer. These drawbacks can make volumetric control of the liquid precursor very difficult.
[0012] The aforementioned inaccuracies in volumetric control of the liquid precursor cause large inaccuracies in final delivery of the precursor vapor to the processing chamber since a small variation in liquid volume (flow rate) results in a large variation in gas volume (flow rate). Further, LMFC-based systems typically use a gas to assist in the vaporization of the liquid precursor, thereby increasing the probability of generating solid particles and aerosols. Additionally, spatial and temporal temperature variations usually occur in the vaporization zone, leading to inconsistent delivery of source reagents.
[0013] Finally, because of the temperature difference between the vaporizer and the pipe leading to the processor, such as pipe 90 in this example, condensation may occur during transport of the precursor vapor, which also contributes to inaccurate delivery of the source reagent.
[0014] [0014]FIG. 1C illustrates another well-known system using a pump for liquid metering of the precursor liquid to a vaporizer. Pump 80 pulls precursor liquid from precursor chamber 10 to a vaporizer 70 . Vapor exits the vaporizer in a heated pipe 90 . The temperature of the pipe is controlled by heating elements, such as heating coils 95 surrounding the pipe, to prevent condensation.
[0015] Pump-based systems have similar disadvantages as LMFC-based systems. Spatial and temporal temperature variations usually occur in the vaporization zone, leading to inconsistent delivery of source reagents. This system is also extremely sensitive to particles and gas dissolved in the liquid. Further, any dead volume of precursor liquid delivered to the vaporizer will increase inaccurate delivery of source gas. Thus, delivery of precursor vapor to the processing chamber lacks high accuracy in this system since a small error in liquid volume measurement or control leads to a large error in vapor volume. Finally, most pumps cannot tolerate high temperatures (maximum 50° C.), below which some precursor liquids have high viscosity.
[0016] Therefore, what is needed is a precursor vapor delivery method and system with control for precise stoichiometry by limiting fluctuations in the concentration of source gas delivered to the processing chamber.
SUMMARY
[0017] In accordance with the present invention, a method and a system are provided for the controlled delivery of source gas to a processing chamber. A source gas delivery method includes providing a precursor chamber configured to hold precursor vapor, providing saturated precursor vapor at a selected pressure within the precursor chamber, and flowing saturated precursor vapor from the precursor chamber to a processing chamber until a selected pressure is provided within the processing chamber. Advantageously, the present invention provides and controls precise stoichiometry involved in the process reactions by delivering accurate amounts of precursor vapor to the processing chamber.
[0018] In another aspect of the present invention, a source gas delivery method includes providing a precursor chamber configured to hold precursor vapor, providing saturated precursor vapor at a selected pressure within the precursor chamber, and diffusing saturated precursor vapor from the precursor chamber to a processing chamber until a selected pressure is provided within the processing chamber.
[0019] In yet another aspect of the present invention, a source gas delivery system includes a precursor chamber configured to hold precursor vapor, a heat source for heating a precursor liquid to provide saturated precursor vapor at a selected pressure within the precursor chamber, and a vapor pathway allowing saturated precursor vapor to enter a processing chamber until a selected pressure is provided in the processing chamber.
[0020] In FIG. 4, an advantage of the present invention is illustrated using graph 400 , which shows how the concentration of the vapor delivered to a processing chamber can vary over time. In a typical vapor delivery system, precursor vapor is delivered at a fairly constant level 402 , with fluctuations in the concentration occurring constantly. This manner of precursor vapor delivery ensures that enough source gas is available during processing operations. Unfortunately, most of the source gas is wasted since only a small percentage is consumed in the processing operation. The wasted gas must be vented, which can also require special procedures and additional treatments.
[0021] In the present invention, once a predetermined concentration of vapor 404 is delivered to the process chamber, the delivery is stopped. As the vapor reagents are consumed in the processing, the concentration level 404 drops, but the amount of wasted gas is substantially reduced since the difference between concentration level 402 and concentration level 404 will not have to be purged.
[0022] These and other features and advantages of the present invention will be more readily apparent from the detailed description of the embodiments set forth below taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1A is a simplified illustration of a bubbler-based delivery system.
[0024] [0024]FIG. 1B is a simplified illustration of a liquid mass flow control delivery system.
[0025] [0025]FIG. 1C is a simplified illustration of a liquid metering by pump delivery system.
[0026] [0026]FIG. 2A illustrates a simplified schematic view of a source gas delivery system in accordance with an embodiment of the present invention.
[0027] [0027]FIG. 2B illustrates another simplified schematic view of a source gas delivery system in accordance with an embodiment of the present invention.
[0028] [0028]FIG. 3 is a graph of vapor pressure versus temperature for TAETO.
[0029] [0029]FIG. 4 is a graph of source gas concentration versus time in a processing chamber.
[0030] [0030]FIG. 5 is a flow chart of several source gas delivery methods in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
[0031] [0031]FIG. 2A illustrates source gas delivery system 300 in accordance with an embodiment of the present invention. A precursor liquid 302 is enclosed in a precursor chamber 304 . Precursor liquid 302 can include liquid reagents having low vapor pressure at room temperature, such as tantalum pentaethoxide (TAETO), triethylaluminum (TEA), trimethylaluminum (TMA), triethlyphosphorous (TEP), and triethylgallium (TEGa) or any other liquid source, such as SiCl 4 , GeCl 4 , HCl and the like. Precursor liquid 302 is not highly volatile but can be heated to form non-negligible precursor vapor.
[0032] Precursor chamber 304 is in thermal contact with a heat source 306 to heat precursor liquid 302 . Heat source 306 can be any heating apparatus which uniformly heats and controls the temperature of precursor liquid 302 , such as a heating bath, heating plate, and convection oven. In the embodiment illustrated in FIG. 2A, a temperature-controlled liquid bath 308 is used to heat precursor chamber 304 . Precursor chamber 304 is at least partially submerged in liquid bath 308 to a level where precursor liquid 302 is at least fully submerged in the bath fluid. In an alternative embodiment, precursor chamber 304 is fully submerged in the liquid bath to allow precursor vapor as well as the precursor liquid to be heated. In this illustrative embodiment, the liquid bath is heated to between approximately 50° C. and approximately 220° C.
[0033] Bath fluids having low volatility, high boiling points, and/or high heat capacities which can be used in liquid bath 308 are available commercially. Examples of bath fluids, with no intention to limit the invention thereby, are the Silicone series of bath fluids, available from Cole-Parmer Instrument Co., Vernon Hills, Ill.
[0034] Precursor chamber 304 includes a control diameter D1. As D1 is made larger, the surface area of exposed precursor liquid 302 is increased. Accordingly, saturated precursor vapor is more quickly formed and made available for delivery to the processing chamber upon heating.
[0035] Control diameter D1 also controls for backflow or negative pressure drop during vapor delivery to processing chamber 340 , which includes a diameter D2. For example, as control diameter D1 is made larger relative to diameter D2, the pressure drop between precursor chamber 304 and processing chamber 340 becomes negligible, thereby controlling for backflow during vapor delivery. In one embodiment, control diameter D1 is in the range of between approximately 25 mm and approximately 300 mm, and diameter D2 is in the range of between approximately 50 mm and approximately 1000 mm.
[0036] Optionally, precursor chamber 304 is operably connected to a precursor source 309 . Precursor source 309 may continuously feed precursor liquid to precursor chamber 304 or it may feed discrete amounts of precursor liquid as needed. In the alternative, precursor chamber 304 is a stand-alone batch chamber that is manually refilled with precursor liquid as needed.
[0037] The source gas delivery system of the present invention further includes a vapor pathway allowing saturated precursor vapor to enter the processing chamber from the precursor chamber. In one embodiment, the vapor pathway includes a vapor inlet 320 located in a space 330 above the surface of liquid precursor 302 in precursor chamber 304 . A first end of pipe 322 is operably connected to vapor inlet 320 . A second end of pipe 322 is operably connected to open/close valve 324 . A first end of pipe 326 is also operably connected to open/close valve 324 , and a second end of pipe 326 is operably connected to processing chamber 340 . Valves and seals which can be used in this system are available commercially from Rohm and Haas Company, North Andover, Mass.
[0038] As shown by the flowchart in FIG. 5 in conjunction with system 300 in FIG. 2A, the source gas delivery method of the present invention includes the selection of a desired pressure of precursor vapor required for processing in processing chamber 340 . By having accurate control over the concentration of precursor vapor delivered to the processing chamber, improved control over stoichiometry, and therefore film composition, is achieved. The stoichiometry for the reaction involving precursor vapor and reactant gases in processing chamber 340 is determined by controlling the total pressure of processing chamber 340 and by controlling the temperature of heat source 306 , which determines the vapor pressure of precursor liquid 302 .
[0039] Dalton's law of partial pressures states that for a mixture of gases in a container, the total pressure exerted is the sum of the pressures that each gas would exert if it were alone. The pressure that each gas would exert if it were alone in the container is known as the partial pressure of each gas. Mole fraction, χ, of a particular component in a mixture, assuming ideal gases, is directly related to its partial pressure, being defined as partial pressure, Pn, divided by total pressure, Ptotal. Mole percentage of a particular component in a mixture is defined as mole fraction multiplied by 100. Thus, in the present invention, reaction stoichiometry and film composition are accurately controlled based upon the precise mole percentage or partial pressure of precursor vapor delivered to processing chamber 340 .
[0040] In accordance with the present invention, the selected pressure is the desired precursor vapor partial pressure needed for processing in processing chamber 340 . To generate the selected pressure, precursor liquid 302 is subjected to a temperature which correlates to the selected precursor vapor pressure. Thus, another step in the source gas delivery method of the present invention is to correlate a temperature to the selected precursor vapor pressure. The correlations between temperature and vapor pressure for pure substances are well known in the art. For example, FIG. 3 is a graph showing the vapor pressure of TAETO corresponding to temperature. Similar graphs exist for other substances.
[0041] Referring again to FIG. 5, a further step in the source gas delivery method of the present invention is to continually heat the precursor liquid at the determined temperature until the precursor liquid/vapor mixture reaches equilibrium. Accordingly, the precursor vapor will be saturated at a vapor pressure equal to the selected pressure. A pressure sensor 318 is optionally used to monitor precursor vapor pressure in precursor chamber 304 (FIG. 2A).
[0042] After heating the precursor liquid at the correlated temperature to form saturated precursor vapor, alternative paths may be taken in the source gas delivery method of the present invention, as shown by FIG. 5 in conjunction with FIG. 2A. Processing chamber 340 may be either vacuumed by a vacuum pump 350 or filled with reactant gases to a preselected pressure before receiving the precursor vapor. In one embodiment, as shown by path 500 , processing chamber 340 is first under vacuum, and a step in the source gas delivery method is to place open/close valve 324 in the open position to allow saturated precursor vapor to enter pipe 322 by diffusion. Precursor vapor then diffuses through pipe 326 to processing chamber 340 . The processing chamber is filled with precursor material and equilibrium is eventually approximated between precursor chamber 304 and processing chamber 340 over time. Once a selected pressure is reached within processing chamber 340 , open/close valve 324 is closed to stop precursor vapor from entering processing chamber 340 . A pressure sensor 360 is used to determine the overall pressure in the processing chamber. Reactant gases are then delivered to the processing chamber to a target overall pressure, after which the processing chamber is activated to start film formation.
[0043] In another embodiment, as shown by path 510 in FIG. 5 in conjunction with FIG. 2A, reactant gases are first loaded into processing chamber 340 to a selected pressure. Open/close valve 324 is opened and precursor vapor is diffused into processing chamber 340 to a target overall pressure. Open/close valve 324 is then closed and the processing chamber is activated to start film formation.
[0044] Generally, no more precursor material is required during processing in the processing chamber once the target overall pressure is achieved. Advantageously, this method prevents precursor material from having to be vented after the processing and thus saves precursor material. Since no carrier gas is used in this embodiment, fluctuations in precursor vapor concentration associated with carrier gas use are eliminated. Further, since no bubbling takes place, the precursor vapor concentration does not fluctuate with changing levels of precursor liquid. Another advantage of the present invention is that any impurities or decomposed products from the precursor liquid are left in the precursor chamber since only the precursor vapor is delivered to the processing chamber. Additionally, no heating elements are necessary to heat the vapor pathway from the precursor chamber to the processing chamber because, unlike vaporizer systems, the temperature difference between the precursor chamber and the vapor pathway is minimal. In addition, the vapor pathway can be made with a large enough diameter to increase the throughput of the precursor vapor while minimizing the possibility of condensation.
[0045] In an alternative embodiment, as shown by path 520 in FIG. 5 in conjunction with FIG. 2B, flow gas may travel along a first pipe 310 to an open/close valve 312 . An open end 316 of pipe 314 is located in a space 330 above the precursor liquid in precursor chamber 304 . If open/close valve 312 is in the open position, flow gas enters pipe 314 and exits at open end 316 into space 330 . Space 330 is initially under vacuum and only precursor vapor will occupy space 330 as the precursor liquid is heated. Once precursor vapor saturation has been reached, open/close valves 312 and 324 are opened and the flow gas is used to directly propel the saturated precursor vapor to the processing chamber, without bubbling, until a target overall pressure is reached. Inert flow gases, such as Ar, He, O 2 , and N 2 , may be delivered to precursor chamber 304 at flowrates of between approximately 100 cc/min to approximately 10,000 cc/min, to propel the saturated precursor vapor. Further, the flow gas may be metered in this embodiment to determine the partial pressure contribution of the flow gas in order to compensate for an increase in the overall pressure within the processing chamber. Flow gas effects on vapor concentration are negligible, since no bubbling occurs and the flow gas is used to only add kinetic energy to the saturated precursor vapor for delivery to processing chamber 340 . Once the target overall pressure is reached, the processing chamber is activated to start film formation.
[0046] In another embodiment, as shown by path 530 in FIG. 5 in conjunction with FIG. 2B, reactant gases are first loaded into processing chamber 340 to a selected pressure. Then open/close valves 312 and 324 are opened and inert flow gas is used to propel the saturated precursor vapor to the processing chamber until a target overall pressure is reached, after which the processing chamber is activated to start film formation.
[0047] In accordance with one embodiment of the present invention, precursor liquid TAETO is heated between approximately 50° C. to approximately 220° C., achieving saturated vapor pressures of between approximately 0.001 Torr (˜0.13 Pa) to approximately 100 Torr (˜13 kPa), respectively. The processing chamber is targeted to achieve an overall pressure ranging between approximately 0.001 Torr (˜0.13 Pa) to approximately 760 Torr (˜1 MPa). The saturated precursor vapor has a mole percentage in the processing chamber ranging from approximately 0.1% to approximately 50%. A layer of tantalum oxide (Ta 2 O 5 ) may be grown to thicknesses ranging between approximately 50 Å to approximately 500 Å.
[0048] In one example, precursor liquid TAETO is heated to 130° C. to achieve a saturated vapor pressure of 0.2 Torr (˜26 Pa) (FIG. 3). The precursor vapor is delivered to the processing chamber to a pressure of 0.2 Torr (˜26 Pa) followed by delivery of reactant gases to an overall target pressure of 1 Torr (˜133 Pa). In an alternative example, reactant gases are delivered to the processing chamber to a pressure of 0.8 Torr (˜106 Pa) followed by the precursor vapor to an overall target pressure of 1 Torr (˜133 Pa). The mixture of 20% mole percentage of precursor vapor is reacted in the processing chamber at 450° C. for 10 minutes to grow about 100 Å of tantalum oxide.
[0049] In another example, precursor liquid TAETO is heated to 200° C. to achieve a saturated vapor pressure of 20 Torr (˜2.6 kPa). The precursor vapor is delivered to the processing chamber to a pressure of 20 Torr (˜2.6 kPa) followed by delivery of reactant gases to an overall target pressure of 100 Torr (˜13 kPa). Alternatively, reactant gases are delivered to the processing chamber to a pressure of 80 Torr (10.6 kPa) followed by the precursor vapor to an overall target pressure of 100 Torr (˜13 kPa). This mixture of 20% mole percentage of precursor vapor is reacted in the processing chamber at 450° C. for 2 minutes to grow about 100 Å of tantalum oxide.
[0050] The above-described embodiments of the present invention are merely meant to be illustrative and not limiting. It will thus be obvious to those skilled in the art that various changes and modifications may be made without departing from this invention in its broader aspects. Therefore, the appended claims encompass all such changes and modifications as falling within the true spirit and scope of this invention. | A method and system are provided for delivering a source gas to a processing chamber. A source gas delivery method includes providing a precursor chamber configured to hold precursor vapor, providing a saturated precursor vapor at a selected pressure within the precursor chamber, and flowing or diffusing saturated precursor vapor from the precursor chamber to the processing chamber until a selected pressure is provided in the processing chamber. A source gas delivery system includes a precursor chamber configured to hold precursor vapor, a heat source for heating a precursor liquid to provide saturated precursor vapor at a selected pressure within the precursor chamber, and a vapor pathway allowing saturated precursor vapor to enter a processing chamber until a selected pressure is provided in the processing chamber. Advantageously, the present invention allows for improved precursor vapor delivery and enhanced control over thin film deposition with less waste of precursor material. | Briefly summarize the main idea's components and working principles as described in the context. | [
"BACKGROUND [0001] 1.",
"Field of the Invention [0002] This invention generally relates to semiconductor manufacturing equipment and, more particularly, to the controlled delivery of source gas.",
"[0003] 2.",
"Description of Related Art [0004] Advanced thin film materials are increasingly important in the manufacture of microelectronic devices.",
"In contrast to traditional thin films, future thin films require new source materials that have low vapor pressures and that are often near their decomposition temperature when heated to achieve an appropriate vapor pressure.",
"Some of the precursors, having both intrinsically low vapor pressure and low thermal decomposition temperature, are considered the best choices for deposition of films of tantalum oxide, tantalum nitride, titanium nitride, copper, and aluminum.",
"For such applications, it is essential that the film morphology and composition be closely controllable.",
"This in turn requires highly reliable and efficient means and methods for delivery of source reagents to the area of film formation.",
"[0005] In some cases, the delivery of reagents into the reactor in the vapor phase has proven difficult because of problems of premature decomposition or stoichiometry control.",
"Examples include the deposition of tantalum oxide from the liquid precursor tantalum pentaethoxide (TAETO) and the deposition of titanium nitride from bis(dialkylamide)titanium reagents.",
"[0006] A precursor is the source of a vapor to be used in forming a thin film.",
"Additionally, precursors often contain impurities, and the presence of those impurities can cause undesirable thermally activated chemical reactions at the vaporization zone, also resulting in formation of involatile solids and liquids at that location.",
"For example, a variety of precursors, such as TAETO, are water-sensitive and hydrolysis can occur at the heated vaporizer zone forming tantalum oxide particulates that may be incorporated into the growing tantalum oxide film with deleterious effects.",
"[0007] Various source reagent delivery systems have been commonly employed to introduce vapors of source reagents to chemical vapor deposition (CVD) reactors.",
"These include bubbler-based systems, liquid mass flow control systems, and liquid metering by pump systems.",
"The use of CVD reactors is well known for thin film deposition and other thermal process steps required in the manufacture of integrated circuits.",
"[0008] [0008 ]FIG. 1A illustrates a typical bubbler-based delivery system, which includes an enclosed precursor chamber 10 at least partially submerged in the liquid of a heating bath 20 .",
"The temperature of the bath may be adjusted to heat or cool precursor chamber 10 .",
"In operation, precursor chamber 10 contains a precursor liquid.",
"An inert carrier gas travels to precursor chamber 10 along a first pipe 30 .",
"The open end of first pipe 30 is located in the precursor liquid.",
"The carrier gas exits the pipe and bubbles to the surface of the precursor liquid.",
"Contained within precursor chamber 10 above the surface of the precursor liquid is a space 40 .",
"An input end for a second pipe 50 is located in space 40 above the surface of the precursor liquid.",
"As the stream of the inert gas passes through the liquid precursor and bubbles to the liquid surface, precursor vapor attains its equilibrium vapor pressure more quickly.",
"A “sparger”",
"(a cap with multiple small perforations) is sometimes added to the end of first pipe 30 to ensure formation of small bubbles and rapid equilibration.",
"The carrier gas and precursor vapor enter second pipe 50 and flow to a processing chamber, where the precursor vapor reacts upon a surface of a heated substrate.",
"The temperature of pipe 50 is controlled by heating elements, such as heating coils 55 , surrounding second pipe 50 to keep the precursor vapor from condensing during transport to the processing chamber.",
"[0009] The performance of bubbler-based delivery systems is complicated by the exponential dependence of liquid vapor pressure on temperature.",
"Small changes in temperature can cause large changes in reagent delivery rate, leading to poor process control.",
"Lower temperatures and/or higher flow rates of the bubbled carrier gas tend to lower vapor pressure.",
"Therefore, fluctuations in carrier gas temperature and flow rate can cause the vapor pressure of the precursor liquid to fluctuate.",
"Accordingly, the precursor vapor will not always be saturated, leading to fluctuating concentrations of the source reagent.",
"Further, vapor concentration in the bubbler-based system is a function of carrier gas contact time in the fluid as the carrier gas bubbles to the surface.",
"Thus, vapor concentration fluctuates over time as the level of precursor liquid in the precursor chamber changes with use.",
"[0010] [0010 ]FIG. 1B illustrates another common delivery system using a liquid mass flow controller (LMFC) to measure and control the flow rate of liquid precursor to a vaporizer.",
"An enclosed precursor chamber 10 includes a precursor liquid.",
"An inert gas travels to precursor chamber 10 along a first pipe 30 .",
"The open end of the pipe is located above the surface of the precursor liquid.",
"Inert gas exits first pipe 30 and pressurizes the precursor liquid within precursor chamber 10 .",
"An input end for second pipe 50 is located in the precursor liquid.",
"When the inert gas enters precursor chamber 10 , the space above the precursor liquid becomes pressurized such that the level of the precursor liquid within precursor chamber 10 is lowered.",
"Precursor liquid enters second pipe 50 and is transported to a LMFC 60 .",
"The precursor liquid exits LMFC 60 and is transported to a vaporizer 70 .",
"The precursor liquid is vaporized and is then typically entrained in a carrier gas which delivers it to the heated substrate.",
"Gas exits the vaporizer through a heated pipe 90 .",
"The temperature of the pipe is controlled by heating elements, such as heating coils 95 , surrounding the pipe.",
"[0011] Disadvantageously, liquid mass flow controllers present a number of drawbacks.",
"LMFCs are extremely sensitive to particles and dissolved gases in the liquid precursor.",
"LMFCs are also sensitive to variations in the temperature of the liquid precursor.",
"Further, most LMFCs cannot operate at temperatures above 40° C., a temperature below which some precursor liquids, such as TAETO, have high viscosity.",
"Another drawback with LMFC-based systems can be attributed to the “dead volume”",
"(e.g. piping) between the LFMC and the vaporizer.",
"Any amount of liquid that remains in the dead volume can contribute in making an inaccurate delivery of source reagent to the vaporizer.",
"These drawbacks can make volumetric control of the liquid precursor very difficult.",
"[0012] The aforementioned inaccuracies in volumetric control of the liquid precursor cause large inaccuracies in final delivery of the precursor vapor to the processing chamber since a small variation in liquid volume (flow rate) results in a large variation in gas volume (flow rate).",
"Further, LMFC-based systems typically use a gas to assist in the vaporization of the liquid precursor, thereby increasing the probability of generating solid particles and aerosols.",
"Additionally, spatial and temporal temperature variations usually occur in the vaporization zone, leading to inconsistent delivery of source reagents.",
"[0013] Finally, because of the temperature difference between the vaporizer and the pipe leading to the processor, such as pipe 90 in this example, condensation may occur during transport of the precursor vapor, which also contributes to inaccurate delivery of the source reagent.",
"[0014] [0014 ]FIG. 1C illustrates another well-known system using a pump for liquid metering of the precursor liquid to a vaporizer.",
"Pump 80 pulls precursor liquid from precursor chamber 10 to a vaporizer 70 .",
"Vapor exits the vaporizer in a heated pipe 90 .",
"The temperature of the pipe is controlled by heating elements, such as heating coils 95 surrounding the pipe, to prevent condensation.",
"[0015] Pump-based systems have similar disadvantages as LMFC-based systems.",
"Spatial and temporal temperature variations usually occur in the vaporization zone, leading to inconsistent delivery of source reagents.",
"This system is also extremely sensitive to particles and gas dissolved in the liquid.",
"Further, any dead volume of precursor liquid delivered to the vaporizer will increase inaccurate delivery of source gas.",
"Thus, delivery of precursor vapor to the processing chamber lacks high accuracy in this system since a small error in liquid volume measurement or control leads to a large error in vapor volume.",
"Finally, most pumps cannot tolerate high temperatures (maximum 50° C.), below which some precursor liquids have high viscosity.",
"[0016] Therefore, what is needed is a precursor vapor delivery method and system with control for precise stoichiometry by limiting fluctuations in the concentration of source gas delivered to the processing chamber.",
"SUMMARY [0017] In accordance with the present invention, a method and a system are provided for the controlled delivery of source gas to a processing chamber.",
"A source gas delivery method includes providing a precursor chamber configured to hold precursor vapor, providing saturated precursor vapor at a selected pressure within the precursor chamber, and flowing saturated precursor vapor from the precursor chamber to a processing chamber until a selected pressure is provided within the processing chamber.",
"Advantageously, the present invention provides and controls precise stoichiometry involved in the process reactions by delivering accurate amounts of precursor vapor to the processing chamber.",
"[0018] In another aspect of the present invention, a source gas delivery method includes providing a precursor chamber configured to hold precursor vapor, providing saturated precursor vapor at a selected pressure within the precursor chamber, and diffusing saturated precursor vapor from the precursor chamber to a processing chamber until a selected pressure is provided within the processing chamber.",
"[0019] In yet another aspect of the present invention, a source gas delivery system includes a precursor chamber configured to hold precursor vapor, a heat source for heating a precursor liquid to provide saturated precursor vapor at a selected pressure within the precursor chamber, and a vapor pathway allowing saturated precursor vapor to enter a processing chamber until a selected pressure is provided in the processing chamber.",
"[0020] In FIG. 4, an advantage of the present invention is illustrated using graph 400 , which shows how the concentration of the vapor delivered to a processing chamber can vary over time.",
"In a typical vapor delivery system, precursor vapor is delivered at a fairly constant level 402 , with fluctuations in the concentration occurring constantly.",
"This manner of precursor vapor delivery ensures that enough source gas is available during processing operations.",
"Unfortunately, most of the source gas is wasted since only a small percentage is consumed in the processing operation.",
"The wasted gas must be vented, which can also require special procedures and additional treatments.",
"[0021] In the present invention, once a predetermined concentration of vapor 404 is delivered to the process chamber, the delivery is stopped.",
"As the vapor reagents are consumed in the processing, the concentration level 404 drops, but the amount of wasted gas is substantially reduced since the difference between concentration level 402 and concentration level 404 will not have to be purged.",
"[0022] These and other features and advantages of the present invention will be more readily apparent from the detailed description of the embodiments set forth below taken in conjunction with the accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0023] [0023 ]FIG. 1A is a simplified illustration of a bubbler-based delivery system.",
"[0024] [0024 ]FIG. 1B is a simplified illustration of a liquid mass flow control delivery system.",
"[0025] [0025 ]FIG. 1C is a simplified illustration of a liquid metering by pump delivery system.",
"[0026] [0026 ]FIG. 2A illustrates a simplified schematic view of a source gas delivery system in accordance with an embodiment of the present invention.",
"[0027] [0027 ]FIG. 2B illustrates another simplified schematic view of a source gas delivery system in accordance with an embodiment of the present invention.",
"[0028] [0028 ]FIG. 3 is a graph of vapor pressure versus temperature for TAETO.",
"[0029] [0029 ]FIG. 4 is a graph of source gas concentration versus time in a processing chamber.",
"[0030] [0030 ]FIG. 5 is a flow chart of several source gas delivery methods in accordance with embodiments of the present invention.",
"DETAILED DESCRIPTION [0031] [0031 ]FIG. 2A illustrates source gas delivery system 300 in accordance with an embodiment of the present invention.",
"A precursor liquid 302 is enclosed in a precursor chamber 304 .",
"Precursor liquid 302 can include liquid reagents having low vapor pressure at room temperature, such as tantalum pentaethoxide (TAETO), triethylaluminum (TEA), trimethylaluminum (TMA), triethlyphosphorous (TEP), and triethylgallium (TEGa) or any other liquid source, such as SiCl 4 , GeCl 4 , HCl and the like.",
"Precursor liquid 302 is not highly volatile but can be heated to form non-negligible precursor vapor.",
"[0032] Precursor chamber 304 is in thermal contact with a heat source 306 to heat precursor liquid 302 .",
"Heat source 306 can be any heating apparatus which uniformly heats and controls the temperature of precursor liquid 302 , such as a heating bath, heating plate, and convection oven.",
"In the embodiment illustrated in FIG. 2A, a temperature-controlled liquid bath 308 is used to heat precursor chamber 304 .",
"Precursor chamber 304 is at least partially submerged in liquid bath 308 to a level where precursor liquid 302 is at least fully submerged in the bath fluid.",
"In an alternative embodiment, precursor chamber 304 is fully submerged in the liquid bath to allow precursor vapor as well as the precursor liquid to be heated.",
"In this illustrative embodiment, the liquid bath is heated to between approximately 50° C. and approximately 220° C. [0033] Bath fluids having low volatility, high boiling points, and/or high heat capacities which can be used in liquid bath 308 are available commercially.",
"Examples of bath fluids, with no intention to limit the invention thereby, are the Silicone series of bath fluids, available from Cole-Parmer Instrument Co., Vernon Hills, Ill.",
"[0034] Precursor chamber 304 includes a control diameter D1.",
"As D1 is made larger, the surface area of exposed precursor liquid 302 is increased.",
"Accordingly, saturated precursor vapor is more quickly formed and made available for delivery to the processing chamber upon heating.",
"[0035] Control diameter D1 also controls for backflow or negative pressure drop during vapor delivery to processing chamber 340 , which includes a diameter D2.",
"For example, as control diameter D1 is made larger relative to diameter D2, the pressure drop between precursor chamber 304 and processing chamber 340 becomes negligible, thereby controlling for backflow during vapor delivery.",
"In one embodiment, control diameter D1 is in the range of between approximately 25 mm and approximately 300 mm, and diameter D2 is in the range of between approximately 50 mm and approximately 1000 mm.",
"[0036] Optionally, precursor chamber 304 is operably connected to a precursor source 309 .",
"Precursor source 309 may continuously feed precursor liquid to precursor chamber 304 or it may feed discrete amounts of precursor liquid as needed.",
"In the alternative, precursor chamber 304 is a stand-alone batch chamber that is manually refilled with precursor liquid as needed.",
"[0037] The source gas delivery system of the present invention further includes a vapor pathway allowing saturated precursor vapor to enter the processing chamber from the precursor chamber.",
"In one embodiment, the vapor pathway includes a vapor inlet 320 located in a space 330 above the surface of liquid precursor 302 in precursor chamber 304 .",
"A first end of pipe 322 is operably connected to vapor inlet 320 .",
"A second end of pipe 322 is operably connected to open/close valve 324 .",
"A first end of pipe 326 is also operably connected to open/close valve 324 , and a second end of pipe 326 is operably connected to processing chamber 340 .",
"Valves and seals which can be used in this system are available commercially from Rohm and Haas Company, North Andover, Mass.",
"[0038] As shown by the flowchart in FIG. 5 in conjunction with system 300 in FIG. 2A, the source gas delivery method of the present invention includes the selection of a desired pressure of precursor vapor required for processing in processing chamber 340 .",
"By having accurate control over the concentration of precursor vapor delivered to the processing chamber, improved control over stoichiometry, and therefore film composition, is achieved.",
"The stoichiometry for the reaction involving precursor vapor and reactant gases in processing chamber 340 is determined by controlling the total pressure of processing chamber 340 and by controlling the temperature of heat source 306 , which determines the vapor pressure of precursor liquid 302 .",
"[0039] Dalton's law of partial pressures states that for a mixture of gases in a container, the total pressure exerted is the sum of the pressures that each gas would exert if it were alone.",
"The pressure that each gas would exert if it were alone in the container is known as the partial pressure of each gas.",
"Mole fraction, χ, of a particular component in a mixture, assuming ideal gases, is directly related to its partial pressure, being defined as partial pressure, Pn, divided by total pressure, Ptotal.",
"Mole percentage of a particular component in a mixture is defined as mole fraction multiplied by 100.",
"Thus, in the present invention, reaction stoichiometry and film composition are accurately controlled based upon the precise mole percentage or partial pressure of precursor vapor delivered to processing chamber 340 .",
"[0040] In accordance with the present invention, the selected pressure is the desired precursor vapor partial pressure needed for processing in processing chamber 340 .",
"To generate the selected pressure, precursor liquid 302 is subjected to a temperature which correlates to the selected precursor vapor pressure.",
"Thus, another step in the source gas delivery method of the present invention is to correlate a temperature to the selected precursor vapor pressure.",
"The correlations between temperature and vapor pressure for pure substances are well known in the art.",
"For example, FIG. 3 is a graph showing the vapor pressure of TAETO corresponding to temperature.",
"Similar graphs exist for other substances.",
"[0041] Referring again to FIG. 5, a further step in the source gas delivery method of the present invention is to continually heat the precursor liquid at the determined temperature until the precursor liquid/vapor mixture reaches equilibrium.",
"Accordingly, the precursor vapor will be saturated at a vapor pressure equal to the selected pressure.",
"A pressure sensor 318 is optionally used to monitor precursor vapor pressure in precursor chamber 304 (FIG.",
"2A).",
"[0042] After heating the precursor liquid at the correlated temperature to form saturated precursor vapor, alternative paths may be taken in the source gas delivery method of the present invention, as shown by FIG. 5 in conjunction with FIG. 2A.",
"Processing chamber 340 may be either vacuumed by a vacuum pump 350 or filled with reactant gases to a preselected pressure before receiving the precursor vapor.",
"In one embodiment, as shown by path 500 , processing chamber 340 is first under vacuum, and a step in the source gas delivery method is to place open/close valve 324 in the open position to allow saturated precursor vapor to enter pipe 322 by diffusion.",
"Precursor vapor then diffuses through pipe 326 to processing chamber 340 .",
"The processing chamber is filled with precursor material and equilibrium is eventually approximated between precursor chamber 304 and processing chamber 340 over time.",
"Once a selected pressure is reached within processing chamber 340 , open/close valve 324 is closed to stop precursor vapor from entering processing chamber 340 .",
"A pressure sensor 360 is used to determine the overall pressure in the processing chamber.",
"Reactant gases are then delivered to the processing chamber to a target overall pressure, after which the processing chamber is activated to start film formation.",
"[0043] In another embodiment, as shown by path 510 in FIG. 5 in conjunction with FIG. 2A, reactant gases are first loaded into processing chamber 340 to a selected pressure.",
"Open/close valve 324 is opened and precursor vapor is diffused into processing chamber 340 to a target overall pressure.",
"Open/close valve 324 is then closed and the processing chamber is activated to start film formation.",
"[0044] Generally, no more precursor material is required during processing in the processing chamber once the target overall pressure is achieved.",
"Advantageously, this method prevents precursor material from having to be vented after the processing and thus saves precursor material.",
"Since no carrier gas is used in this embodiment, fluctuations in precursor vapor concentration associated with carrier gas use are eliminated.",
"Further, since no bubbling takes place, the precursor vapor concentration does not fluctuate with changing levels of precursor liquid.",
"Another advantage of the present invention is that any impurities or decomposed products from the precursor liquid are left in the precursor chamber since only the precursor vapor is delivered to the processing chamber.",
"Additionally, no heating elements are necessary to heat the vapor pathway from the precursor chamber to the processing chamber because, unlike vaporizer systems, the temperature difference between the precursor chamber and the vapor pathway is minimal.",
"In addition, the vapor pathway can be made with a large enough diameter to increase the throughput of the precursor vapor while minimizing the possibility of condensation.",
"[0045] In an alternative embodiment, as shown by path 520 in FIG. 5 in conjunction with FIG. 2B, flow gas may travel along a first pipe 310 to an open/close valve 312 .",
"An open end 316 of pipe 314 is located in a space 330 above the precursor liquid in precursor chamber 304 .",
"If open/close valve 312 is in the open position, flow gas enters pipe 314 and exits at open end 316 into space 330 .",
"Space 330 is initially under vacuum and only precursor vapor will occupy space 330 as the precursor liquid is heated.",
"Once precursor vapor saturation has been reached, open/close valves 312 and 324 are opened and the flow gas is used to directly propel the saturated precursor vapor to the processing chamber, without bubbling, until a target overall pressure is reached.",
"Inert flow gases, such as Ar, He, O 2 , and N 2 , may be delivered to precursor chamber 304 at flowrates of between approximately 100 cc/min to approximately 10,000 cc/min, to propel the saturated precursor vapor.",
"Further, the flow gas may be metered in this embodiment to determine the partial pressure contribution of the flow gas in order to compensate for an increase in the overall pressure within the processing chamber.",
"Flow gas effects on vapor concentration are negligible, since no bubbling occurs and the flow gas is used to only add kinetic energy to the saturated precursor vapor for delivery to processing chamber 340 .",
"Once the target overall pressure is reached, the processing chamber is activated to start film formation.",
"[0046] In another embodiment, as shown by path 530 in FIG. 5 in conjunction with FIG. 2B, reactant gases are first loaded into processing chamber 340 to a selected pressure.",
"Then open/close valves 312 and 324 are opened and inert flow gas is used to propel the saturated precursor vapor to the processing chamber until a target overall pressure is reached, after which the processing chamber is activated to start film formation.",
"[0047] In accordance with one embodiment of the present invention, precursor liquid TAETO is heated between approximately 50° C. to approximately 220° C., achieving saturated vapor pressures of between approximately 0.001 Torr (˜0.13 Pa) to approximately 100 Torr (˜13 kPa), respectively.",
"The processing chamber is targeted to achieve an overall pressure ranging between approximately 0.001 Torr (˜0.13 Pa) to approximately 760 Torr (˜1 MPa).",
"The saturated precursor vapor has a mole percentage in the processing chamber ranging from approximately 0.1% to approximately 50%.",
"A layer of tantalum oxide (Ta 2 O 5 ) may be grown to thicknesses ranging between approximately 50 Å to approximately 500 Å.",
"[0048] In one example, precursor liquid TAETO is heated to 130° C. to achieve a saturated vapor pressure of 0.2 Torr (˜26 Pa) (FIG.",
"3).",
"The precursor vapor is delivered to the processing chamber to a pressure of 0.2 Torr (˜26 Pa) followed by delivery of reactant gases to an overall target pressure of 1 Torr (˜133 Pa).",
"In an alternative example, reactant gases are delivered to the processing chamber to a pressure of 0.8 Torr (˜106 Pa) followed by the precursor vapor to an overall target pressure of 1 Torr (˜133 Pa).",
"The mixture of 20% mole percentage of precursor vapor is reacted in the processing chamber at 450° C. for 10 minutes to grow about 100 Å of tantalum oxide.",
"[0049] In another example, precursor liquid TAETO is heated to 200° C. to achieve a saturated vapor pressure of 20 Torr (˜2.6 kPa).",
"The precursor vapor is delivered to the processing chamber to a pressure of 20 Torr (˜2.6 kPa) followed by delivery of reactant gases to an overall target pressure of 100 Torr (˜13 kPa).",
"Alternatively, reactant gases are delivered to the processing chamber to a pressure of 80 Torr (10.6 kPa) followed by the precursor vapor to an overall target pressure of 100 Torr (˜13 kPa).",
"This mixture of 20% mole percentage of precursor vapor is reacted in the processing chamber at 450° C. for 2 minutes to grow about 100 Å of tantalum oxide.",
"[0050] The above-described embodiments of the present invention are merely meant to be illustrative and not limiting.",
"It will thus be obvious to those skilled in the art that various changes and modifications may be made without departing from this invention in its broader aspects.",
"Therefore, the appended claims encompass all such changes and modifications as falling within the true spirit and scope of this invention."
] |
CROSS-REFERENCED RELATED APPLICATIONS
[0001] This application is related to an application titled “Dynamically Adjusted Cache Power Supply to Optimize for Cache Access or Power Consumption”, H.P. docket number 10016613-1 filed on or about the same day as the present application.
FIELD OF THE INVENTION
[0002] This invention relates generally to electronic circuits. More particularly, this invention relates to improving cache memory performance and reducing cache memory size.
BACKGROUND OF THE INVENTION
[0003] As the size of microprocessors continues to grow, the size of the cache memory included on a microprocessor chip may grow as well. In some applications, cache memory may utilize more than half the physical size of a microprocessor. Methods to reduce the size of cache memory are needed.
[0004] On-chip cache memory on a microprocessor may be divided into groups: one group stores data and another group stores addresses. Within each of these groups, cache may be further grouped according to how fast information may be accessed. A first group, usually called L1, may consist of a small amount of memory, for example 16 k bytes. L1 usually has very fast access times. A second group, usually called L2, may consist of a larger amount of memory, for example 256 k bytes, however the access time of L2 may be slower than L1. A third group, usually called L3, may have even a larger amount of memory than L2, for example 4M bytes. The memory contained in L3 may have slower access times than L1 and L2.
[0005] A “hit” occurs when the CPU asks for information from a section of the cache and finds it there. A “miss” occurs when the CPU asks for information from a section of the cache and the information isn't there. If a miss occurs in a L1 section of cache, the CPU may look in a L2 section of cache. If a miss occurs in the L2 section, the CPU may look in L3.
[0006] Since performance is a major reason for having a memory hierarchy, the speed of hits and misses is important. Hit time is the time to access a level of the memory hierarchy, this includes the time needed to determine whether the access is a hit or a miss. The miss penalty is the time to replace the information from a higher level of cache memory, plus the time to deliver the information to the CPU. Because an lower level of cache memory, for example L1, is usually smaller and usually built with faster memory circuits, the hit time will be much smaller than the time to access information from a higher level of cache memory, for example L2.
[0007] Tags are used to determine whether a requested word is in a particular cache memory or not. An individual tag may be assigned to each individual cache memory in the cache hierarchy. FIG. 1 shows a cache hierarchy with three levels of cache memory. Tag L1, 108 is assigned to Cache L1, 102 and they are connected through bus 118 . Tag L2, 110 is assigned to Cache L2, 104 and they are connected through bus 120 . Tag L3, 112 is assigned to Cache L3, 106 and they are connected through bus 122 . Bus 114 connects Cache L1, 102 and Cache L2, 104 . Bus 116 connects Cache L2, 104 , and Cache L3, 106 . A tag should have enough addresses to access all the words contained in a cache. Larger caches require larger tags and smaller caches require smaller tags.
[0008] When a miss occurs, the CPU may have to wait a certain number of cycles before it can continue with processing. This is commonly called a “stall.” A CPU may stall until the correct information is retrieved from memory. A cache hierarchy helps to reduce the overall time to acquire information for processing. Part of the time consumed during a miss, is the time used in accessing information from a higher level of cache memory. If the time required to access information from a higher level could be reduced, the overall performance of a CPU could be improved.
[0009] The invention described improves the overall CPU performance as well as reduces the physical size and power consumed by the cache memory.
SUMMARY OF THE INVENTION
[0010] An embodiment of the invention provides a system and a method for simplifying a cache memory by using multiple tags and a large cache subdivided to form a smaller second cache. One tag controls both the large cache and the second cache. Another tag controls only the smaller second cache. By using this approach, the performance of a CPU may be improved. The physical size of the cache memory and the power consumed by the cache memory may be reduced. In addition, the write-through time, the write-back time, the latency, and the coherency of the cache memory system may also be improved along with improving the ability of multiple-processor systems to snoop cache memory.
[0011] Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawing, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a schematic drawing of a cache memory hierarchy containing three cache memory elements controlled by three TAGs.
[0013] [0013]FIG. 2 is a schematic drawing of a cache memory hierarchy where one cache memory array is a subset of another cache memory array.
[0014] [0014]FIG. 3 is a schematic drawing of a cache memory hierarchy where the size of a cache memory array contained in another cache memory is variable.
[0015] [0015]FIG. 4 is a schematic drawing illustrating the principle of write-back in a standard cache memory hierarchy.
[0016] [0016]FIG. 5 is a schematic drawing illustrating the principle of write-back in a simplified cache memory hierarchy
[0017] [0017]FIG. 6 is a schematic drawing illustrating the principle of write-through in a standard cache memory hierarchy.
[0018] [0018]FIG. 7 is a schematic drawing illustrating the principle of write-through in a simplified cache memory hierarchy
[0019] [0019]FIG. 8 is a schematic drawing illustrating the principle of coherency in a standard cache memory hierarchy.
[0020] [0020]FIG. 9 is a schematic drawing illustrating the principle of coherency in a simplified cache memory hierarchy.
[0021] [0021]FIG. 10 is a schematic drawing illustrating how a cache frame may be moved within another cache.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] [0022]FIG. 1 shows a cache hierarchy with three levels of cache memory. Tag L1, 108 is assigned to Cache L1, 102 and they are connected through bus 118 . Tag L2, 110 is assigned to Cache L2, 104 and they are connected through bus 120 . Tag L3, 112 is assigned to Cache L3, 106 and they are connected through bus 122 . Bus 114 connects Cache L1, 102 and Cache L2, 104 . Bus 116 connects Cache L2, 104 , and Cache L3, 106 . A tag should have enough addresses to access all the words contained in a cache. Larger caches require larger tags and smaller caches require smaller tags.
[0023] Each cache in FIG. 1 one is physically distinct from the other. Each cache has a tag associated with it. FIG. 2 illustrates how physical memory may be shared between two caches. In FIG. 2, cache L1, 202 , is physically distinct from caches L2 and L3. Cache L1, 202 , is controlled by tag L1, 208 , through bus 214 . Cache L2, 204 consists of a physical section of cache L3, 206 . Tag L2, 210 , controls only cache L2, 204 while tag L3, 212 , controls cache L3, 206 . Since cache L2, 204 is part of cache L3, 206 , tag L3, 212 also controls cache L2, 204 . Bus 220 connects cache L1, 202 , to cache L2, 204 , and to part of cache L3, 206 . Tag L2, 210 , controls cache L2, 204 , through bus 216 . Tag L3, 212 , controls cache L3, 206 through bus 218 .
[0024] Because cache L2, 204 is a subset of cache L3, 206 , a bus between them is not necessary. The information contained in cache L2, 204 , is also part of cache L3, 206 . Removing the need for a bus between L2, 204 , and L3, 206 , reduces the size and complexity of the cache hierarchy. It also helps reduce the power consumed in the cache hierarchy. Size and power are also reduced when cache L2, 204 , physically shares part of the memory of cache L3, 206 . In a standard cache hierarchy, as shown in FIG. 1, cache L2, 104 , is physically distinct from cache L3, 106 . As a result, a standard hierarchy, as shown in FIG. 1, may use more area and more power than the hierarchy shown in FIG. 2.
[0025] The size of cache L2, 304 , may be varied depending on the application. If an application needs a relatively large amount of L2 cache, 304 , a larger section of L3, 306 , is used. If an application needs a relatively small amount of L2 cache, 304 , a smaller section of L3, 306 , is used. By adjusting the size of cache L2, 304 , according to an application's needs, the overall performance of the CPU may be improved. FIG. 3 illustrates how the size of cache L2, 304 , may be increased when compared to cache L2, 204 , in FIG. 2. The size of the cache L2, 304 , is only limited by the size of the tag controlling it, tag L2, 310 .
[0026] In addition to reducing the size and power of a cache hierarchy, the cache hierarchy shown in FIG. 2 may also reduce the “write-through” and “write-back” times, improve the “coherency” of the cache, and reduce the latency of the CPU.
[0027] There are two basic options when writing to a cache: write-through and write-back. Both write-back and write-though caches have advantages.
[0028] With a write-back cache, no extra hardware is needed to write at the speed of the lowest level cache. Another advantage a write-back has is that multiple writes to lower level values often only generate a single write to a higher level cache, thus creating greater bandwidth.
[0029] One advantage of a write-through cache is that it is inherently coherent within a cycle or two. Another advantage a write-though cache has is that on a read miss a lower cache does not need to be flushed before new data is read in.
[0030] The frame-based, simplified, cache described herein, is inherently write-through because both levels of cache are written to the same cell. Extra hardware is not needed as it is in a standard write-through cache hierarchy. Because the frame defining the smaller cache in the frame-based, simplified cache can be moved, a flush isn't necessary. FIG. 10 illustrates how a lower level cache defined by a frame can be redefined to avoid flushing data. A flush occurs when data in a lower level is updated and the previous data is moved to a higher level of cache. If data in cache L2, 1002 , is flushed, data 1006 must be written to a location in cache L3, 1004 and new data from L3, 1004 must be written back to L2, 1002 . This may require several cycles to accomplish. If, however, the frame defining cache L2, 1002 , is redefined as cache L2 1008 , a flush isn't necessary. By moving the frame that defines the L2 cache, the old data is automatically moved to L3, 1010 and the new data is automatically contained in the newly defined L2, 1008 .
[0031] Write-back, also called “copy back” or “store in”, occurs when information is written only to a block in a cache. The modified cache block is written to higher level cache memory only when it is replaced. FIG. 4 is an illustration of two levels of cache memory used in a write-back configuration. In FIG. 4, cache L2, 402 , is controlled by tag L2, 406 through bus 410 . Cache L3, 404 , is controlled by tag L3, 408 through bus 414 . Information, 416 may be written from cache L2, 402 to cache L3, 404 through bus 412 . A write-back cache can “hide” writes by deferring the write until a port is not busy. A write-though cache does not have this advantage.
[0032] Write-through occurs when information is written to the current cache memory level and a higher cache memory level. FIG. 6 is an illustration of two levels of cache memory where information is written to both levels of cache. In FIG. 6, cache L2, 602 , is controlled by tag L2, 606 through bus 610 . Cache L3, 604 , is controlled by tag L3, 608 through bus 614 . Information may be written to both caches L2, 602 , and L3, 604 , in parallel. In order to write both caches in parallel as opposed to writing one cache at a time, at least one extra state-machine may be needed and more connectivity may be required.
[0033] [0033]FIG. 5 illustrates how a write-back time may be improved by writing to a physical location only one time. In FIG. 5, cache L2, 502 , is controlled by tag L2, 506 , through bus 510 and tag L3, 508 , through bus 512 . Cache L3, 504 , is controlled by tag L3, 508 through bus 512 , only. Information, 514 , stored in cache L2, 502 , is also stored in cache L3, 504 because cache L2, 502 is part of cache L3, 504 . Because information, 514 , stored in cache L2, 502 , is simultaneously stored in cache L3, 504 , write-through occurs in both cache L2, 502 , and cache L3, 504 . In addition, this simplified hierarchy, reduces the number of state-machines required and the amount of connectivity needed in a standard write-through cache as shown in FIG. 4. The reduction of the number of state-machines required and the amount of connectivity needed also reduces the overall physical size of the cache and reduces the power consumed by the cache.
[0034] [0034]FIG. 7 illustrates how write-through time may be improved by writing to a physical location only one time. In FIG. 7, cache L2, 702 , is controlled by tag L2, 706 , through bus 710 and tag L3, 708 , through bus 712 . Cache L3, 704 , is controlled by tag L3, 708 through bus 712 , only. Information, 714 , stored in cache L2, 702 , is also stored in cache L3, 704 because cache L2, 702 is part of cache L3, 704 . Because information, 714 , stored in cache L2, 702 , is simultaneously stored in cache L3, 704 , write-through occurs in both cache L2, 702 , and cache L3, 704 at nearly the same time. Because both caches L2 and L3 are written at nearly the same time, write-through time is reduced when compared to write-through times in a standard cache hierarchy as shown in FIG. 6. In addition, this simplified hierarchy, reduces the number of state-machines required and the amount of connectivity needed in a standard write-through cache as shown in FIG. 6. The reduction of the number of state-machines required and the amount of connectivity needed also reduces the overall physical size of the cache and reduces the power consumed by the cache.
[0035] Coherency is an issure when the same information is stored in several levels of a cache memory hierarchy. FIG. 8 illustrates the principle of coherency. In FIG. 8, cache L1, 802 , is controlled by tag L1, 808 through bus 818 . Cache L2, 804 , is controlled by tag L2, 810 through bus 820 . Cache L3, 806 , is controlled by tag L3, 812 , through bus 822 . Information may be transferred to and from caches L1, 802 , and L2, 804 , through bus 814 . Information may be transferred to and from caches L2, 804 , and L3, 806 , through bus 816 . In order to maintain coherency, information must be transferred from cache L1, 802 , to cache L2, 804 and then from cache L2, 804 to cache L3, 806 . Transferring information from one cache level to another requires more circuitry, more power and more physical area. The time required to maintain coherency decreases the memory bandwidth of the CPU. Increased latency slows the CPU performance.
[0036] A write-through cache is coherent by design. If a cache is coherent, external resources only have to look at the higher level cache and not the lower level because it is guaranteed the data in the higher level will match the data in the lower level.
[0037] A write-back cache is not coherent. External sources must look at both levels of cache, thus reducing bandwidth.
[0038] Coherency may be obtained by physically forming a lower cache memory level from part of a larger, higher cache memory level. In FIG. 9, cache L1, 902 , is controlled by tag L1, 908 through bus 914 . Cache L2, 904 , is controlled by tag L2, 910 through bus 916 and by tag L3, 906 through bus 918 . Cache L3, 906 , is controlled by tag L3, 912 , through bus 918 . Information, 922 may be transferred to and from caches L1, 902 , and L2, 904 , through bus 920 . Information, 922 , stored in cache L2, 904 , is also stored in cache L3, 906 because cache L2, 904 is part of cache L3, 906 . Because information, 922 , stored in cache L2, 904 , is simultaneously stored in cache L3, 906 , coherency between cache L2, 904 , and L3, 906 is always maintained. This also reduces the amount of circuitry needed, lowers the power, and reduces the physical area needed. Because the time to maintain coherency is decreased, the bandwidth of the CPU is increased. Reduced latency improves the CPU performance.
[0039] In addition to the improvements described, a simplified cache also improves the ability of a multiprocessor system to “snoop” cache memory. Every cache that has a copy of the data from a block of physical memory also has a copy of the information about it. These caches are usually on a shared-memory bus, and all cache controllers monitor or “snoop” on the bus to determine whether or not they have a copy of the shared block.
[0040] Snooping protocols should locate all the caches that share the object to be written. In a standard hierarchy, write-back cache, each level of cache must be checked when snooping. Because the information stored in a framed based, simplified cache is physically located in the same place for two levels of cache memory, the time used for snooping may be reduced. Reducing the snoop time may increase the bandwidth of the CPU.
[0041] The foregoing description of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art. | A system and method for reducing the power and the size of a cache memory is implemented by creating a large cache which is subdivided into a smaller cache. One tag controls both the large cache and the smaller, subdivided cache. A second tag controls only the smaller cache. In addition to saving power and area, this system and method may be used to reduce the write-through and write-back effort, improve the latency and the coherency of a cache memory, and improve the ability of multiprocessor system to snoop cache memory. | Provide a concise summary of the essential information conveyed in the context. | [
"CROSS-REFERENCED RELATED APPLICATIONS [0001] This application is related to an application titled “Dynamically Adjusted Cache Power Supply to Optimize for Cache Access or Power Consumption”, H.P. docket number 10016613-1 filed on or about the same day as the present application.",
"FIELD OF THE INVENTION [0002] This invention relates generally to electronic circuits.",
"More particularly, this invention relates to improving cache memory performance and reducing cache memory size.",
"BACKGROUND OF THE INVENTION [0003] As the size of microprocessors continues to grow, the size of the cache memory included on a microprocessor chip may grow as well.",
"In some applications, cache memory may utilize more than half the physical size of a microprocessor.",
"Methods to reduce the size of cache memory are needed.",
"[0004] On-chip cache memory on a microprocessor may be divided into groups: one group stores data and another group stores addresses.",
"Within each of these groups, cache may be further grouped according to how fast information may be accessed.",
"A first group, usually called L1, may consist of a small amount of memory, for example 16 k bytes.",
"L1 usually has very fast access times.",
"A second group, usually called L2, may consist of a larger amount of memory, for example 256 k bytes, however the access time of L2 may be slower than L1.",
"A third group, usually called L3, may have even a larger amount of memory than L2, for example 4M bytes.",
"The memory contained in L3 may have slower access times than L1 and L2.",
"[0005] A “hit”",
"occurs when the CPU asks for information from a section of the cache and finds it there.",
"A “miss”",
"occurs when the CPU asks for information from a section of the cache and the information isn't there.",
"If a miss occurs in a L1 section of cache, the CPU may look in a L2 section of cache.",
"If a miss occurs in the L2 section, the CPU may look in L3.",
"[0006] Since performance is a major reason for having a memory hierarchy, the speed of hits and misses is important.",
"Hit time is the time to access a level of the memory hierarchy, this includes the time needed to determine whether the access is a hit or a miss.",
"The miss penalty is the time to replace the information from a higher level of cache memory, plus the time to deliver the information to the CPU.",
"Because an lower level of cache memory, for example L1, is usually smaller and usually built with faster memory circuits, the hit time will be much smaller than the time to access information from a higher level of cache memory, for example L2.",
"[0007] Tags are used to determine whether a requested word is in a particular cache memory or not.",
"An individual tag may be assigned to each individual cache memory in the cache hierarchy.",
"FIG. 1 shows a cache hierarchy with three levels of cache memory.",
"Tag L1, 108 is assigned to Cache L1, 102 and they are connected through bus 118 .",
"Tag L2, 110 is assigned to Cache L2, 104 and they are connected through bus 120 .",
"Tag L3, 112 is assigned to Cache L3, 106 and they are connected through bus 122 .",
"Bus 114 connects Cache L1, 102 and Cache L2, 104 .",
"Bus 116 connects Cache L2, 104 , and Cache L3, 106 .",
"A tag should have enough addresses to access all the words contained in a cache.",
"Larger caches require larger tags and smaller caches require smaller tags.",
"[0008] When a miss occurs, the CPU may have to wait a certain number of cycles before it can continue with processing.",
"This is commonly called a “stall.”",
"A CPU may stall until the correct information is retrieved from memory.",
"A cache hierarchy helps to reduce the overall time to acquire information for processing.",
"Part of the time consumed during a miss, is the time used in accessing information from a higher level of cache memory.",
"If the time required to access information from a higher level could be reduced, the overall performance of a CPU could be improved.",
"[0009] The invention described improves the overall CPU performance as well as reduces the physical size and power consumed by the cache memory.",
"SUMMARY OF THE INVENTION [0010] An embodiment of the invention provides a system and a method for simplifying a cache memory by using multiple tags and a large cache subdivided to form a smaller second cache.",
"One tag controls both the large cache and the second cache.",
"Another tag controls only the smaller second cache.",
"By using this approach, the performance of a CPU may be improved.",
"The physical size of the cache memory and the power consumed by the cache memory may be reduced.",
"In addition, the write-through time, the write-back time, the latency, and the coherency of the cache memory system may also be improved along with improving the ability of multiple-processor systems to snoop cache memory.",
"[0011] Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawing, illustrating by way of example the principles of the invention.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0012] [0012 ]FIG. 1 is a schematic drawing of a cache memory hierarchy containing three cache memory elements controlled by three TAGs.",
"[0013] [0013 ]FIG. 2 is a schematic drawing of a cache memory hierarchy where one cache memory array is a subset of another cache memory array.",
"[0014] [0014 ]FIG. 3 is a schematic drawing of a cache memory hierarchy where the size of a cache memory array contained in another cache memory is variable.",
"[0015] [0015 ]FIG. 4 is a schematic drawing illustrating the principle of write-back in a standard cache memory hierarchy.",
"[0016] [0016 ]FIG. 5 is a schematic drawing illustrating the principle of write-back in a simplified cache memory hierarchy [0017] [0017 ]FIG. 6 is a schematic drawing illustrating the principle of write-through in a standard cache memory hierarchy.",
"[0018] [0018 ]FIG. 7 is a schematic drawing illustrating the principle of write-through in a simplified cache memory hierarchy [0019] [0019 ]FIG. 8 is a schematic drawing illustrating the principle of coherency in a standard cache memory hierarchy.",
"[0020] [0020 ]FIG. 9 is a schematic drawing illustrating the principle of coherency in a simplified cache memory hierarchy.",
"[0021] [0021 ]FIG. 10 is a schematic drawing illustrating how a cache frame may be moved within another cache.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0022] [0022 ]FIG. 1 shows a cache hierarchy with three levels of cache memory.",
"Tag L1, 108 is assigned to Cache L1, 102 and they are connected through bus 118 .",
"Tag L2, 110 is assigned to Cache L2, 104 and they are connected through bus 120 .",
"Tag L3, 112 is assigned to Cache L3, 106 and they are connected through bus 122 .",
"Bus 114 connects Cache L1, 102 and Cache L2, 104 .",
"Bus 116 connects Cache L2, 104 , and Cache L3, 106 .",
"A tag should have enough addresses to access all the words contained in a cache.",
"Larger caches require larger tags and smaller caches require smaller tags.",
"[0023] Each cache in FIG. 1 one is physically distinct from the other.",
"Each cache has a tag associated with it.",
"FIG. 2 illustrates how physical memory may be shared between two caches.",
"In FIG. 2, cache L1, 202 , is physically distinct from caches L2 and L3.",
"Cache L1, 202 , is controlled by tag L1, 208 , through bus 214 .",
"Cache L2, 204 consists of a physical section of cache L3, 206 .",
"Tag L2, 210 , controls only cache L2, 204 while tag L3, 212 , controls cache L3, 206 .",
"Since cache L2, 204 is part of cache L3, 206 , tag L3, 212 also controls cache L2, 204 .",
"Bus 220 connects cache L1, 202 , to cache L2, 204 , and to part of cache L3, 206 .",
"Tag L2, 210 , controls cache L2, 204 , through bus 216 .",
"Tag L3, 212 , controls cache L3, 206 through bus 218 .",
"[0024] Because cache L2, 204 is a subset of cache L3, 206 , a bus between them is not necessary.",
"The information contained in cache L2, 204 , is also part of cache L3, 206 .",
"Removing the need for a bus between L2, 204 , and L3, 206 , reduces the size and complexity of the cache hierarchy.",
"It also helps reduce the power consumed in the cache hierarchy.",
"Size and power are also reduced when cache L2, 204 , physically shares part of the memory of cache L3, 206 .",
"In a standard cache hierarchy, as shown in FIG. 1, cache L2, 104 , is physically distinct from cache L3, 106 .",
"As a result, a standard hierarchy, as shown in FIG. 1, may use more area and more power than the hierarchy shown in FIG. 2. [0025] The size of cache L2, 304 , may be varied depending on the application.",
"If an application needs a relatively large amount of L2 cache, 304 , a larger section of L3, 306 , is used.",
"If an application needs a relatively small amount of L2 cache, 304 , a smaller section of L3, 306 , is used.",
"By adjusting the size of cache L2, 304 , according to an application's needs, the overall performance of the CPU may be improved.",
"FIG. 3 illustrates how the size of cache L2, 304 , may be increased when compared to cache L2, 204 , in FIG. 2. The size of the cache L2, 304 , is only limited by the size of the tag controlling it, tag L2, 310 .",
"[0026] In addition to reducing the size and power of a cache hierarchy, the cache hierarchy shown in FIG. 2 may also reduce the “write-through”",
"and “write-back”",
"times, improve the “coherency”",
"of the cache, and reduce the latency of the CPU.",
"[0027] There are two basic options when writing to a cache: write-through and write-back.",
"Both write-back and write-though caches have advantages.",
"[0028] With a write-back cache, no extra hardware is needed to write at the speed of the lowest level cache.",
"Another advantage a write-back has is that multiple writes to lower level values often only generate a single write to a higher level cache, thus creating greater bandwidth.",
"[0029] One advantage of a write-through cache is that it is inherently coherent within a cycle or two.",
"Another advantage a write-though cache has is that on a read miss a lower cache does not need to be flushed before new data is read in.",
"[0030] The frame-based, simplified, cache described herein, is inherently write-through because both levels of cache are written to the same cell.",
"Extra hardware is not needed as it is in a standard write-through cache hierarchy.",
"Because the frame defining the smaller cache in the frame-based, simplified cache can be moved, a flush isn't necessary.",
"FIG. 10 illustrates how a lower level cache defined by a frame can be redefined to avoid flushing data.",
"A flush occurs when data in a lower level is updated and the previous data is moved to a higher level of cache.",
"If data in cache L2, 1002 , is flushed, data 1006 must be written to a location in cache L3, 1004 and new data from L3, 1004 must be written back to L2, 1002 .",
"This may require several cycles to accomplish.",
"If, however, the frame defining cache L2, 1002 , is redefined as cache L2 1008 , a flush isn't necessary.",
"By moving the frame that defines the L2 cache, the old data is automatically moved to L3, 1010 and the new data is automatically contained in the newly defined L2, 1008 .",
"[0031] Write-back, also called “copy back”",
"or “store in”, occurs when information is written only to a block in a cache.",
"The modified cache block is written to higher level cache memory only when it is replaced.",
"FIG. 4 is an illustration of two levels of cache memory used in a write-back configuration.",
"In FIG. 4, cache L2, 402 , is controlled by tag L2, 406 through bus 410 .",
"Cache L3, 404 , is controlled by tag L3, 408 through bus 414 .",
"Information, 416 may be written from cache L2, 402 to cache L3, 404 through bus 412 .",
"A write-back cache can “hide”",
"writes by deferring the write until a port is not busy.",
"A write-though cache does not have this advantage.",
"[0032] Write-through occurs when information is written to the current cache memory level and a higher cache memory level.",
"FIG. 6 is an illustration of two levels of cache memory where information is written to both levels of cache.",
"In FIG. 6, cache L2, 602 , is controlled by tag L2, 606 through bus 610 .",
"Cache L3, 604 , is controlled by tag L3, 608 through bus 614 .",
"Information may be written to both caches L2, 602 , and L3, 604 , in parallel.",
"In order to write both caches in parallel as opposed to writing one cache at a time, at least one extra state-machine may be needed and more connectivity may be required.",
"[0033] [0033 ]FIG. 5 illustrates how a write-back time may be improved by writing to a physical location only one time.",
"In FIG. 5, cache L2, 502 , is controlled by tag L2, 506 , through bus 510 and tag L3, 508 , through bus 512 .",
"Cache L3, 504 , is controlled by tag L3, 508 through bus 512 , only.",
"Information, 514 , stored in cache L2, 502 , is also stored in cache L3, 504 because cache L2, 502 is part of cache L3, 504 .",
"Because information, 514 , stored in cache L2, 502 , is simultaneously stored in cache L3, 504 , write-through occurs in both cache L2, 502 , and cache L3, 504 .",
"In addition, this simplified hierarchy, reduces the number of state-machines required and the amount of connectivity needed in a standard write-through cache as shown in FIG. 4. The reduction of the number of state-machines required and the amount of connectivity needed also reduces the overall physical size of the cache and reduces the power consumed by the cache.",
"[0034] [0034 ]FIG. 7 illustrates how write-through time may be improved by writing to a physical location only one time.",
"In FIG. 7, cache L2, 702 , is controlled by tag L2, 706 , through bus 710 and tag L3, 708 , through bus 712 .",
"Cache L3, 704 , is controlled by tag L3, 708 through bus 712 , only.",
"Information, 714 , stored in cache L2, 702 , is also stored in cache L3, 704 because cache L2, 702 is part of cache L3, 704 .",
"Because information, 714 , stored in cache L2, 702 , is simultaneously stored in cache L3, 704 , write-through occurs in both cache L2, 702 , and cache L3, 704 at nearly the same time.",
"Because both caches L2 and L3 are written at nearly the same time, write-through time is reduced when compared to write-through times in a standard cache hierarchy as shown in FIG. 6. In addition, this simplified hierarchy, reduces the number of state-machines required and the amount of connectivity needed in a standard write-through cache as shown in FIG. 6. The reduction of the number of state-machines required and the amount of connectivity needed also reduces the overall physical size of the cache and reduces the power consumed by the cache.",
"[0035] Coherency is an issure when the same information is stored in several levels of a cache memory hierarchy.",
"FIG. 8 illustrates the principle of coherency.",
"In FIG. 8, cache L1, 802 , is controlled by tag L1, 808 through bus 818 .",
"Cache L2, 804 , is controlled by tag L2, 810 through bus 820 .",
"Cache L3, 806 , is controlled by tag L3, 812 , through bus 822 .",
"Information may be transferred to and from caches L1, 802 , and L2, 804 , through bus 814 .",
"Information may be transferred to and from caches L2, 804 , and L3, 806 , through bus 816 .",
"In order to maintain coherency, information must be transferred from cache L1, 802 , to cache L2, 804 and then from cache L2, 804 to cache L3, 806 .",
"Transferring information from one cache level to another requires more circuitry, more power and more physical area.",
"The time required to maintain coherency decreases the memory bandwidth of the CPU.",
"Increased latency slows the CPU performance.",
"[0036] A write-through cache is coherent by design.",
"If a cache is coherent, external resources only have to look at the higher level cache and not the lower level because it is guaranteed the data in the higher level will match the data in the lower level.",
"[0037] A write-back cache is not coherent.",
"External sources must look at both levels of cache, thus reducing bandwidth.",
"[0038] Coherency may be obtained by physically forming a lower cache memory level from part of a larger, higher cache memory level.",
"In FIG. 9, cache L1, 902 , is controlled by tag L1, 908 through bus 914 .",
"Cache L2, 904 , is controlled by tag L2, 910 through bus 916 and by tag L3, 906 through bus 918 .",
"Cache L3, 906 , is controlled by tag L3, 912 , through bus 918 .",
"Information, 922 may be transferred to and from caches L1, 902 , and L2, 904 , through bus 920 .",
"Information, 922 , stored in cache L2, 904 , is also stored in cache L3, 906 because cache L2, 904 is part of cache L3, 906 .",
"Because information, 922 , stored in cache L2, 904 , is simultaneously stored in cache L3, 906 , coherency between cache L2, 904 , and L3, 906 is always maintained.",
"This also reduces the amount of circuitry needed, lowers the power, and reduces the physical area needed.",
"Because the time to maintain coherency is decreased, the bandwidth of the CPU is increased.",
"Reduced latency improves the CPU performance.",
"[0039] In addition to the improvements described, a simplified cache also improves the ability of a multiprocessor system to “snoop”",
"cache memory.",
"Every cache that has a copy of the data from a block of physical memory also has a copy of the information about it.",
"These caches are usually on a shared-memory bus, and all cache controllers monitor or “snoop”",
"on the bus to determine whether or not they have a copy of the shared block.",
"[0040] Snooping protocols should locate all the caches that share the object to be written.",
"In a standard hierarchy, write-back cache, each level of cache must be checked when snooping.",
"Because the information stored in a framed based, simplified cache is physically located in the same place for two levels of cache memory, the time used for snooping may be reduced.",
"Reducing the snoop time may increase the bandwidth of the CPU.",
"[0041] The foregoing description of the present invention has been presented for purposes of illustration and description.",
"It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings.",
"The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated.",
"It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art."
] |
FIELD OF THE INVENTION
The invention relates to flexible antenna coupling to related electronic components, and more particularly, to a capacitively coupled flexible antenna system employed in an active wireless data transceiver (WDX) device and method.
BACKGROUND OF THE INVENTION
Many applications incorporate radio frequency identification (RFID) tags. RFID tags employ reflected energy originally transmitted from an RFID reader, and do not generate RF energy. Some Real Time Location Systems (RTLSs) track objects by associated RFID tags. For individuals, a badge is used for tracking in environments such as health-care facilities, warehouses, and other areas where location is important. These RFID personnel badges communicate with fixed or hand-held readers. These devices employ a combination of antennas and electronics. They provide structures to support and protect the antennas and electronics, and to mount or attach them to objects. In many applications size, shape and mechanical properties such as flexibility, are important but impeded. Bulky materials and construction add undue thickness and stiffness to devices. These devices require adequate electrical connections, mechanical support, and appropriate positioning of components such as connectors and antennas. Structures for these purposes can add complexity, thickness, inflexibility and cost to the RFID device.
Additionally, RFID systems operate over various frequencies from high-frequency (HF) through super-high-frequency (SHF). Multiple operating issues arise in these ranges. While the performance of an RFID tag operating in the HF band may be less affected by the tag's proximity to the human body, a typical worn device is approximately 10 cm in length, including the antenna. This is a small fraction of a wavelength for the lower frequencies. Antennas which are a small fraction of a wavelength in linear dimensions are very inefficient radiators and receptors. As a result, the useful operating range for the HF band can be just a few inches from the reader antenna, significantly limiting the usefulness of HF tags. RFID systems operating at higher frequencies, however, may provide longer ranges in part because the shorter wavelength is more comparable to the antenna dimensions. This dimension match improves efficiency. However, compared to the HF band, signals at these higher frequencies are much more strongly affected by obstacles and materials in the immediate environment of the antenna due to the shorter wavelengths. Furthermore, antennas operating on or adjacent to the human body will be severely detuned and possibly rendered inoperable. Thus, the usability of these antennas in identification devices with RFID capability is very limited. When on or near the surface of a human body, the reactive near fields are influenced by the human tissue and there may be an impedance mismatch between the antenna and connected circuits, resulting in poor overall efficiency. This mismatch may detune the antenna and reduce the energy radiated away from the body, further impairing performance.
Another characteristic of RFID systems is that the performance of such systems is governed by the Radar Equation (1).
P
r
=
P
t
G
T
A
r
σ
F
4
(
4
π
)
2
R
4
(
1
)
Where P r =the power returning to the receiving antenna, P t =the transmitter power, G t =the gain of the transmitting antenna, A r =the effective aperture (area) of the receiving antenna, σ=the radar cross section or scattering coefficient of the target, F=the pattern propagation factor, and R=the range
Essentially, this means that the system performance is limited by the fourth power (1/R 4 ) of the distance to the RFID tag. This is due to the fact that the RFID interrogator transmitter power needs to reflect off the RFID tag and be received by the interrogator.
The above problems with RFID systems may result in limited range, difficulty simultaneously tracking multiple proximate tags, and limited information capacity. What is needed is an economical, flexible and wearable device that efficiently communicates information in support of applications such as personnel or equipment location.
SUMMARY OF THE INVENTION
In contrast to RFID devices, the subject invention is a Wireless Data Transceiver (WDX). The WDX has, in part, a battery, RF oscillator, transmitter, receiver and antenna. The WDX generates its own RF energy. Therefore, the performance of the WDX is controlled by the square of the distance to the interrogating transceiver. Embodiments include wearable data transceiver (WDX) communication devices incorporating flexible antennas that are coupled to associated electronics. Embodiments comprise badges, wristbands or bracelets. They may be incorporated with clothing at locations such as collars, cuffs and hems and employ various colors. Frequency ranges may comprise bands of 300-347 MHz, 433 MHz, and 902-928 MHz. Standardized European bands as well as other ISM bands around 2.4 GHz and 5.8 GHz may be used in embodiments. There are also other frequency embodiments in the 7 GHz range used for ultra wide band. Other frequency bands may be used. Application environments include, but are not limited to hospitals, clinics, schools, warehouses, office building, factories, and prisons.
An embodiment provides a device for communication comprising an enclosure; a flexible antenna component; and communication circuitry for generating and receiving signals, wherein the communication circuitry is in electrical communication with the antenna component and the communication circuitry and the antenna component are within the enclosure, wherein the device is an active real time location and identification device. For further embodiments, the electrical communication with the antenna component and the communication circuitry comprises capacitive coupling of the antenna to the circuitry; and the capacitive coupling comprises an adhesive affixing the antenna component to the circuitry. In another embodiment, the device is matched to a proximate body of a wearer, whereby communication performance is enhanced. For further embodiments, the enclosure is flexible; components of the enclosure are seam welded, whereby device size is reduced; or components of the enclosure are RF seam welded. Optionally, components of the enclosure are heat seam welded. In embodiments, the circuit comprises a power source and an RF oscillator. In yet further embodiments, the device is affixed to at least one of collar, hem, backpack strap, and object; and the device is disposable. For some embodiments, assembly of the circuitry and the antenna is inserted through a slot defined by the enclosure, the slot being sealed once fastened around an appendage of a wearer. For others, the assembly of the circuitry and the antenna is inserted through a slot defined by the enclosure, and the slot is sealed prior to fastening around an appendage of a wearer. In yet others, the assembly of the circuitry and the antenna is inserted through a slot defined by the enclosure prior to seam welding components of the enclosure. Additionally for some embodiments, the communication circuitry comprises an inflexible circuit board; and it comprises at least one battery coplanar with circuit board of the communication circuitry. Another embodiment comprises clips retaining the at least one coplanar battery, whereby thickness of the device is reduced. While for others the color of the device is selectable. Another embodiment provides that the device comprises a matching network at about approximately 315 MHz matching a differential transmitter output impedance of about approximately 100 ohms.
Yet another embodiment provides a method of identifying a subject, comprising the steps of storing information in circuitry; placing the circuitry in electrical connection with an antenna component; inserting assembly of the circuitry and the antenna in an enclosure; attaching the enclosure to the subject to be associated with the stored information; and accessing the information in the circuitry. For other embodiments, the enclosure comprises means for attaching the enclosure to the subject, the enclosure further comprising means for retaining the assembly, wherein the retaining means comprises a resilient body portion defining an opening therein and a retaining lip adjacent the opening, whereby the opening may be deformed to permit insertion of the assembly into the body portion and the retaining lip assists in retaining the assembly in the body portion; the assembly retaining means are associated with the attaching means. Further embodiments provide that the identifying further comprises locating the subject by RF communication; and removing a tab activates the device.
A further embodiment is a method for operating on electromagnetic signals using a device comprising an antenna coupled to circuitry, the method comprising the steps of positioning the device proximate an individual; coupling the device to the individual by proximity; receiving a receive signal; coupling the receive signal to the antenna; receiving the receive signal by the circuitry, wherein the circuitry is coupled with the antenna; decoding the received signal by a processor; generating transmit data; generating a transmit signal by the circuitry; coupling the transmit signal to the antenna, wherein the antenna is coupled with the circuitry; transmitting the transmit signal. In another embodiment, the coupling of the circuitry with the antenna is capacitive.
The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. It should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
Figures are not necessarily to scale and illustrations of relative sizes, shapes and other detailed attributes of elements may be schematic rather than literal or precise.
FIG. 1 is a simplified diagram of a bracelet device configured in accordance with an embodiment.
FIGS. 2A-2D are simplified diagrams of device component configurations in accordance with embodiments.
FIG. 3 is a simplified exploded diagram of device component layers in accordance with one embodiment.
FIG. 4A-4C depict simplified views of device activation/deactivation embodiments.
FIG. 5 is a simplified diagram of a functional schematic in accordance with one embodiment.
FIGS. 6A and 6B depict equivalent and matching circuits for device components in accordance with one embodiment.
FIG. 7 is a flow chart of a method of operation in accordance with one embodiment.
FIG. 8 is a simplified diagram of device body placement components in accordance with one embodiment.
FIG. 9 is a simplified diagram of an operational system configuration in accordance with one embodiment.
FIGS. 10 A-E are detailed illustrations of a wrist band system in accordance with one embodiment.
DETAILED DESCRIPTION
Embodiments include a wearable data transceiver (WDX) in a bracelet form. They are physically dimensioned to match existing non-active bracelets. To provide for a small form-factor, seams are RF seam welded, avoiding the bulk of adhesive-joined seams. Materials employed allow the bracelet to be created in various colors. Embodiments are packaged inside two layers of vinyl creating a soft and flexible bracelet. It comprises a flexible antenna, retaining flexibility when the assembly is inserted into the bracelet. The active circuitry is built on a rigid, inflexible, printed circuit board, but is sufficiently small to not impair bracelet functionality. The assembly of circuitry and antenna components can either be inserted through a slot which is sealed once fastened around an individual's wrist, or it can be inserted prior to welding. In embodiments, the slot remains to provide for an activation pull tab. Another embodiment may have a pull tab inside the pocket of the enclosure and no external slot. Since the bracelet is made of flexible vinyl, the tab could be pulled out of position by squeezing it through the vinyl and pulling it out of position, thus enabling the device. In embodiments, the device is affixed to a wrist, ankle, neck or other part of a person, animal or object. It may be inserted inside an article of clothing such as a pant or dress hem, point of a collar, shirt cuff, waist belt, suspenders, or jacket cuff. Embodiments are disposable following a single use. For example, the wrist band can be cut off the wrist or ankle or they can be re-usable and employ rechargeable batteries for long term operation.
For embodiments, the pull tab is used with a bar coded identification number on it such that the bracelet can be scanned at check in to associate it with a hospital patient and, at the same time, pulling the tab activates the WDX device. By activating the WDX only when it is being put on the patient, battery power is saved thereby reducing the overall size of the device and extending its operational life. Batteries co-planar with the circuit board keep overall height thin, avoiding a noticeable bump. Embodiments include special battery contacts for this purpose.
The antenna is tuned for optimal performance in the presence of, or contact with, the human body. This extends battery life and increases the distance and accuracy of wearable data transceiver position determination.
FIGS. 1A-1E depict simplified diagrams of a bracelet device 100 configured in accordance with an embodiment.
FIG. 1A is a side view of first component layer 105 and second component layer 110 . For embodiments, first component layer 105 and second component layer 110 materials are vinyl. In embodiments, vinyl is 0.005″ thick; however, the thickness can be changed for the particular application. A belt for a waist might be made of a material that looks like leather or may be leather. For embodiments, the thickness of the material would be adjusted to be thicker and stronger. The material could also be changed for the particular environment. For example, the WDX can be placed inside rubber gloves used to handle chemicals.
FIG. 1B shows a plan view of first and second layers attached to each other in shaded first welding region 115 . In no-weld region 120 , first component layer 105 and second component layer 110 are not attached, forming a pocket. Width of no-weld region, first width 125 , is approximately 0.87 inch minimum. Device outside width at no-weld region 120 , second width 130 , is approximately 1 inch. Device width at first welding region 115 , third width 135 , is approximately 0.6 inch. Overall device length 140 is approximately 10.85 inches. Slit 145 is provided in first component layer 105 . In embodiments, device components are inserted through slit 145 .
FIG. 1C is a plan view of device 100 with third component 150 included. Embodiments of third component 150 have dimensions of about 2.2″×0.55″ and comprises adhesive tape used to hold the device together once wrapped around the wrist. Other embodiments use different attachment methods.
FIG. 1D identifies device side view for area 155 shown in detail in FIG. 1E .
FIG. 1E side view depicts third component 155 proximate first and second component layers 160 . For embodiments, third component 150 material is 0.002″-0.005″ thick pressure sensitive adhesive (PSA). Third component 150 PSA initially has a release liner on the surface facing first component layer 105 . This is removed to attach third component 150 to first and second component layers 105 and 110 . Slit 145 is present in third component 150 and aligned with slit 145 in first component layer 105 . In embodiments, third component 150 is adhered to first component layer 105 after welding first component layer 105 and second component layer 110 . For embodiments, third component is on the slot side of the device so that the device is sealed once assembled on a wrist.
FIGS. 2A-2D show various configurations 200 of the device with respect to the batteries, circuitry, and the antenna for embodiments of the invention.
FIG. 2A depicts use of circuit board 205 . Antenna component 210 comprises a conductive silver screen printed antenna element 215 over substrate 220 using, in embodiments, 3M™ very high bonding (VHB™) adhesive tape in region 225 to bond them together. A 0.002″ inch (467 MP from 3M™) adhesive thickness is used for embodiments. Other embodiments use 0.005″ thick VHB (468 MP from 3M™). Further embodiments use 9505 and 9502 VHB versions from 3M™. Version selection stems from the relationship of the thickness to the tuning parameters. Embodiments employ 0.005 inch thick polyester for substrate 220 . Conducting components may be metals, polymers, inks, carbon, and organic material. The ohmic loss of the material is taken into account in the design to avoid unnecessary losses. The figure also shows the use of conductive plates 230 and 235 . In embodiments, conductive plates 230 are round copper on circuit board 205 , and conductive plates 235 are conductive silver ink on substrate 220 . Plates 230 and 235 function as the plates of a capacitor, coupling antenna and circuitry components. In one embodiment, the diameter of plates is 0.25-inch, and they are separated by 0.005-inch of adhesive dielectric. Conductive plates 230 and 235 are aligned over each other, with circuit components 240 and power source 245 laterally opposite antenna component 210 . Circuit components and batteries are outside of regions 225 and 230 when assembled. The artisan will appreciate that conductive plates 230 and 235 may be shapes other than circular, and that minor misalignments of the plates will not appreciably affect the operation. Assembled length in embodiments is approximately 4 inches. In embodiments, circuit board material is Flame Retardant 4 (FR4) and thickness is 0.015 inch. Attributes include compliance with Underwriters Laboratories UL 94-V0 flammability standard. Dielectric constant properties include values of 4.7 maximum with 4.35 at 500 MHz, and 4.34 at 1 GHz. In embodiments, the antenna of the subject invention is a balanced, electrically-small loop antenna. Other antennas may be implemented, and do not necessarily have to be a loop. In the case of electrically small loop antennas, it is desirable to maximize the enclosed area of the loop. The shape of the loop, in this case, is immaterial except for maximizing its enclosed area. Matching component values were determined with device components in proximity to a body.
FIG. 2B depicts a device first side 250 and second side 255 Batteries 260 are on first side 250 and circuit components 240 on second side 255 . Leftmost battery of 260 may be omitted if the extra power capacity were not required.
FIG. 2C depicts a device first side 265 and second side 270 . Battery 275 and circuit components 240 are on first side 265 and battery 275 ′ is on second side 270 .
FIG. 2D depicts battery 280 co-planar with the illustrated circuit board segment 285 retrained by clips 290 .
FIG. 3 depicts a simplified exploded diagram 300 of device component layers. Antenna element layer 305 is affixed to substrate layer 310 by adhesive 315 . For embodiments, adhesive is in coupling regions only.
FIGS. 4A-4C depict device activation and de-activation implementation embodiments 400. In FIG. 4A , pulling pull tab or strip 405 starts the system by operating tab switch 410 on substrate 415 . In FIG. 4B , pushing push button 420 starts the device by operating button switch 425 on substrate 430 . In FIG. 4C , pulling tab 435 starts the system by enabling electrical contact between battery 440 and battery clip 445 . In embodiments, battery 440 is located within an aperture in substrate 450 . For other embodiments, the device is activated by external force on the flexible enclosure, closing a circuit. For embodiments, cutting disables the device. Cutting the bracelet off at the antenna is sufficient in embodiments to stop transmissions and uses a task already employed for removing the device. For some embodiments it is not required that the device be turned off; for some embodiments the batteries will run out in a short time.
FIG. 5 is a simplified diagram 500 of a functional schematic of a WDX device 505 . Flexible antenna 510 is coupled 515 to circuitry 520 . Coupling embodiments are capacitive. Circuitry 520 operates from power source 525 incorporated in WDX device 505 . WDX device 505 communicates with transceiver 530 to exchange data and establish WDX device 505 location. In embodiments, circuitry 520 components comprise microprocessor 535 , radio frequency (RF) oscillator 540 , switch 545 , RF receiver 550 , RF demodulator 555 , RF modulator 560 , and RF transmitter 565 . Each embodiment comprises a power supply and RF oscillator. Note that RF oscillator component 540 generates the RF signal for RF signal transmission, distinct from an integrated circuit clock-generating oscillator. Components may be contained within other components. Components of other various embodiments (not shown) comprise analog to digital converter (ADC), digital to analog converter (DAC), and memory. Integrated circuit component form-factors include, but are not limited to, small-outline integrated circuit (SOIC) and chip on board with an epoxy encapsulant (glob top).
FIGS. 6A and 6B depict equivalent and matching circuits, respectively, for device embodiments.
FIG. 6A depicts an equivalent circuit 600 A for a WDX device with antenna component 605 and circuitry component 610 . In embodiments, antenna component 605 and circuitry component 610 are capacitively coupled by components 615 . Antenna component 605 can be modeled as reactance 620 in series with resistor 625 . Reactance 620 represents the reactance of the antenna. Resistor 625 represents power dissipation through the losses in the antenna and in the coupled dielectric plus the radiated energy. Circuitry component 615 comprises effective source impedance 630 and effective voltage source 635 from the circuitry.
FIG. 6B depicts a matching circuit 600 B for a WDX device. TP_ANT 1 640 and TP_ANT 2 645 are the pads on the printed circuit board (PCB) which interface with the flexible antenna. The components are mirrored since the output of the transmitter (on the left side, not labeled) is a differential, balanced output; thus, only one side is described. C 12 650 of 33 pF, L 1 655 of 18 nH and C 13 660 of 22 pF form a “pi” network which serves two purposes. First, it matches the impedance of the antenna at points TP_ANT 1 640 and TP_ANT 2 645 to the transmitter output which is approximately a 100-ohm differential impedance. Secondly, it forms a low-pass filter with a cutoff frequency slightly above the intended band of operation. This filter action helps insure compliance with FCC requirements for harmonic suppression. The values shown are representative and specific to the embodiment application in the 315 MHz band. Changes in at least any of the following conditions would require different values: different operating frequency, different antenna size or shape, optimization for other than a bracelet.
FIG. 7 is a flow chart 700 of a method of operation of an embodiment of the WDX device. The steps include positioning the device proximate an individual, 705 . Coupling the device to an individual by proximity, 710 . Receiving an RF signal, 715 comprising RF signal coupled to the antenna, 720 . Circuitry receives the RF signal via coupling with the antenna, 725 . Microprocessor decodes received signal data and generates data to transmit, 730 . The circuitry generates an RF signal, 735 . The RF signal is coupled to the antenna, 740 . The device transmits the RF signal, 745 . Note that the steps may be performed in alternate orders.
FIG. 8 depicts particular, but not exhaustive, body locations 800 for the WDX device. Body 805 locations for device mounting include wrist 810 , garment hem 815 , waist 820 , chest 825 , and collar 830 . Nonlimiting embodiment locations include sleeve cuffs, belts, gloves, shoes, and an embodiment that attaches to the skin like an adhesive strip.
FIG. 9 is a simplified diagram 900 of an operational system configuration embodiment. Transceiver 905 is in communication with multiple WDX devices, in this case within a building. WDX devices 910 , 915 , 920 , and 925 communicate with transceiver 905 . Additional WDX devices 930 may be operational within the facility building. In embodiments, the transceiver 905 antenna is circularly polarized to support a wearable data transceiver antenna of random linear polarization. This would avoid polarization fades.
FIGS. 10 A-E are detailed scale illustrations of a wrist band system embodiment depicting circuitry and antenna components and their insertion into a wrist band enclosure.
FIG. 10A is a detailed illustration 1000 A of circuitry 1005 with pull tab 1010 and antenna 1015 components comprising assembly 1020 beside wrist band enclosure 1025 .
FIG. 10B is a detailed illustration 1000 B of assembly 1020 partially inserted into wrist band enclosure 1025 .
FIG. 10C is a detailed illustration 1000 C of assembly 1020 (not visible) within wrist band enclosure 1025 depicting pull tab 1010 .
FIG. 10D is a detailed scale illustration 1000 D of top or front of circuitry component.
FIG. 10E is a detailed scale illustration 1000 E of bottom or back of circuitry component.
The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | A flexible antenna capacitively coupled to related circuitry components for an active wearable data transceiver electronic location and identification device. Wearable data transceivers (WDXs) are employed as bracelets, badges, and may be incorporated with back pack straps and clothing at locations such as collars, cuffs, and hems. They employ various colors. Active transceiver communication devices are also mounted on objects for real time location tracking and identification. Body-mounted WDXs match the body with the antenna for sending and receiving signals. WDX power includes coplanar battery cells and circuitry has radio transmitter and radio receiver components. | Summarize the key points of the given patent document. | [
"FIELD OF THE INVENTION The invention relates to flexible antenna coupling to related electronic components, and more particularly, to a capacitively coupled flexible antenna system employed in an active wireless data transceiver (WDX) device and method.",
"BACKGROUND OF THE INVENTION Many applications incorporate radio frequency identification (RFID) tags.",
"RFID tags employ reflected energy originally transmitted from an RFID reader, and do not generate RF energy.",
"Some Real Time Location Systems (RTLSs) track objects by associated RFID tags.",
"For individuals, a badge is used for tracking in environments such as health-care facilities, warehouses, and other areas where location is important.",
"These RFID personnel badges communicate with fixed or hand-held readers.",
"These devices employ a combination of antennas and electronics.",
"They provide structures to support and protect the antennas and electronics, and to mount or attach them to objects.",
"In many applications size, shape and mechanical properties such as flexibility, are important but impeded.",
"Bulky materials and construction add undue thickness and stiffness to devices.",
"These devices require adequate electrical connections, mechanical support, and appropriate positioning of components such as connectors and antennas.",
"Structures for these purposes can add complexity, thickness, inflexibility and cost to the RFID device.",
"Additionally, RFID systems operate over various frequencies from high-frequency (HF) through super-high-frequency (SHF).",
"Multiple operating issues arise in these ranges.",
"While the performance of an RFID tag operating in the HF band may be less affected by the tag's proximity to the human body, a typical worn device is approximately 10 cm in length, including the antenna.",
"This is a small fraction of a wavelength for the lower frequencies.",
"Antennas which are a small fraction of a wavelength in linear dimensions are very inefficient radiators and receptors.",
"As a result, the useful operating range for the HF band can be just a few inches from the reader antenna, significantly limiting the usefulness of HF tags.",
"RFID systems operating at higher frequencies, however, may provide longer ranges in part because the shorter wavelength is more comparable to the antenna dimensions.",
"This dimension match improves efficiency.",
"However, compared to the HF band, signals at these higher frequencies are much more strongly affected by obstacles and materials in the immediate environment of the antenna due to the shorter wavelengths.",
"Furthermore, antennas operating on or adjacent to the human body will be severely detuned and possibly rendered inoperable.",
"Thus, the usability of these antennas in identification devices with RFID capability is very limited.",
"When on or near the surface of a human body, the reactive near fields are influenced by the human tissue and there may be an impedance mismatch between the antenna and connected circuits, resulting in poor overall efficiency.",
"This mismatch may detune the antenna and reduce the energy radiated away from the body, further impairing performance.",
"Another characteristic of RFID systems is that the performance of such systems is governed by the Radar Equation (1).",
"P r = P t G T A r σ F 4 ( 4 π ) 2 R 4 ( 1 ) Where P r =the power returning to the receiving antenna, P t =the transmitter power, G t =the gain of the transmitting antenna, A r =the effective aperture (area) of the receiving antenna, σ=the radar cross section or scattering coefficient of the target, F=the pattern propagation factor, and R=the range Essentially, this means that the system performance is limited by the fourth power (1/R 4 ) of the distance to the RFID tag.",
"This is due to the fact that the RFID interrogator transmitter power needs to reflect off the RFID tag and be received by the interrogator.",
"The above problems with RFID systems may result in limited range, difficulty simultaneously tracking multiple proximate tags, and limited information capacity.",
"What is needed is an economical, flexible and wearable device that efficiently communicates information in support of applications such as personnel or equipment location.",
"SUMMARY OF THE INVENTION In contrast to RFID devices, the subject invention is a Wireless Data Transceiver (WDX).",
"The WDX has, in part, a battery, RF oscillator, transmitter, receiver and antenna.",
"The WDX generates its own RF energy.",
"Therefore, the performance of the WDX is controlled by the square of the distance to the interrogating transceiver.",
"Embodiments include wearable data transceiver (WDX) communication devices incorporating flexible antennas that are coupled to associated electronics.",
"Embodiments comprise badges, wristbands or bracelets.",
"They may be incorporated with clothing at locations such as collars, cuffs and hems and employ various colors.",
"Frequency ranges may comprise bands of 300-347 MHz, 433 MHz, and 902-928 MHz.",
"Standardized European bands as well as other ISM bands around 2.4 GHz and 5.8 GHz may be used in embodiments.",
"There are also other frequency embodiments in the 7 GHz range used for ultra wide band.",
"Other frequency bands may be used.",
"Application environments include, but are not limited to hospitals, clinics, schools, warehouses, office building, factories, and prisons.",
"An embodiment provides a device for communication comprising an enclosure;",
"a flexible antenna component;",
"and communication circuitry for generating and receiving signals, wherein the communication circuitry is in electrical communication with the antenna component and the communication circuitry and the antenna component are within the enclosure, wherein the device is an active real time location and identification device.",
"For further embodiments, the electrical communication with the antenna component and the communication circuitry comprises capacitive coupling of the antenna to the circuitry;",
"and the capacitive coupling comprises an adhesive affixing the antenna component to the circuitry.",
"In another embodiment, the device is matched to a proximate body of a wearer, whereby communication performance is enhanced.",
"For further embodiments, the enclosure is flexible;",
"components of the enclosure are seam welded, whereby device size is reduced;",
"or components of the enclosure are RF seam welded.",
"Optionally, components of the enclosure are heat seam welded.",
"In embodiments, the circuit comprises a power source and an RF oscillator.",
"In yet further embodiments, the device is affixed to at least one of collar, hem, backpack strap, and object;",
"and the device is disposable.",
"For some embodiments, assembly of the circuitry and the antenna is inserted through a slot defined by the enclosure, the slot being sealed once fastened around an appendage of a wearer.",
"For others, the assembly of the circuitry and the antenna is inserted through a slot defined by the enclosure, and the slot is sealed prior to fastening around an appendage of a wearer.",
"In yet others, the assembly of the circuitry and the antenna is inserted through a slot defined by the enclosure prior to seam welding components of the enclosure.",
"Additionally for some embodiments, the communication circuitry comprises an inflexible circuit board;",
"and it comprises at least one battery coplanar with circuit board of the communication circuitry.",
"Another embodiment comprises clips retaining the at least one coplanar battery, whereby thickness of the device is reduced.",
"While for others the color of the device is selectable.",
"Another embodiment provides that the device comprises a matching network at about approximately 315 MHz matching a differential transmitter output impedance of about approximately 100 ohms.",
"Yet another embodiment provides a method of identifying a subject, comprising the steps of storing information in circuitry;",
"placing the circuitry in electrical connection with an antenna component;",
"inserting assembly of the circuitry and the antenna in an enclosure;",
"attaching the enclosure to the subject to be associated with the stored information;",
"and accessing the information in the circuitry.",
"For other embodiments, the enclosure comprises means for attaching the enclosure to the subject, the enclosure further comprising means for retaining the assembly, wherein the retaining means comprises a resilient body portion defining an opening therein and a retaining lip adjacent the opening, whereby the opening may be deformed to permit insertion of the assembly into the body portion and the retaining lip assists in retaining the assembly in the body portion;",
"the assembly retaining means are associated with the attaching means.",
"Further embodiments provide that the identifying further comprises locating the subject by RF communication;",
"and removing a tab activates the device.",
"A further embodiment is a method for operating on electromagnetic signals using a device comprising an antenna coupled to circuitry, the method comprising the steps of positioning the device proximate an individual;",
"coupling the device to the individual by proximity;",
"receiving a receive signal;",
"coupling the receive signal to the antenna;",
"receiving the receive signal by the circuitry, wherein the circuitry is coupled with the antenna;",
"decoding the received signal by a processor;",
"generating transmit data;",
"generating a transmit signal by the circuitry;",
"coupling the transmit signal to the antenna, wherein the antenna is coupled with the circuitry;",
"transmitting the transmit signal.",
"In another embodiment, the coupling of the circuitry with the antenna is capacitive.",
"The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims.",
"It should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.",
"BRIEF DESCRIPTION OF THE DRAWINGS Figures are not necessarily to scale and illustrations of relative sizes, shapes and other detailed attributes of elements may be schematic rather than literal or precise.",
"FIG. 1 is a simplified diagram of a bracelet device configured in accordance with an embodiment.",
"FIGS. 2A-2D are simplified diagrams of device component configurations in accordance with embodiments.",
"FIG. 3 is a simplified exploded diagram of device component layers in accordance with one embodiment.",
"FIG. 4A-4C depict simplified views of device activation/deactivation embodiments.",
"FIG. 5 is a simplified diagram of a functional schematic in accordance with one embodiment.",
"FIGS. 6A and 6B depict equivalent and matching circuits for device components in accordance with one embodiment.",
"FIG. 7 is a flow chart of a method of operation in accordance with one embodiment.",
"FIG. 8 is a simplified diagram of device body placement components in accordance with one embodiment.",
"FIG. 9 is a simplified diagram of an operational system configuration in accordance with one embodiment.",
"FIGS. 10 A-E are detailed illustrations of a wrist band system in accordance with one embodiment.",
"DETAILED DESCRIPTION Embodiments include a wearable data transceiver (WDX) in a bracelet form.",
"They are physically dimensioned to match existing non-active bracelets.",
"To provide for a small form-factor, seams are RF seam welded, avoiding the bulk of adhesive-joined seams.",
"Materials employed allow the bracelet to be created in various colors.",
"Embodiments are packaged inside two layers of vinyl creating a soft and flexible bracelet.",
"It comprises a flexible antenna, retaining flexibility when the assembly is inserted into the bracelet.",
"The active circuitry is built on a rigid, inflexible, printed circuit board, but is sufficiently small to not impair bracelet functionality.",
"The assembly of circuitry and antenna components can either be inserted through a slot which is sealed once fastened around an individual's wrist, or it can be inserted prior to welding.",
"In embodiments, the slot remains to provide for an activation pull tab.",
"Another embodiment may have a pull tab inside the pocket of the enclosure and no external slot.",
"Since the bracelet is made of flexible vinyl, the tab could be pulled out of position by squeezing it through the vinyl and pulling it out of position, thus enabling the device.",
"In embodiments, the device is affixed to a wrist, ankle, neck or other part of a person, animal or object.",
"It may be inserted inside an article of clothing such as a pant or dress hem, point of a collar, shirt cuff, waist belt, suspenders, or jacket cuff.",
"Embodiments are disposable following a single use.",
"For example, the wrist band can be cut off the wrist or ankle or they can be re-usable and employ rechargeable batteries for long term operation.",
"For embodiments, the pull tab is used with a bar coded identification number on it such that the bracelet can be scanned at check in to associate it with a hospital patient and, at the same time, pulling the tab activates the WDX device.",
"By activating the WDX only when it is being put on the patient, battery power is saved thereby reducing the overall size of the device and extending its operational life.",
"Batteries co-planar with the circuit board keep overall height thin, avoiding a noticeable bump.",
"Embodiments include special battery contacts for this purpose.",
"The antenna is tuned for optimal performance in the presence of, or contact with, the human body.",
"This extends battery life and increases the distance and accuracy of wearable data transceiver position determination.",
"FIGS. 1A-1E depict simplified diagrams of a bracelet device 100 configured in accordance with an embodiment.",
"FIG. 1A is a side view of first component layer 105 and second component layer 110 .",
"For embodiments, first component layer 105 and second component layer 110 materials are vinyl.",
"In embodiments, vinyl is 0.005″ thick;",
"however, the thickness can be changed for the particular application.",
"A belt for a waist might be made of a material that looks like leather or may be leather.",
"For embodiments, the thickness of the material would be adjusted to be thicker and stronger.",
"The material could also be changed for the particular environment.",
"For example, the WDX can be placed inside rubber gloves used to handle chemicals.",
"FIG. 1B shows a plan view of first and second layers attached to each other in shaded first welding region 115 .",
"In no-weld region 120 , first component layer 105 and second component layer 110 are not attached, forming a pocket.",
"Width of no-weld region, first width 125 , is approximately 0.87 inch minimum.",
"Device outside width at no-weld region 120 , second width 130 , is approximately 1 inch.",
"Device width at first welding region 115 , third width 135 , is approximately 0.6 inch.",
"Overall device length 140 is approximately 10.85 inches.",
"Slit 145 is provided in first component layer 105 .",
"In embodiments, device components are inserted through slit 145 .",
"FIG. 1C is a plan view of device 100 with third component 150 included.",
"Embodiments of third component 150 have dimensions of about 2.2″×0.55″ and comprises adhesive tape used to hold the device together once wrapped around the wrist.",
"Other embodiments use different attachment methods.",
"FIG. 1D identifies device side view for area 155 shown in detail in FIG. 1E .",
"FIG. 1E side view depicts third component 155 proximate first and second component layers 160 .",
"For embodiments, third component 150 material is 0.002″-0.005″ thick pressure sensitive adhesive (PSA).",
"Third component 150 PSA initially has a release liner on the surface facing first component layer 105 .",
"This is removed to attach third component 150 to first and second component layers 105 and 110 .",
"Slit 145 is present in third component 150 and aligned with slit 145 in first component layer 105 .",
"In embodiments, third component 150 is adhered to first component layer 105 after welding first component layer 105 and second component layer 110 .",
"For embodiments, third component is on the slot side of the device so that the device is sealed once assembled on a wrist.",
"FIGS. 2A-2D show various configurations 200 of the device with respect to the batteries, circuitry, and the antenna for embodiments of the invention.",
"FIG. 2A depicts use of circuit board 205 .",
"Antenna component 210 comprises a conductive silver screen printed antenna element 215 over substrate 220 using, in embodiments, 3M™ very high bonding (VHB™) adhesive tape in region 225 to bond them together.",
"A 0.002″ inch (467 MP from 3M™) adhesive thickness is used for embodiments.",
"Other embodiments use 0.005″ thick VHB (468 MP from 3M™).",
"Further embodiments use 9505 and 9502 VHB versions from 3M™.",
"Version selection stems from the relationship of the thickness to the tuning parameters.",
"Embodiments employ 0.005 inch thick polyester for substrate 220 .",
"Conducting components may be metals, polymers, inks, carbon, and organic material.",
"The ohmic loss of the material is taken into account in the design to avoid unnecessary losses.",
"The figure also shows the use of conductive plates 230 and 235 .",
"In embodiments, conductive plates 230 are round copper on circuit board 205 , and conductive plates 235 are conductive silver ink on substrate 220 .",
"Plates 230 and 235 function as the plates of a capacitor, coupling antenna and circuitry components.",
"In one embodiment, the diameter of plates is 0.25-inch, and they are separated by 0.005-inch of adhesive dielectric.",
"Conductive plates 230 and 235 are aligned over each other, with circuit components 240 and power source 245 laterally opposite antenna component 210 .",
"Circuit components and batteries are outside of regions 225 and 230 when assembled.",
"The artisan will appreciate that conductive plates 230 and 235 may be shapes other than circular, and that minor misalignments of the plates will not appreciably affect the operation.",
"Assembled length in embodiments is approximately 4 inches.",
"In embodiments, circuit board material is Flame Retardant 4 (FR4) and thickness is 0.015 inch.",
"Attributes include compliance with Underwriters Laboratories UL 94-V0 flammability standard.",
"Dielectric constant properties include values of 4.7 maximum with 4.35 at 500 MHz, and 4.34 at 1 GHz.",
"In embodiments, the antenna of the subject invention is a balanced, electrically-small loop antenna.",
"Other antennas may be implemented, and do not necessarily have to be a loop.",
"In the case of electrically small loop antennas, it is desirable to maximize the enclosed area of the loop.",
"The shape of the loop, in this case, is immaterial except for maximizing its enclosed area.",
"Matching component values were determined with device components in proximity to a body.",
"FIG. 2B depicts a device first side 250 and second side 255 Batteries 260 are on first side 250 and circuit components 240 on second side 255 .",
"Leftmost battery of 260 may be omitted if the extra power capacity were not required.",
"FIG. 2C depicts a device first side 265 and second side 270 .",
"Battery 275 and circuit components 240 are on first side 265 and battery 275 ′ is on second side 270 .",
"FIG. 2D depicts battery 280 co-planar with the illustrated circuit board segment 285 retrained by clips 290 .",
"FIG. 3 depicts a simplified exploded diagram 300 of device component layers.",
"Antenna element layer 305 is affixed to substrate layer 310 by adhesive 315 .",
"For embodiments, adhesive is in coupling regions only.",
"FIGS. 4A-4C depict device activation and de-activation implementation embodiments 400.",
"In FIG. 4A , pulling pull tab or strip 405 starts the system by operating tab switch 410 on substrate 415 .",
"In FIG. 4B , pushing push button 420 starts the device by operating button switch 425 on substrate 430 .",
"In FIG. 4C , pulling tab 435 starts the system by enabling electrical contact between battery 440 and battery clip 445 .",
"In embodiments, battery 440 is located within an aperture in substrate 450 .",
"For other embodiments, the device is activated by external force on the flexible enclosure, closing a circuit.",
"For embodiments, cutting disables the device.",
"Cutting the bracelet off at the antenna is sufficient in embodiments to stop transmissions and uses a task already employed for removing the device.",
"For some embodiments it is not required that the device be turned off;",
"for some embodiments the batteries will run out in a short time.",
"FIG. 5 is a simplified diagram 500 of a functional schematic of a WDX device 505 .",
"Flexible antenna 510 is coupled 515 to circuitry 520 .",
"Coupling embodiments are capacitive.",
"Circuitry 520 operates from power source 525 incorporated in WDX device 505 .",
"WDX device 505 communicates with transceiver 530 to exchange data and establish WDX device 505 location.",
"In embodiments, circuitry 520 components comprise microprocessor 535 , radio frequency (RF) oscillator 540 , switch 545 , RF receiver 550 , RF demodulator 555 , RF modulator 560 , and RF transmitter 565 .",
"Each embodiment comprises a power supply and RF oscillator.",
"Note that RF oscillator component 540 generates the RF signal for RF signal transmission, distinct from an integrated circuit clock-generating oscillator.",
"Components may be contained within other components.",
"Components of other various embodiments (not shown) comprise analog to digital converter (ADC), digital to analog converter (DAC), and memory.",
"Integrated circuit component form-factors include, but are not limited to, small-outline integrated circuit (SOIC) and chip on board with an epoxy encapsulant (glob top).",
"FIGS. 6A and 6B depict equivalent and matching circuits, respectively, for device embodiments.",
"FIG. 6A depicts an equivalent circuit 600 A for a WDX device with antenna component 605 and circuitry component 610 .",
"In embodiments, antenna component 605 and circuitry component 610 are capacitively coupled by components 615 .",
"Antenna component 605 can be modeled as reactance 620 in series with resistor 625 .",
"Reactance 620 represents the reactance of the antenna.",
"Resistor 625 represents power dissipation through the losses in the antenna and in the coupled dielectric plus the radiated energy.",
"Circuitry component 615 comprises effective source impedance 630 and effective voltage source 635 from the circuitry.",
"FIG. 6B depicts a matching circuit 600 B for a WDX device.",
"TP_ANT 1 640 and TP_ANT 2 645 are the pads on the printed circuit board (PCB) which interface with the flexible antenna.",
"The components are mirrored since the output of the transmitter (on the left side, not labeled) is a differential, balanced output;",
"thus, only one side is described.",
"C 12 650 of 33 pF, L 1 655 of 18 nH and C 13 660 of 22 pF form a “pi”",
"network which serves two purposes.",
"First, it matches the impedance of the antenna at points TP_ANT 1 640 and TP_ANT 2 645 to the transmitter output which is approximately a 100-ohm differential impedance.",
"Secondly, it forms a low-pass filter with a cutoff frequency slightly above the intended band of operation.",
"This filter action helps insure compliance with FCC requirements for harmonic suppression.",
"The values shown are representative and specific to the embodiment application in the 315 MHz band.",
"Changes in at least any of the following conditions would require different values: different operating frequency, different antenna size or shape, optimization for other than a bracelet.",
"FIG. 7 is a flow chart 700 of a method of operation of an embodiment of the WDX device.",
"The steps include positioning the device proximate an individual, 705 .",
"Coupling the device to an individual by proximity, 710 .",
"Receiving an RF signal, 715 comprising RF signal coupled to the antenna, 720 .",
"Circuitry receives the RF signal via coupling with the antenna, 725 .",
"Microprocessor decodes received signal data and generates data to transmit, 730 .",
"The circuitry generates an RF signal, 735 .",
"The RF signal is coupled to the antenna, 740 .",
"The device transmits the RF signal, 745 .",
"Note that the steps may be performed in alternate orders.",
"FIG. 8 depicts particular, but not exhaustive, body locations 800 for the WDX device.",
"Body 805 locations for device mounting include wrist 810 , garment hem 815 , waist 820 , chest 825 , and collar 830 .",
"Nonlimiting embodiment locations include sleeve cuffs, belts, gloves, shoes, and an embodiment that attaches to the skin like an adhesive strip.",
"FIG. 9 is a simplified diagram 900 of an operational system configuration embodiment.",
"Transceiver 905 is in communication with multiple WDX devices, in this case within a building.",
"WDX devices 910 , 915 , 920 , and 925 communicate with transceiver 905 .",
"Additional WDX devices 930 may be operational within the facility building.",
"In embodiments, the transceiver 905 antenna is circularly polarized to support a wearable data transceiver antenna of random linear polarization.",
"This would avoid polarization fades.",
"FIGS. 10 A-E are detailed scale illustrations of a wrist band system embodiment depicting circuitry and antenna components and their insertion into a wrist band enclosure.",
"FIG. 10A is a detailed illustration 1000 A of circuitry 1005 with pull tab 1010 and antenna 1015 components comprising assembly 1020 beside wrist band enclosure 1025 .",
"FIG. 10B is a detailed illustration 1000 B of assembly 1020 partially inserted into wrist band enclosure 1025 .",
"FIG. 10C is a detailed illustration 1000 C of assembly 1020 (not visible) within wrist band enclosure 1025 depicting pull tab 1010 .",
"FIG. 10D is a detailed scale illustration 1000 D of top or front of circuitry component.",
"FIG. 10E is a detailed scale illustration 1000 E of bottom or back of circuitry component.",
"The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description.",
"It is not intended to be exhaustive or to limit the invention to the precise form disclosed.",
"Many modifications and variations are possible in light of this disclosure.",
"It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto."
] |
FIELD OF INVENTION
This invention relates to the field of measuring the sharpness of knife cutting edges, specifically industrial knives, using capacitance sensing as the measurement technique.
BACKGROUND
Several methods are known for measuring the sharpness of knives, for example, of the type used on slitters, choppers and other similar machines. Such machines are typically used in cutting webs, such as plastic sheet, film supports, cloth material and the like. One of the known methods is to take a plastic mold of the knife edge. When the mold has cured, it is removed from the knife and sliced with a razor. The knife profile is then viewed under a microscope to get a visual indication of the sharpness of the cutting edge of the knife. This requires that a specially trained technician make a subjective determination of the knife sharpness and the point at which the knife should be re-sharpened.
Another method is to use a small piece of lead on the end of a punch-like device. A technician places the lead directly over the cutting edge of the knife and strikes the punch, causing a small indentation in the lead corresponding to the knife profile. This lead model is then cut and the knife profile examined in a manner similar to the plastic mold method. In addition to the reliance on the subjective judgment of a trained technician, other problems with this method are that the results are dependent on the angle that the punch is held over the knife edge and the force with which the punch is struck. Additionally, there is the possibility that the knife edge can be damaged in the process.
Non-contact capacitance measurement techniques, in general, are also known. Examples are found in U.S. Pat. Nos. 3,641,431-Pigage et al and 4,620,281-Thompson et al. The '431 patent involves measurement of radial trueness of the position of cutter blades retained in an indexer of a gear cutting machine. A capacitance probe is mounted in a holder positioned adjacent the blades and measured capacitance of the air gap between the probe and the face or edge of the cutter blade is used to determine radial trueness of the blade position in the indexer. This arrangement does not measure sharpness of the cutting edge of the cutter blades, however. In the '281 patent, the condition of a cutting tool is sensed during the cutting operation by means of a capacitive sensor mounted on the cutting tool. The capacitive sensor is used to measure the distance between the tool sensor and the freshly cut surface of the workpiece being cut. Reduction in the measured distance provides an indication of nose wear of the cutting tool. Such an arrangement does not provide a direct measurement of knife sharpness. In addition, it assumes the ability to measure capacitance between the capacitive probe and a workpiece and, as such, is not suitable for use in directly measuring the sharpness of knives used in slitter and chopper equipment used for cutting webs and the like.
It is therefore an object of the present invention to provide a method and apparatus for measuring knife sharpness directly and in a non-contact manner.
It is a further object of the invention to provide non-contact knife sharpness measurement which is simple in structure and operation and provides repeatable measurement with a high degree of accuracy.
It is another object of the invention to provide non-contact knife sharpness measurement that directly measures the sharpness of the knife without relying on subjective judgment of a technician.
SUMMARY OF THE INVENTION
Thus, in accordance with the invention, apparatus is provided for measuring the sharpness of the cutting edge of a knife, wherein the cutting edge is formed nominally at a line of intersection between two converging cutting side surfaces defining an acute angle therebetween. The measuring apparatus comprises a capacitance sensor probe including an active sensor area having a principal reference plane useful in defining the spatial orientation of the active sensor area. The apparatus further comprises means for holding the active sensor area of the probe repeatably at a predetermined nominal offset from the cutting edge with the principal reference plane of the active sensor area substantially normal to a plane bisecting the acute angle formed between the side cutting surfaces of the knife and with the active sensor area substantially symmetrically positioned laterally with respect to such plane. The apparatus finally includes means for coupling the sensor probe to a capacitance measuring instrument whereby changes in sharpness of the cutting edge can be measured by changes in capacitance between the cutting edge and the sensor active area in successive measurements.
In the method of the invention, the degree of sharpness is measured of an elongated cutting edge of a knife wherein the cutting edge is generally at an intersection between two converging cutting faces of the knife which form an acute angle therebetween. The method of the invention comprises the steps of positioning a capacitance sensor probe having an active sensor area at a predetermined nominal offset from the cutting edge of the knife; orienting a principal reference plane of the active sensor area of the probe perpendicular to a plane bisecting the aforesaid acute angle. Preferably, the active sensor area has an elongate dimension in the principal reference plane and the method would then include the step of orienting the elongated dimension substantially in alignment with the lengthwise dimension of the cutting edge. Finally, the method includes the step of measuring the capacitance between the active sensor area of the probe and the cutting edge to determine wear of the cutting edge from a predetermined sharp condition.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view from the bottom of knife sharpness measuring apparatus of the invention.
FIG. 2 is a side elevation view of the FIG. 1 measuring apparatus.
FIG. 3 is a schematic end view of a capacitive sensor probe useful in the apparatus of FIG. 1.
FIGS. 4a-4c are plan views of laminar components useful in the fabrication of the sensor probe of FIG. 3.
FIG. 5 is a perspective view of a coaxial connector useful in the fabrication of the sensor probe of the apparatus of FIG. 1.
FIG. 6 is schematic representation of a sensor probe and knife edge useful in describing the present invention.
FIG. 7 is a graph of measurement characteristics of the apparatus of FIG. 1.
DESCRIPTION
Referring to FIGS. 1 and 2, knife sharpness measuring apparatus of the invention includes a capacitance sensor probe 10 and a holder 12 for positioning the sensor probe on the knife 13 to be measured. Knife 13 as shown in FIG. 2 includes a cutting edge 13a formed nominally at a line of intersection between converging side cutting surfaces 13b. and 13c which define an acute angle α therebetween. As shown in FIGS. 3 and 4a-4c, in a presently preferred form of the invention, sensor probe 10 is comprised of a plurality of sandwiched metallic laminations 15, 20 and 22 each of which is formed on a corresponding insulative, adhesive substrate 15a, 20c and 22c. These substrates serve as bonding agents when the laminates are sandwiched together to form the completed sensor assembly and as electrical insulation between adjacent laminates. In the fabrication process, the central lamination 15, shown in FIG. 4c, is preferably made of copper and is etched by known techniques to form a capacitance sensor 16 terminating at one end in an active sensor area 16a perpendicular to the sheet of the drawing and at the other end in an electrical contact terminal 16b. A shield area 18 is formed on laminate 15 to provide an active lateral shield along the edges of capacitance sensor 16. In FIG. 4b, laminate 20, of which two are required and preferably also made of copper, is etched as shown to provide outer active shield areas 20a to shield the face areas of capacitance sensor 16. An isolated central area 20b is formed which will eventually be electrically connected to contact terminal 16b. A pair of laminates 22, preferably made of stainless steel, are etched as shown in FIG. 4a to form an outer ground shield for sensor probe 10 which will be electrically in contact with knife 13 via holder 12 and which serves to isolate the sensor 16 and shields 20 from the surrounding environment. After bonding the laminations together as shown in FIG. 3, holes 23 and 24 are drilled to provide electrical connection to central capacitance sensor 16 and to the active shield areas 18 and 20a. For this purpose, a central capacitance sensor connector wire 26 and peripheral active shield connector wires 27 of a threaded coaxial connector 25 (FIG. 5) are inserted into holes 23 and 24, respectively, and soldered in place. Terminals 27 are connected on the reverse side of sensor 16 to a shield cap 28.
The active sensor area 16a at the end of sensor probe 10 is preferably created by precision cutting with a diamond cutter along line 29 (FIG. 4a). When cut, the active sensor area 16a. is then defined by a principal reference plane which corresponds in FIG. 3 to the plane of the drawing sheet. In FIG. 4c, the principal reference plane is perpendicular to the plane of the drawing sheet and coincident with the elongated axis or dimension of area 16a represented by line 29.
Referring again to FIGS. 1 and 2, holder 12 functions as a gauge body to hold the active capacitance sensor area 16a repeatably in proper orientation relative to the cutting edge of the knife 13 for capacitance measurement purposes. More specifically, holder 12 is provided with an internal slot 30 and set screw 31 for receiving and fixedly holding the laminated sensor probe 10 in the holder. Outer knife contact projections 32a, 32b and center knife contact projection 32c straddle the capacitance probe active sensor area 16a and are adapted to contact knife surfaces 13b, 13c simultaneously to position the active sensor area 16b at a predetermined nominal offset distance from the knife cutting edge and to substantially align the elongated axis of sensor area 16a with the lengthwise dimension of the cutting edge of the knife 13. Although any number of contacts may be used, a three point contact is preferred for the inherent stability it provides to the gauge body when positioned on the knife cutting surfaces 13b, 13c. Holder 12 is further provided with an additional pair of contact projections 33a and 33b spaced significantly from the first set of contact projections 32a-32c for contacting knife 13 at a position remote for the cutting surfaces for holding the principal reference plane of the sensor area 16a perpendicular to a plane 35 bisecting the acute angle α formed by the convergence of the cutting surfaces 13b, 13c of the knife. Holder 12 is preferably made from an electrically conductive material, such as stainless steel, so as provide electrical contact between the ground plane represented by the knife and the outer ground shields 22 of sensor 10.
It can be shown that when a capacitive probe, such as the active sensor area 16a of sensor 16, is suitably placed over the cutting edge of knife 13, a capacitance measuring instrument connected to that probe with the knife at ground potential will read a capacitive value that depends on the geometry of the probe, the nominal distance from the probe active area to the knife edge and the geometry of the knife edge in accordance with the relationship:
C=KA/d
where:
C=capacitance
K=a constant
A=active measurement area
d=distance between the sensor and target (ground point).
Thus with the probe geometry fixed and a probe holder such as described above designed to place the sensor active area repeatably over the knife cutting edge in a fixed orientation, the only variable is the knife geometry.
Referring to FIG. 6 the relationship of the active sensor area 16a to the knife cutting edge is shown schematically with sensor area 16a positioned at a nominal offset, x, from the actual line of intersection e of the converging side surfaces 13b and 13c of the knife. The cutting edge 13a of a theoretically perfectly sharpened would coincide with this line. In actuality, a freshly sharpened knife edge would have some finite radius as shown by edge 13a'. It can be seen that as the knife edge wears during repeated cutting operations, the edge radius increases and the the average distance from the sensor active area 16a to the worn knife edges 13a" and 13a'" correspondingly increases with a consequent decrease in capacitance measurement. Thus, a probe repeatably placed over the cutting edge of knife at a fixed nominal distance from the knife edge (nominal offset) will have a capacitance value that will vary with changes in knife radius caused by knife wear. FIG. 7 illustrates the manner in which measured capacitance, in picofarads, varies as a function of knife radius.
In the performance of the method of the invention, sensor 10 is initially placed over a knife edge of a known degree of sharpness and positioned at a predetermined nominal offset from the cutting edge with the principal plane of the sensor active area normal to the plane bisecting the acute angle of the knife edge and with an elongated dimension of the active sensor area aligned with the cutting edge. The capacitance of this arrangement is measured to form a baseline measurement corresponding to a "sharp" knife. Then as the knife is used in slitting or chopping operations, the sensor is periodically re-placed in this same position over the knife edge and capacitance measurement taken. The measurement can then be compared to a pre-calibrated graph of the type shown in FIG. 7, or else the capacitance reading can be digitized and fed to a microcomputer having a lookup table in memory with appropriate values which can then be converted to a visual readout of appropriate type, such as actual knife radius or percent degree of sharpness.
It will be appreciated that the geometry of the active sensor area 16a may be other than the elongated rectangle shown in FIG. 3. For example, an oval, circle or diamond shaped active area may be used. However, at present, the rectangular shape represents the presently preferred mode of practicing the invention due at least in part to the fact that it lends itself to easy fabrication of the sensor using the laminar fabrication process described above. In addition, due to the fact that an ultra narrow rectangle is more readily confined to the actual cutting edge, a more sensitive measurement of an average capacitance along an extended length of the knife cutting edge can be obtained.
The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | Non-contact measurement of the sharpness of the cutting edge of a slitting or chopping knife is made repeatably placing a capacitance sensor probe symmetrically over the cutting edge at a predetermined distance (nominal offset) from the calibrated sharp edge of the knife and measuring the capacitance to derive a measurement that varies with knife wear (increasing knife edge radius). A novel sensor holder allowing for repeatable precision placement of the sensor. | Briefly summarize the invention's components and working principles as described in the document. | [
"FIELD OF INVENTION This invention relates to the field of measuring the sharpness of knife cutting edges, specifically industrial knives, using capacitance sensing as the measurement technique.",
"BACKGROUND Several methods are known for measuring the sharpness of knives, for example, of the type used on slitters, choppers and other similar machines.",
"Such machines are typically used in cutting webs, such as plastic sheet, film supports, cloth material and the like.",
"One of the known methods is to take a plastic mold of the knife edge.",
"When the mold has cured, it is removed from the knife and sliced with a razor.",
"The knife profile is then viewed under a microscope to get a visual indication of the sharpness of the cutting edge of the knife.",
"This requires that a specially trained technician make a subjective determination of the knife sharpness and the point at which the knife should be re-sharpened.",
"Another method is to use a small piece of lead on the end of a punch-like device.",
"A technician places the lead directly over the cutting edge of the knife and strikes the punch, causing a small indentation in the lead corresponding to the knife profile.",
"This lead model is then cut and the knife profile examined in a manner similar to the plastic mold method.",
"In addition to the reliance on the subjective judgment of a trained technician, other problems with this method are that the results are dependent on the angle that the punch is held over the knife edge and the force with which the punch is struck.",
"Additionally, there is the possibility that the knife edge can be damaged in the process.",
"Non-contact capacitance measurement techniques, in general, are also known.",
"Examples are found in U.S. Pat. Nos. 3,641,431-Pigage et al and 4,620,281-Thompson et al.",
"The '431 patent involves measurement of radial trueness of the position of cutter blades retained in an indexer of a gear cutting machine.",
"A capacitance probe is mounted in a holder positioned adjacent the blades and measured capacitance of the air gap between the probe and the face or edge of the cutter blade is used to determine radial trueness of the blade position in the indexer.",
"This arrangement does not measure sharpness of the cutting edge of the cutter blades, however.",
"In the '281 patent, the condition of a cutting tool is sensed during the cutting operation by means of a capacitive sensor mounted on the cutting tool.",
"The capacitive sensor is used to measure the distance between the tool sensor and the freshly cut surface of the workpiece being cut.",
"Reduction in the measured distance provides an indication of nose wear of the cutting tool.",
"Such an arrangement does not provide a direct measurement of knife sharpness.",
"In addition, it assumes the ability to measure capacitance between the capacitive probe and a workpiece and, as such, is not suitable for use in directly measuring the sharpness of knives used in slitter and chopper equipment used for cutting webs and the like.",
"It is therefore an object of the present invention to provide a method and apparatus for measuring knife sharpness directly and in a non-contact manner.",
"It is a further object of the invention to provide non-contact knife sharpness measurement which is simple in structure and operation and provides repeatable measurement with a high degree of accuracy.",
"It is another object of the invention to provide non-contact knife sharpness measurement that directly measures the sharpness of the knife without relying on subjective judgment of a technician.",
"SUMMARY OF THE INVENTION Thus, in accordance with the invention, apparatus is provided for measuring the sharpness of the cutting edge of a knife, wherein the cutting edge is formed nominally at a line of intersection between two converging cutting side surfaces defining an acute angle therebetween.",
"The measuring apparatus comprises a capacitance sensor probe including an active sensor area having a principal reference plane useful in defining the spatial orientation of the active sensor area.",
"The apparatus further comprises means for holding the active sensor area of the probe repeatably at a predetermined nominal offset from the cutting edge with the principal reference plane of the active sensor area substantially normal to a plane bisecting the acute angle formed between the side cutting surfaces of the knife and with the active sensor area substantially symmetrically positioned laterally with respect to such plane.",
"The apparatus finally includes means for coupling the sensor probe to a capacitance measuring instrument whereby changes in sharpness of the cutting edge can be measured by changes in capacitance between the cutting edge and the sensor active area in successive measurements.",
"In the method of the invention, the degree of sharpness is measured of an elongated cutting edge of a knife wherein the cutting edge is generally at an intersection between two converging cutting faces of the knife which form an acute angle therebetween.",
"The method of the invention comprises the steps of positioning a capacitance sensor probe having an active sensor area at a predetermined nominal offset from the cutting edge of the knife;",
"orienting a principal reference plane of the active sensor area of the probe perpendicular to a plane bisecting the aforesaid acute angle.",
"Preferably, the active sensor area has an elongate dimension in the principal reference plane and the method would then include the step of orienting the elongated dimension substantially in alignment with the lengthwise dimension of the cutting edge.",
"Finally, the method includes the step of measuring the capacitance between the active sensor area of the probe and the cutting edge to determine wear of the cutting edge from a predetermined sharp condition.",
"BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 is a perspective view from the bottom of knife sharpness measuring apparatus of the invention.",
"FIG. 2 is a side elevation view of the FIG. 1 measuring apparatus.",
"FIG. 3 is a schematic end view of a capacitive sensor probe useful in the apparatus of FIG. 1. FIGS. 4a-4c are plan views of laminar components useful in the fabrication of the sensor probe of FIG. 3. FIG. 5 is a perspective view of a coaxial connector useful in the fabrication of the sensor probe of the apparatus of FIG. 1. FIG. 6 is schematic representation of a sensor probe and knife edge useful in describing the present invention.",
"FIG. 7 is a graph of measurement characteristics of the apparatus of FIG. 1. DESCRIPTION Referring to FIGS. 1 and 2, knife sharpness measuring apparatus of the invention includes a capacitance sensor probe 10 and a holder 12 for positioning the sensor probe on the knife 13 to be measured.",
"Knife 13 as shown in FIG. 2 includes a cutting edge 13a formed nominally at a line of intersection between converging side cutting surfaces 13b.",
"and 13c which define an acute angle α therebetween.",
"As shown in FIGS. 3 and 4a-4c, in a presently preferred form of the invention, sensor probe 10 is comprised of a plurality of sandwiched metallic laminations 15, 20 and 22 each of which is formed on a corresponding insulative, adhesive substrate 15a, 20c and 22c.",
"These substrates serve as bonding agents when the laminates are sandwiched together to form the completed sensor assembly and as electrical insulation between adjacent laminates.",
"In the fabrication process, the central lamination 15, shown in FIG. 4c, is preferably made of copper and is etched by known techniques to form a capacitance sensor 16 terminating at one end in an active sensor area 16a perpendicular to the sheet of the drawing and at the other end in an electrical contact terminal 16b.",
"A shield area 18 is formed on laminate 15 to provide an active lateral shield along the edges of capacitance sensor 16.",
"In FIG. 4b, laminate 20, of which two are required and preferably also made of copper, is etched as shown to provide outer active shield areas 20a to shield the face areas of capacitance sensor 16.",
"An isolated central area 20b is formed which will eventually be electrically connected to contact terminal 16b.",
"A pair of laminates 22, preferably made of stainless steel, are etched as shown in FIG. 4a to form an outer ground shield for sensor probe 10 which will be electrically in contact with knife 13 via holder 12 and which serves to isolate the sensor 16 and shields 20 from the surrounding environment.",
"After bonding the laminations together as shown in FIG. 3, holes 23 and 24 are drilled to provide electrical connection to central capacitance sensor 16 and to the active shield areas 18 and 20a.",
"For this purpose, a central capacitance sensor connector wire 26 and peripheral active shield connector wires 27 of a threaded coaxial connector 25 (FIG.",
"5) are inserted into holes 23 and 24, respectively, and soldered in place.",
"Terminals 27 are connected on the reverse side of sensor 16 to a shield cap 28.",
"The active sensor area 16a at the end of sensor probe 10 is preferably created by precision cutting with a diamond cutter along line 29 (FIG.",
"4a).",
"When cut, the active sensor area 16a.",
"is then defined by a principal reference plane which corresponds in FIG. 3 to the plane of the drawing sheet.",
"In FIG. 4c, the principal reference plane is perpendicular to the plane of the drawing sheet and coincident with the elongated axis or dimension of area 16a represented by line 29.",
"Referring again to FIGS. 1 and 2, holder 12 functions as a gauge body to hold the active capacitance sensor area 16a repeatably in proper orientation relative to the cutting edge of the knife 13 for capacitance measurement purposes.",
"More specifically, holder 12 is provided with an internal slot 30 and set screw 31 for receiving and fixedly holding the laminated sensor probe 10 in the holder.",
"Outer knife contact projections 32a, 32b and center knife contact projection 32c straddle the capacitance probe active sensor area 16a and are adapted to contact knife surfaces 13b, 13c simultaneously to position the active sensor area 16b at a predetermined nominal offset distance from the knife cutting edge and to substantially align the elongated axis of sensor area 16a with the lengthwise dimension of the cutting edge of the knife 13.",
"Although any number of contacts may be used, a three point contact is preferred for the inherent stability it provides to the gauge body when positioned on the knife cutting surfaces 13b, 13c.",
"Holder 12 is further provided with an additional pair of contact projections 33a and 33b spaced significantly from the first set of contact projections 32a-32c for contacting knife 13 at a position remote for the cutting surfaces for holding the principal reference plane of the sensor area 16a perpendicular to a plane 35 bisecting the acute angle α formed by the convergence of the cutting surfaces 13b, 13c of the knife.",
"Holder 12 is preferably made from an electrically conductive material, such as stainless steel, so as provide electrical contact between the ground plane represented by the knife and the outer ground shields 22 of sensor 10.",
"It can be shown that when a capacitive probe, such as the active sensor area 16a of sensor 16, is suitably placed over the cutting edge of knife 13, a capacitance measuring instrument connected to that probe with the knife at ground potential will read a capacitive value that depends on the geometry of the probe, the nominal distance from the probe active area to the knife edge and the geometry of the knife edge in accordance with the relationship: C=KA/d where: C=capacitance K=a constant A=active measurement area d=distance between the sensor and target (ground point).",
"Thus with the probe geometry fixed and a probe holder such as described above designed to place the sensor active area repeatably over the knife cutting edge in a fixed orientation, the only variable is the knife geometry.",
"Referring to FIG. 6 the relationship of the active sensor area 16a to the knife cutting edge is shown schematically with sensor area 16a positioned at a nominal offset, x, from the actual line of intersection e of the converging side surfaces 13b and 13c of the knife.",
"The cutting edge 13a of a theoretically perfectly sharpened would coincide with this line.",
"In actuality, a freshly sharpened knife edge would have some finite radius as shown by edge 13a'.",
"It can be seen that as the knife edge wears during repeated cutting operations, the edge radius increases and the the average distance from the sensor active area 16a to the worn knife edges 13a"",
"and 13a'"",
"correspondingly increases with a consequent decrease in capacitance measurement.",
"Thus, a probe repeatably placed over the cutting edge of knife at a fixed nominal distance from the knife edge (nominal offset) will have a capacitance value that will vary with changes in knife radius caused by knife wear.",
"FIG. 7 illustrates the manner in which measured capacitance, in picofarads, varies as a function of knife radius.",
"In the performance of the method of the invention, sensor 10 is initially placed over a knife edge of a known degree of sharpness and positioned at a predetermined nominal offset from the cutting edge with the principal plane of the sensor active area normal to the plane bisecting the acute angle of the knife edge and with an elongated dimension of the active sensor area aligned with the cutting edge.",
"The capacitance of this arrangement is measured to form a baseline measurement corresponding to a "sharp"",
"knife.",
"Then as the knife is used in slitting or chopping operations, the sensor is periodically re-placed in this same position over the knife edge and capacitance measurement taken.",
"The measurement can then be compared to a pre-calibrated graph of the type shown in FIG. 7, or else the capacitance reading can be digitized and fed to a microcomputer having a lookup table in memory with appropriate values which can then be converted to a visual readout of appropriate type, such as actual knife radius or percent degree of sharpness.",
"It will be appreciated that the geometry of the active sensor area 16a may be other than the elongated rectangle shown in FIG. 3. For example, an oval, circle or diamond shaped active area may be used.",
"However, at present, the rectangular shape represents the presently preferred mode of practicing the invention due at least in part to the fact that it lends itself to easy fabrication of the sensor using the laminar fabrication process described above.",
"In addition, due to the fact that an ultra narrow rectangle is more readily confined to the actual cutting edge, a more sensitive measurement of an average capacitance along an extended length of the knife cutting edge can be obtained.",
"The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention."
] |
RELATED PATENT APPLICATION
The present patent application is based on U.S. Provisional Patent Application No. 60/484,291, filed on 3 Jul. 2003.
FIELD OF THE INVENTION
The field of this invention is dental hygiene devices. In particular this invention relates to dental hygiene devices in the form of powered toothbrushes. Still further this invention is directed to the field of dental hygiene devices where an antiseptic liquid is introduced into the oral cavity during a tooth brushing procedure.
BACKGROUND OF THE INVENTION
The present invention relates to a dental hygiene device, and more specifically an electrically power operated toothbrush system which may be battery operated which permits brushing of teeth and also irrigation of the periodontal and dental areas with an antiseptic solution or the like. In particular, the invention is directed to a toothbrush system a mechanism which irrigates periodontal structures and teeth with a fluid such as an antiseptic solution which also concurrently illuminates the area in the mouth being worked on thereby allowing a user to have a visual assessment of the effectiveness of the user's personal dental hygiene efforts.
The present invention is further directed to a battery-powered toothbrush system with enhanced brushing effected by motor-driven oscillating and/or rotating bristles having an irrigation mechanism which includes a telescoping fluid chamber sliding along a piston-like lower portion of a toothbrush handle. A complementary base member defining a docking station is provided which includes a detachable fluid reservoir and microswitch-controlled filling mechanism which provides for the integrated and user-friendly multi-functionality of the dental hygiene device disclosed herein.
Additionally, the invention is directed to a dental hygiene system having dental hygiene heads that are interchangeable and connectable to the handle housing. The interchangeable dental hygiene heads provide a variety of bristles, such as soft, hard, abrasive, etc; a number of different fluid outlet nozzles; and a fiberoptic illumination head, thereby allowing a user to combine enhanced brushing, fluid delivery under pressure, and illumination to further a user's optimal personal dental hygiene.
The present invention is particularly directed to a dental hygiene system with interchangeable dental hygiene heads, having bristles and fiberoptic lighting combined with an irrigating sub-assembly that encompasses a telescoping fluid chamber in the toothbrush handle with the lower end of the toothbrush assembly formed as the piston seated in the fluid chamber. The telescoping fluid chamber is adapted to be refilled by the docking of the toothbrush assembly in a complementary docking base member that has an interchangeable fluid reservoir.
The invention is directed as well to the dental hygiene device docking base member that includes a detachable fluid reservoir and microswitch-controlled valve mechanism for the refilling of the telescoping handle chamber at least in large part automatically. The docking base member is adapted to receivingly and matingly dock the aforesaid toothbrush assembly and provide a user with a refilling process that starts and stops with practically no need for user input.
PRIOR ART
There have been numerous attempts in the prior art to develop an electric toothbrush system that delivers a fluid, such as toothpaste gel or an antiseptic solution, to the periodontal areas while the user brushes. None has seen widespread use or commercial success reflecting the more or less inelegant means chosen to design such prior art devices.
The adoption of such a dual function toothbrush system by users requires that such a device be substantially automatic, formed with a comfortable roughly fusiform shape with ergonomically placed control buttons, be fool-proof and safe.
The present invention has overcome the disadvantages of the prior art with the present dental hygiene device disclosed herein having a distinguishing telescoping fluid chamber in the handle balancing the toothbrush head at the opposite end. Handle fiberoptics optically conveys illumination to the oral area of a user which is also advantageous over the prior art.
A frequently neglected aspect of personal dental hygiene is the adequate irrigation of gums, gingival and sub-gingival tissues. It is important to irrigate the oral cavity for an adequate amount of time with an antiseptic solution. Clinical evidence abounds to show that effective anti-tartar and anti-gingivitis prophylaxis improves with the amount of time the periodontal tissues are exposed to the solution which generally requires at least one or two minutes of irrigation. The amount of irrigation needed depends on whether the objective is prophylaxis or inducing regression of on-going periodontal pathology. Areas of the gum-lines and gums needing more application of brushing and antiseptic irrigation can often be identified by visual inspection. There is thus a need in the field of personal dental hygiene devices for an electric toothbrush assembly that both irrigates and illuminates the periodontal area of interest, such as disclosed in the present invention.
Toothbrush systems with combination brushing and irrigation means are known in the prior art. U.S. Pat. Nos. 5,321,866 and 5,301,381 as well as Patent Application Publication No. 2002-0152565 A1, all by the same inventor as the subject invention; disclose toothbrush systems representing earlier embodiments of brushing and irrigation systems for dental hygiene. Differences between the subject invention system and the inventor's previous Patents and Disclosures include a new concept for the fluid pumping system, removing the handle bellows systems and forming a telescoping fluid chamber on the base end of the toothbrush handle among other concepts as will be further described. The illuminating mechanism as described in the present invention is a further advantage over the prior art.
Other toothbrush systems with a handle reservoir include U.S. Pat. No. 6,669,390; and U.S. Pat. No. 6,575,203, however, such prior art devices include disadvantages as previously referred to above.
U.S. Pat. No. 6,164,967 is directed to a fluid delivering dental cleaning device, which is dissimilar to the subject invention concept with regard to the placement and nature of the fluid reservoir as well as the manner in which the reservoir needs to be filled.
Other Patent references that incorporate telescoping fluid dispensing chambers include U.S. Pat. No. 6,302,305 and U.S. Pat. No. 6,719,729. In these references, the telescoping fluid pump differs structurally as well as in its coupling with a base reservoir coupled to the removable toothbrush assembly as well as the integration with dental specific functionalities.
U.S. Pat No. 6,735,803 is directed to an electrical dentifrice-dispensing toothbrush with a replaceable unit and a refillable cartridge. The device has neither the type of refill system nor the telescoping handle chamber nor the illuminating means as disclosed in the present invention.
The present invention thus fills a need for a personal dental hygiene system in which a user may choose the particular dental hygiene head functions, both by choosing which head to attach to the handle housing and by using the control buttons on the dental hygiene toothbrush assembly to activate and deactivate the brushing and irrigating and illuminating functional options. The invention further discloses an innovative solution to the problem of how to store an irrigating fluid in the device handle and to refill the handle fluid chamber with minimal demands on a user.
SUMMARY OF THE INVENTION
A dental hygiene device is provided where there is included a dental hygiene head having displaceable bristles secured to the dental hygiene head and extending therefrom. This system is adapted for brushing a dental surface within an oral cavity. The dental hygiene head includes an irrigation mechanism for irrigating the dental surface with a fluid which may be antiseptic in composition. The irrigation mechanism is fixedly located adjacent to the displaceable bristles. A longitudinally extended handle housing is connected to the dental hygiene head and is adapted to be held by an operator. The handle housing has a control mechanism mounted on it for activation and deactivation of the dental hygiene device.
Additionally, at least one handle pump is provided for displacing the fluid being passed through the dental hygiene device. The handle pump is mounted in the handle housing and is in fluid communication with the irrigation mechanism through a first fluid conduit.
A telescoping handle member housing is further provided which is slidingly engagable with the handle housing and is telescopingly received therein at a piston end of the handle housing opposite the dental hygiene head and further in fluid communication with the handle pump by a second fluid conduit. The dental hygiene head, handle housing and telescoping handle chamber housing are all in combination defined as a handle assembly.
A fluid reservoir which is in detachable fluid communication with a docking base member is provided. The docking base member is in detachable fluid communication with the telescoping handle chamber housing and the docking base member is adapted to receivingly detachably dock with the handle assembly. In this manner, filling of the telescoping handle chamber with the fluid in the fluid reservoir is achieved and is controlled by at least one base microswitch mechanism formed in the docking base member. The base microswitch mechanism may be magnetically and electrically coupled to at least one handle microswitch mechanism mounted in the handle assembly. The base and handle microswitch mechanisms are in respective functional alignment when the handle assembly is docked on the docking base member.
In further summary of the invention, a dental hygiene device is provided which includes a handle assembly and a docking base member. The handle assembly includes a dental hygiene head, a handle housing and a telescoping handle chamber housing. The docking base member with its fluid reservoir incorporated therein constitutes the docking station for the handle assembly. Placing the handle assembly into the docking base member activates microswitches to refill the telescoping fluid chamber with fluid from the reservoir responsive to the pressure sensed by the microswitches in the docking base member as well as the handle housing. The handle housing is coupled between the dental hygiene head and the telescoping handle chamber housing. The handle housing has control switch mechanisms as well as a motor and connecting elements for causing the bristles located in the dental hygiene head to vibrate, oscillate, and possibly rotate.
The handle housing further includes a pumping mechanism and connections for propelling a fluid such as an antiseptic, antibacterial, fluoride, tartar control, whitening agent or other prescription or over-the-counter fluid based medication.
The handle housing contains a component board mounted thereon with at least one motor, a fluid pump and control switch mechanisms which is further adapted to connect to the dental hygiene head.
The dental hygiene head may be permanently connected to or in the alternative replaceably and interchangeably connectable to the handle housing.
The dental hygiene head includes a multiplicity of bristles fixedly contained thereon and projecting therefrom which are connected to a drive-shaft transferring torque to enable rotary and oscillatory displacement of the bristles.
The driveshaft is then rotatingly connected with a handle brush motor mounted in the handle housing and is mounted preferably on a component board. The dental hygiene head further includes at least one fluid outlet nozzle for directing a flow of the appropriate fluid as previously described to the user's dental, oral and periodontal structures, surfaces and recesses.
The handle housing is fitted between the dental hygiene head and the telescoping handle chamber housing. The handle includes control switch mechanisms as well as a motor and connecting elements for allowing the bristles to be displaced.
Further included is a pumping mechanism and couplings for propelling the fluid. The dental hygiene device in overall concept includes a docking base member with a fluid reservoir and constitutes a docking station for the toothbrush device into the docking base member activating microswitch mechanism to refill the telescoping fluid chamber with fluid from the reservoir responsive to pressure sensed by the microswitch mechanisms in the docking base as well as in the handle housing.
The fluid is pumped through a pump mounted within the handle into a first fluid conduit to reach the fluid outlet nozzle to reach a fluid outlet nozzle. In one embodiment, there is a dedicated handle pump motor mounted on a component board in the handle housing.
In a further embodiment of the invention there is a unitary handle motor and there are provided clutch and gearing mechanisms connected to and interposed between the motor and a driveshaft and further between the motor and the handle pump so as to divide the torqueing force generated by the motor between the driveshaft and the handle pump.
The clutch and gearing mechanisms may use a unitary or single handle motor to power both the handle pump and the driveshaft.
The overall system may include a mechanism for modulating the fluid flow, allowing a user to choose the particular kind of fluid stream projected from the fluid outlet nozzle such as a continuous, pulsatile, rhythmic, fluid discharge pressure and associated fluidic parameters.
A fiber optic illumination subassembly may be provided which provides illumination for a user to visually inspect and observe areas of interest in the oral cavity that may require more intense care. The illumination subassembly is provided at the working end of the dental hygiene head and light is emitted at an illumination head which is optically connected to a light source by an interposed bundle of optically transmissive fibers in the handle housing.
The bundled optically transmissive fibers terminate adjacent the bristles and the fluid outlet nozzle.
The first fluid conduit which may be a flexible non-distensible tubing is formed from or incorporates the bundled optically transmissive filaments. Thus, the first fluid conduit may be a flexible non-distensible optically transmissive cylinder containing a moving fluid which is pumped out of the telescoping handle chamber and delivered under pressure from the fluid outlet nozzle. In such a case, the illumination head projects a cross-sectional ring of light around the fluid stream permitting the user to visually monitor the effectiveness of the dental hygiene procedure.
The handle housing may be formed on a bottom end which is the end opposite the dental hygiene head interface and is formed as a piston to be telescopingly received in the handle fluid chamber. Thus the piston end of the handle housing is displaced with respect to the telescoping handle chamber along a central axis of the handle housing dependent upon the amount of fluid within the chamber.
When the chamber is in a full condition (maximum fluid in the chamber), the telescoping handle chamber is displaced downwardly and away from the dental hygiene head. As the fluid chamber is emptied, the telescoping handle chamber moves toward the dental hygiene head.
The handle housing is further equipped with microswitch mechanisms such as magnetic relay switches to permit electromagnetic communication with a docking base member on which the dental hygiene device is then refilled. The handle housing may be provided with batteries for powering the brush motor and the pump motor. If these batteries are of the rechargeable type, the dental hygiene device may be provided with induction coils in the docking base member and the handle assembly which line up when the docking approximates the respective charging coils in the docking base member with corresponding elements in the handle housing.
Fluid is retained with the docking base member reservoir by a valve until the handle assembly is docked. Once docked, the microswitch mechanisms are triggered to open the unidirectional (or check valve) valve mechanisms as well as to activate the pump in the docking member and thus induce filling of the telescoping handle chamber with fluid from the docking base member reservoir.
Once the telescoping handle chamber has been filled to capacity with fluid, the microswitch mechanisms discontinue the pumping, close the valve or valves and thereby automatically terminate the filling process.
All of the connections for fluid communication from the elements are adapted to be fitted with O-rings to provide substantially leak proof fluid transfers. Additionally, the docking base member fluid reservoir may be equipped with a reservoir illumination device which provides a visual mechanism for a user to assess the relative status of the reservoir aside from any aesthetic appeal.
An important objective of the present invention is to provide a dental hygiene device which requires minimal amount of maintenance by the user.
A further objective of the instant invention is to provide a dental hygiene device which requires minimal behavior modification to accomplish both brushing dental surfaces and applying a pulsating cleansing liquid to areas especially as may be identified by the illuminating element.
Another object of the present invention is to provide in a unitary dental hygiene device a system which replaces a plurality of dental hygiene implements such as a toothbrush and an irrigation device as well as to help a user to visually identify dental areas that may need increased care and attention as disclosed by the illumination provided.
Another object of the subject invention is to provide a dental hygiene system wherein the refilling of the handle chamber with fluid from a reservoir can be accomplished automatically, efficiently, and economically.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the dental hygiene device showing the toothbrush docked in a docking base member;
FIG. 2 is a perspective view of the handle assembly showing the dental hygiene head connected to the handle housing and the telescoping handle chamber housing;
FIG. 3A is a perspective exploded view showing the connection of the dental hygiene head with the handle housing;
FIG. 3B is a perspective cutaway view of the dental hygiene head connected to the handle housing and telescoping handle chamber housing;
FIG. 4A is a perspective view of the dental hygiene head in relation to the handle housing;
FIG. 4B is a cutaway perspective view of the telescoping handle chamber empty of fluid;
FIG. 4C is a cutaway perspective view of the telescoping handle chamber with the chamber filled with fluid;
FIG. 5 is an elevation cross-sectional illustration of the dental hygiene head;
FIG. 6 is an exploded view partially cutaway, of the handle housing with an end cap aligned thereto showing both a pump motor and a brush motor;
FIG. 7A is a perspective view of the component board which is mounted in the handle housing;
FIG. 7B is a top cross-sectional view of the handle housing;
FIG. 7C is side cross-sectional view of the handle housing;
FIG. 8 is a cutaway perspective view of the dental hygiene device; and,
FIGS. 9A and 9B are schematic representations of the ball valve mechanism shown when the handle assembly is mounted on the docking base member 50 and when the handle assembly is removed from the docking base member assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1–8 and particularly with respect to FIGS. 1 and 8 , there is shown dental hygiene device 10 which is adapted to be mounted on base surface 100 . In dental hygiene device 10 includes docking base member 50 in combination with fluid reservoir housing 55 as shown. The combination of docking base member 50 and fluid reservoir housing 55 is substantially L-shaped in contour for permitting mounting of dental hygiene head 20 , handle housing 30 and telescoping handle chamber housing 40 in combination within a base portion of docking base member 50 all combined in a compact and volume efficient manner. As is seen, fluid reservoir housing 55 contains fluid 15 which may be an antiseptic, antibacterial, fluoride, tartar control, whitening agent, or other prescription or over-the-counter fluid based medication, not important to the invention concept with the exception that fluid 15 be adapted to be emitted or passed through dental hygiene device 10 adjacent or through bristles 22 into the oral cavity of a user.
Docking base member 50 and fluid reservoir housing 55 may be formed of a plastic material composition or some like composition not important to the invention concept as herein detailed with the exception that fluid reservoir housing 55 and docking base member 50 be fluid tight to permit maintenance of fluid 15 within fluid reservoir housing 55 without external seepage. Fluid 15 is shown in FIG. 1 to be partially loaded or filled within fluid reservoir chamber 102 . It is to be further noted that fluid reservoir housing 55 may be transparent or translucent to permit a user to visually access fluid 15 within fluid reservoir housing 55 .
Docking base member 50 includes base actuation mechanism 80 which may be a simple on/off power switch well known in the art. Docking base member 50 includes docking lower base surface 104 within which power mechanism or base actuation mechanism 80 is mounted. Additionally, dental hygiene device 10 includes dental hygiene head 20 coupled to handle housing 30 and telescoping chamber housing 40 which define handle assembly 12 in combination. As is seen in FIGS. 1 and 8 , handle assembly 12 is mounted within docking base member 50 and is insertable within U-shaped reservoir housing member 106 secured to an outer wall of fluid reservoir housing 55 . In this manner, handle assembly 12 is releasably attached in a confined manner to docking base member 50 and fluid reservoir housing 55 when dental hygiene device 10 is not in use.
As shown in FIGS. 1 and 8 , dental hygiene head 20 , handle housing 30 and telescoping handle chamber housing 40 are docked or mounted in docking base member 40 which contains fluid reservoir chamber 102 . Dental hygiene head 20 as shown includes bristles 22 and further includes fluid outlet nozzle 26 which may be mounted adjacent bristles 22 , interspersed within bristles 22 , or in some other location not important to the inventive concept as herein described with the exception that fluid 15 be passed from the area adjacent or within dental hygiene head 20 into the oral cavity during use. The structure of dental hygiene head 20 , handle assembly 12 and telescoping handle chamber housing 40 may be formed of a lightweight composition such as a plastic composition or some light material not important to the inventive concept as herein described. Fluid outlet nozzle 26 may be formed of plastic or some like material to allow emission of light around a nozzle opening.
Referring now to FIG. 8 , fluid 15 within fluid reservoir chamber 102 is passed from fluid reservoir chamber 102 into base pump 53 , first base conduit 108 , through pressure limit cutoff switch 54 B, through second base conduit 110 and eventually into telescoping handle chamber housing 40 to be described in detail in following paragraphs.
Referring now to FIG. 2 , handle assembly 12 is shown wherein dental hygiene head 20 is coupled to handle housing 30 which in turn is mounted to telescoping handle chamber housing 40 . Fluid 15 which is contained within telescoping handle chamber 112 of telescoping handle chamber housing 40 is passed through siphon hose 45 A for fluid communication with a second fluid conduit 31 shown in FIG. 7A . Fluid conduit 31 extends in an axial direction for fluid connection with piston fluid pump 33 shown in FIG. 7B within handle housing 30 .
As fluid 15 is charged or displaced from telescoping handle chamber housing 40 , handle housing piston end 37 is displaced along guide tracks 38 in a direction indicated by directional arrow 48 shown in FIG. 2 . As seen in FIGS. 2 and 3B handle housing 12 includes control switch 35 A which is a depressible switch which may be simply a power on/off switch for activating displacement, oscillation and/or rotation of bristles 22 . Control switch 35 B is a depressible switch member which can interrupt or allow fluid delivery to outlet nozzle 26 for passage of fluid into the oral cavity.
Referring now to FIG. 3A the dental hygiene head 20 is shown in a detached position with respect to handle housing 30 . It is understood that in operation, dental hygiene head 20 is mounted to handle housing 30 in a manner wherein dental hygiene head 20 matingly engages first fluid conduit 24 within head opening 114 in a manner to provide fluid communication between dental hygiene head 20 and handle housing 30 for passage of fluid therethrough. As provided in FIG. 7A , first fluid conduit 24 provides for a continuous flow of fluid through first fluid conduit 24 into dental hygiene head 20 for emission from fluid outlet nozzle 26 . As seen in FIG. 7A , the fluid path extends from siphon tube 45 B through second fluid conduit 31 into first fluid conduit 24 ′ and then further into first fluid conduit 24 formed within dental hygiene head 20 .
Second fluid conduit 31 is in fluid communication with siphon tube 45 B shown in FIG. 7A and is mounted therein with an O-ring 60 which is used to prevent fluid leakage.
Actuation of bristles 22 is more clearly seen in FIG. 5 wherein driveshaft 29 (actuated by motor 34 shown in FIG. 3B ) rotates about an axial direction and is coupled to bristle head actuation member 116 which includes cam-like recess 118 which is coupled to driveshaft 29 . As driveshaft 29 rotates about the axial direction, bristle head actuation member 116 causes a displacement of bristles 22 in a manner well known in the art. Driveshaft 29 is coupled to motor 34 either directly or through a gear reduction system (not shown). Driveshaft 29 shown in FIG. 5 is adapted to be coupled to driveshaft extension 29 ′ which in itself is coupled to motor 34 . First fluid nozzle 24 includes at an end section O-ring 60 ′ shown in FIG. 5 for prevention of leakage of a fluid passing therethrough.
Referring now to FIG. 7A–C , component board 32 is provided in mounted fashion with siphon tube 45 B, second fluid conduit 31 and first fluid conduit 24 ′ for passage of fluid therethrough. Each of the aforementioned elements are in fluid communication each with respect to the other. Component board 32 includes motor 34 mounted thereon which, may be actuated by batteries 36 being electrically coupled to motor 34 and actuated in an on/off condition. Motor 34 may be a standard motor which is well known in the commercial field for actuation of dental devices. As is seen in FIG. 7B , motor 34 is coupled to piston 124 through motor gear 120 and motor bevel gear 122 wherein piston member 124 is mounted eccentrically on motor bevel gear 20 for providing linear reversible motion to piston 124 for driving fluid through piston pump 33 . In overall context, the combination of motor gear 120 , and motor bevel gear 122 may be defined as cam piston coupling 340 . In this manner, motor 34 upon actuation drives fluid through piston pump 33 for passage of fluid into first fluid conduit extension 24 ′ of dental hygiene head 20 .
Referring now to FIGS. 3A and 3B , telescoping handle chamber housing 30 includes siphon tube 45 B extending in an axial direction from a frontal surface of handle chamber housing 40 to a rear surface 126 which includes valve recess 41 formed within recess rear surface 126 . Valve recess 41 contains therein a standard ball valve for insert of fluid into chamber 112 which is then passed into siphon tube 45 B subsequent to chamber 112 being filled.
In the embodiment shown in FIG. 3A , telescoping chamber housing 40 includes siphon hose 45 A which is coupled on opposing ends to siphon tube 45 B and inlet from second base conduit 110 . In particular, fluid reservoir housing 55 of docking base member 50 is connected to fill the telescoping handle chamber 112 . Guide tracks 37 are provided to constrain and facilitate the longitudinal sliding relationship as well as to avoid twisting of various tubes and elements as handle chamber 40 is either emptied or filled.
As may further be understood, either siphon hose 45 A shown in the embodiment provided in FIGS. 2 and 3B or siphon tube 45 B of the embodiment shown in FIGS. 3A and 4C transports fluid from the telescoping handle chamber housing to the second fluid conduit 31 and then into pump 33 in handle housing 30 .
Referring to FIGS. 4B and 4C such show the full condition and empting condition of telescoping handle chamber 40 with the handle piston end 37 substantially retracted in FIG. 4C where the fluid 15 is substantially filling the telescoping handle chamber housing 40 . FIG. 4B is directed to the condition where there is substantially no fluid within telescoping handle chamber housing 40 and the piston end of the handle housing 37 is located at a distal end of the telescoping handle chamber housing. O-rings 60 ′″ provide for fluid tight seal to maintain the fluid in a condition which is substantially leak proof with respect to telescoping handle chamber housing 40 . FIG. 6 is directed to an embodiment wherein handle housing 30 is formed with a forward casing end cap 27 which is coupled to the front end of the handle housing 30 for permitting access to component board 32 . Component board 32 is mounted internal handle housing 30 with projecting fluid conduit 24 and motor drive 29 that project through apertures in the formed through end cap of 27 for respective alignment of the elements and connection to the driveshaft 29 and first fluid conduit 24 of dental hygiene head 20 . As shown in FIG. 6 , second fluid conduit 31 transports fluid from telescoping handle chamber of 40 to piston fluid pump 33 mounted on component board 32 . Motor 34 A is coupled to clutch and gear mechanisms 35 mounted on component board 32 . The motor and clutch and gear mechanism 35 are then coupled to an actuate piston pump 33 and motor driveshaft 25 .
Referring to FIG. 8 the dental hygiene device 10 with the handle assembly 12 is mounted in the docking base member 50 . Microswitches are provided and includes magnetic relay switch 54 A and pressure limit cut-off switch 54 B formed in-line with the fluid conduit in docking base member 50 . Base pump 53 is in fluid communication with fluid reservoir 50 at its outlet where tank release valve mechanism 58 controls flow of fluid 15 out of the reservoir 55 . Base pump activation mechanism 80 is a global activation switch for turning on/off dental hygiene device 10 .
FIG. 9A and FIG. 9B are schematic diagrams of valve control mechanism 43 for controlling flow of fluid 15 from docking base member 50 to telescoping handle chamber housing 40 of a handle assembly 12 . Valve mechanism 43 may be a standard check ball valve mechanism which includes ball member 128 mounted within valve housing 130 and having an inlet opening 132 for passage of liquid into chamber 112 . Ball 128 is biased by spring member 134 and fluid 15 when assembly 12 is mounted on base 50 , shown in FIG. 9A and blocks opening 132 . When assembly 12 is removed from base 50 , fluid flow into chamber 112 is terminated and fluid within chamber 12 may enter opening 136 for passage threrethrough to siphon tube 45 B or into siphon hose 45 A as shown respectively in FIGS. 3A and 3B . When assembly 12 is mounted on base 50 , ball member 128 is forced upwardly to terminate any flow into assembly 12 but permit flow through conduit 138 and then further through opening 136 into chamber 112 . Member 138 may simply be a conduit which extends from base 50 and is in fluid communication with second base conduit 110 . Mounting of assembly 12 on base 50 permits locational displacement of ball 128 as has previously been described.
Thus, as is seen in FIGS. 9A and 9B , ball valve mechanism 43 is in physical cooperation with nipple-like projection 138 which extends from docking base member 50 and is received within valve recess 41 of telescoping handle chamber 40 which displaces the spring-biased ball to a closed position. The displacement of ball 128 in an upward direction opens the aperture 136 within the wall of element 130 and provides an open passageway for fluid 15 to be transported from fluid reservoir 55 of the docking base member 50 into the telescoping handle chamber 40 . Simultaneously, aperture 134 connecting fluid chamber 40 and siphon tube 45 B is closed by the displacement by the ball valve mechanism 43 preventing incoming fluid 15 from entering handle housing 30 .
Illumination mechanism for illuminating the oral cavity may be provided for dental hygiene device 10 . Light emitting lamp 28 A may be mounted internal dental hygiene head 20 and powered by batteries 36 . Light from emitting device 28 A is transmitted by fiber optic means that comprise a fiber optic bundle 25 A formed of an optically transmissive filament combination in alignment. Such may be formed of glass or plastic filaments. Fiber optic bundle 25 A and light therein thus extends axially through handle housing 30 , through dental hygiene head 20 and terminates adjacent to fluid outlet nozzle 26 and bristles 22 . Thus, fluid outlet nozzle 26 may serve both as a light transmissive section surrounding a fluid outlet nozzle opening formed substantially at the center of the fluid outlet nozzle 26 .
The illumination of fluid reservoir 55 of docking base member 50 may be provided by a light emitting device 57 in the docking base member 50 either in close proximity to fluid reservoir 55 or in optical communication therewith. Preferred light emitting devices 28 A and 57 may include light emitting diodes and/or diodes and/or incandescent and/or halogen light bulbs.
Although this invention has been described in connection with specific forms and embodiments thereof, it would be appreciated if various modifications other than those discussed above may be resorted to without the departing from the spirit or scope of the invention. For example, equivalent elements may be substituted for those specifically shown and described, certain features may be used independently of other features, and in certain cases, particular locations of elements may be reversed or interposed, all without departing from the spirit or scope of the invention as defined in the appended claims. | A dental hygiene system provided with interchangeable dental heads permits power-enhanced brushing and concurrent fluid irrigation to optimize a user's personal dental hygiene efforts. The system has a handle assembly with an irrigation nozzle in close proximity to displaceable bristles driven by a battery-operated handle motor. Pumping of irrigation fluid such as an antiseptic solution into the oral cavity is also motor driven. A telescoping chamber with irrigation fluid fits on the piston-like base end of the handle and is refilled by docking the handle assembly on a complementary docking station that includes a detachable fluid reservoir, microswitch controls and a base fluid pump. Docking of the handle assembly triggers the microswitches and opens a check valve in the bottom of the handle chamber, which activates the flow of fluid from the reservoir into the chamber. An optional fiberoptic subassembly illuminates the oral cavity. | Briefly summarize the main idea's components and working principles as described in the context. | [
"RELATED PATENT APPLICATION The present patent application is based on U.S. Provisional Patent Application No. 60/484,291, filed on 3 Jul. 2003.",
"FIELD OF THE INVENTION The field of this invention is dental hygiene devices.",
"In particular this invention relates to dental hygiene devices in the form of powered toothbrushes.",
"Still further this invention is directed to the field of dental hygiene devices where an antiseptic liquid is introduced into the oral cavity during a tooth brushing procedure.",
"BACKGROUND OF THE INVENTION The present invention relates to a dental hygiene device, and more specifically an electrically power operated toothbrush system which may be battery operated which permits brushing of teeth and also irrigation of the periodontal and dental areas with an antiseptic solution or the like.",
"In particular, the invention is directed to a toothbrush system a mechanism which irrigates periodontal structures and teeth with a fluid such as an antiseptic solution which also concurrently illuminates the area in the mouth being worked on thereby allowing a user to have a visual assessment of the effectiveness of the user's personal dental hygiene efforts.",
"The present invention is further directed to a battery-powered toothbrush system with enhanced brushing effected by motor-driven oscillating and/or rotating bristles having an irrigation mechanism which includes a telescoping fluid chamber sliding along a piston-like lower portion of a toothbrush handle.",
"A complementary base member defining a docking station is provided which includes a detachable fluid reservoir and microswitch-controlled filling mechanism which provides for the integrated and user-friendly multi-functionality of the dental hygiene device disclosed herein.",
"Additionally, the invention is directed to a dental hygiene system having dental hygiene heads that are interchangeable and connectable to the handle housing.",
"The interchangeable dental hygiene heads provide a variety of bristles, such as soft, hard, abrasive, etc;",
"a number of different fluid outlet nozzles;",
"and a fiberoptic illumination head, thereby allowing a user to combine enhanced brushing, fluid delivery under pressure, and illumination to further a user's optimal personal dental hygiene.",
"The present invention is particularly directed to a dental hygiene system with interchangeable dental hygiene heads, having bristles and fiberoptic lighting combined with an irrigating sub-assembly that encompasses a telescoping fluid chamber in the toothbrush handle with the lower end of the toothbrush assembly formed as the piston seated in the fluid chamber.",
"The telescoping fluid chamber is adapted to be refilled by the docking of the toothbrush assembly in a complementary docking base member that has an interchangeable fluid reservoir.",
"The invention is directed as well to the dental hygiene device docking base member that includes a detachable fluid reservoir and microswitch-controlled valve mechanism for the refilling of the telescoping handle chamber at least in large part automatically.",
"The docking base member is adapted to receivingly and matingly dock the aforesaid toothbrush assembly and provide a user with a refilling process that starts and stops with practically no need for user input.",
"PRIOR ART There have been numerous attempts in the prior art to develop an electric toothbrush system that delivers a fluid, such as toothpaste gel or an antiseptic solution, to the periodontal areas while the user brushes.",
"None has seen widespread use or commercial success reflecting the more or less inelegant means chosen to design such prior art devices.",
"The adoption of such a dual function toothbrush system by users requires that such a device be substantially automatic, formed with a comfortable roughly fusiform shape with ergonomically placed control buttons, be fool-proof and safe.",
"The present invention has overcome the disadvantages of the prior art with the present dental hygiene device disclosed herein having a distinguishing telescoping fluid chamber in the handle balancing the toothbrush head at the opposite end.",
"Handle fiberoptics optically conveys illumination to the oral area of a user which is also advantageous over the prior art.",
"A frequently neglected aspect of personal dental hygiene is the adequate irrigation of gums, gingival and sub-gingival tissues.",
"It is important to irrigate the oral cavity for an adequate amount of time with an antiseptic solution.",
"Clinical evidence abounds to show that effective anti-tartar and anti-gingivitis prophylaxis improves with the amount of time the periodontal tissues are exposed to the solution which generally requires at least one or two minutes of irrigation.",
"The amount of irrigation needed depends on whether the objective is prophylaxis or inducing regression of on-going periodontal pathology.",
"Areas of the gum-lines and gums needing more application of brushing and antiseptic irrigation can often be identified by visual inspection.",
"There is thus a need in the field of personal dental hygiene devices for an electric toothbrush assembly that both irrigates and illuminates the periodontal area of interest, such as disclosed in the present invention.",
"Toothbrush systems with combination brushing and irrigation means are known in the prior art.",
"U.S. Pat. Nos. 5,321,866 and 5,301,381 as well as Patent Application Publication No. 2002-0152565 A1, all by the same inventor as the subject invention;",
"disclose toothbrush systems representing earlier embodiments of brushing and irrigation systems for dental hygiene.",
"Differences between the subject invention system and the inventor's previous Patents and Disclosures include a new concept for the fluid pumping system, removing the handle bellows systems and forming a telescoping fluid chamber on the base end of the toothbrush handle among other concepts as will be further described.",
"The illuminating mechanism as described in the present invention is a further advantage over the prior art.",
"Other toothbrush systems with a handle reservoir include U.S. Pat. No. 6,669,390;",
"and U.S. Pat. No. 6,575,203, however, such prior art devices include disadvantages as previously referred to above.",
"U.S. Pat. No. 6,164,967 is directed to a fluid delivering dental cleaning device, which is dissimilar to the subject invention concept with regard to the placement and nature of the fluid reservoir as well as the manner in which the reservoir needs to be filled.",
"Other Patent references that incorporate telescoping fluid dispensing chambers include U.S. Pat. No. 6,302,305 and U.S. Pat. No. 6,719,729.",
"In these references, the telescoping fluid pump differs structurally as well as in its coupling with a base reservoir coupled to the removable toothbrush assembly as well as the integration with dental specific functionalities.",
"U.S. Pat No. 6,735,803 is directed to an electrical dentifrice-dispensing toothbrush with a replaceable unit and a refillable cartridge.",
"The device has neither the type of refill system nor the telescoping handle chamber nor the illuminating means as disclosed in the present invention.",
"The present invention thus fills a need for a personal dental hygiene system in which a user may choose the particular dental hygiene head functions, both by choosing which head to attach to the handle housing and by using the control buttons on the dental hygiene toothbrush assembly to activate and deactivate the brushing and irrigating and illuminating functional options.",
"The invention further discloses an innovative solution to the problem of how to store an irrigating fluid in the device handle and to refill the handle fluid chamber with minimal demands on a user.",
"SUMMARY OF THE INVENTION A dental hygiene device is provided where there is included a dental hygiene head having displaceable bristles secured to the dental hygiene head and extending therefrom.",
"This system is adapted for brushing a dental surface within an oral cavity.",
"The dental hygiene head includes an irrigation mechanism for irrigating the dental surface with a fluid which may be antiseptic in composition.",
"The irrigation mechanism is fixedly located adjacent to the displaceable bristles.",
"A longitudinally extended handle housing is connected to the dental hygiene head and is adapted to be held by an operator.",
"The handle housing has a control mechanism mounted on it for activation and deactivation of the dental hygiene device.",
"Additionally, at least one handle pump is provided for displacing the fluid being passed through the dental hygiene device.",
"The handle pump is mounted in the handle housing and is in fluid communication with the irrigation mechanism through a first fluid conduit.",
"A telescoping handle member housing is further provided which is slidingly engagable with the handle housing and is telescopingly received therein at a piston end of the handle housing opposite the dental hygiene head and further in fluid communication with the handle pump by a second fluid conduit.",
"The dental hygiene head, handle housing and telescoping handle chamber housing are all in combination defined as a handle assembly.",
"A fluid reservoir which is in detachable fluid communication with a docking base member is provided.",
"The docking base member is in detachable fluid communication with the telescoping handle chamber housing and the docking base member is adapted to receivingly detachably dock with the handle assembly.",
"In this manner, filling of the telescoping handle chamber with the fluid in the fluid reservoir is achieved and is controlled by at least one base microswitch mechanism formed in the docking base member.",
"The base microswitch mechanism may be magnetically and electrically coupled to at least one handle microswitch mechanism mounted in the handle assembly.",
"The base and handle microswitch mechanisms are in respective functional alignment when the handle assembly is docked on the docking base member.",
"In further summary of the invention, a dental hygiene device is provided which includes a handle assembly and a docking base member.",
"The handle assembly includes a dental hygiene head, a handle housing and a telescoping handle chamber housing.",
"The docking base member with its fluid reservoir incorporated therein constitutes the docking station for the handle assembly.",
"Placing the handle assembly into the docking base member activates microswitches to refill the telescoping fluid chamber with fluid from the reservoir responsive to the pressure sensed by the microswitches in the docking base member as well as the handle housing.",
"The handle housing is coupled between the dental hygiene head and the telescoping handle chamber housing.",
"The handle housing has control switch mechanisms as well as a motor and connecting elements for causing the bristles located in the dental hygiene head to vibrate, oscillate, and possibly rotate.",
"The handle housing further includes a pumping mechanism and connections for propelling a fluid such as an antiseptic, antibacterial, fluoride, tartar control, whitening agent or other prescription or over-the-counter fluid based medication.",
"The handle housing contains a component board mounted thereon with at least one motor, a fluid pump and control switch mechanisms which is further adapted to connect to the dental hygiene head.",
"The dental hygiene head may be permanently connected to or in the alternative replaceably and interchangeably connectable to the handle housing.",
"The dental hygiene head includes a multiplicity of bristles fixedly contained thereon and projecting therefrom which are connected to a drive-shaft transferring torque to enable rotary and oscillatory displacement of the bristles.",
"The driveshaft is then rotatingly connected with a handle brush motor mounted in the handle housing and is mounted preferably on a component board.",
"The dental hygiene head further includes at least one fluid outlet nozzle for directing a flow of the appropriate fluid as previously described to the user's dental, oral and periodontal structures, surfaces and recesses.",
"The handle housing is fitted between the dental hygiene head and the telescoping handle chamber housing.",
"The handle includes control switch mechanisms as well as a motor and connecting elements for allowing the bristles to be displaced.",
"Further included is a pumping mechanism and couplings for propelling the fluid.",
"The dental hygiene device in overall concept includes a docking base member with a fluid reservoir and constitutes a docking station for the toothbrush device into the docking base member activating microswitch mechanism to refill the telescoping fluid chamber with fluid from the reservoir responsive to pressure sensed by the microswitch mechanisms in the docking base as well as in the handle housing.",
"The fluid is pumped through a pump mounted within the handle into a first fluid conduit to reach the fluid outlet nozzle to reach a fluid outlet nozzle.",
"In one embodiment, there is a dedicated handle pump motor mounted on a component board in the handle housing.",
"In a further embodiment of the invention there is a unitary handle motor and there are provided clutch and gearing mechanisms connected to and interposed between the motor and a driveshaft and further between the motor and the handle pump so as to divide the torqueing force generated by the motor between the driveshaft and the handle pump.",
"The clutch and gearing mechanisms may use a unitary or single handle motor to power both the handle pump and the driveshaft.",
"The overall system may include a mechanism for modulating the fluid flow, allowing a user to choose the particular kind of fluid stream projected from the fluid outlet nozzle such as a continuous, pulsatile, rhythmic, fluid discharge pressure and associated fluidic parameters.",
"A fiber optic illumination subassembly may be provided which provides illumination for a user to visually inspect and observe areas of interest in the oral cavity that may require more intense care.",
"The illumination subassembly is provided at the working end of the dental hygiene head and light is emitted at an illumination head which is optically connected to a light source by an interposed bundle of optically transmissive fibers in the handle housing.",
"The bundled optically transmissive fibers terminate adjacent the bristles and the fluid outlet nozzle.",
"The first fluid conduit which may be a flexible non-distensible tubing is formed from or incorporates the bundled optically transmissive filaments.",
"Thus, the first fluid conduit may be a flexible non-distensible optically transmissive cylinder containing a moving fluid which is pumped out of the telescoping handle chamber and delivered under pressure from the fluid outlet nozzle.",
"In such a case, the illumination head projects a cross-sectional ring of light around the fluid stream permitting the user to visually monitor the effectiveness of the dental hygiene procedure.",
"The handle housing may be formed on a bottom end which is the end opposite the dental hygiene head interface and is formed as a piston to be telescopingly received in the handle fluid chamber.",
"Thus the piston end of the handle housing is displaced with respect to the telescoping handle chamber along a central axis of the handle housing dependent upon the amount of fluid within the chamber.",
"When the chamber is in a full condition (maximum fluid in the chamber), the telescoping handle chamber is displaced downwardly and away from the dental hygiene head.",
"As the fluid chamber is emptied, the telescoping handle chamber moves toward the dental hygiene head.",
"The handle housing is further equipped with microswitch mechanisms such as magnetic relay switches to permit electromagnetic communication with a docking base member on which the dental hygiene device is then refilled.",
"The handle housing may be provided with batteries for powering the brush motor and the pump motor.",
"If these batteries are of the rechargeable type, the dental hygiene device may be provided with induction coils in the docking base member and the handle assembly which line up when the docking approximates the respective charging coils in the docking base member with corresponding elements in the handle housing.",
"Fluid is retained with the docking base member reservoir by a valve until the handle assembly is docked.",
"Once docked, the microswitch mechanisms are triggered to open the unidirectional (or check valve) valve mechanisms as well as to activate the pump in the docking member and thus induce filling of the telescoping handle chamber with fluid from the docking base member reservoir.",
"Once the telescoping handle chamber has been filled to capacity with fluid, the microswitch mechanisms discontinue the pumping, close the valve or valves and thereby automatically terminate the filling process.",
"All of the connections for fluid communication from the elements are adapted to be fitted with O-rings to provide substantially leak proof fluid transfers.",
"Additionally, the docking base member fluid reservoir may be equipped with a reservoir illumination device which provides a visual mechanism for a user to assess the relative status of the reservoir aside from any aesthetic appeal.",
"An important objective of the present invention is to provide a dental hygiene device which requires minimal amount of maintenance by the user.",
"A further objective of the instant invention is to provide a dental hygiene device which requires minimal behavior modification to accomplish both brushing dental surfaces and applying a pulsating cleansing liquid to areas especially as may be identified by the illuminating element.",
"Another object of the present invention is to provide in a unitary dental hygiene device a system which replaces a plurality of dental hygiene implements such as a toothbrush and an irrigation device as well as to help a user to visually identify dental areas that may need increased care and attention as disclosed by the illumination provided.",
"Another object of the subject invention is to provide a dental hygiene system wherein the refilling of the handle chamber with fluid from a reservoir can be accomplished automatically, efficiently, and economically.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the dental hygiene device showing the toothbrush docked in a docking base member;",
"FIG. 2 is a perspective view of the handle assembly showing the dental hygiene head connected to the handle housing and the telescoping handle chamber housing;",
"FIG. 3A is a perspective exploded view showing the connection of the dental hygiene head with the handle housing;",
"FIG. 3B is a perspective cutaway view of the dental hygiene head connected to the handle housing and telescoping handle chamber housing;",
"FIG. 4A is a perspective view of the dental hygiene head in relation to the handle housing;",
"FIG. 4B is a cutaway perspective view of the telescoping handle chamber empty of fluid;",
"FIG. 4C is a cutaway perspective view of the telescoping handle chamber with the chamber filled with fluid;",
"FIG. 5 is an elevation cross-sectional illustration of the dental hygiene head;",
"FIG. 6 is an exploded view partially cutaway, of the handle housing with an end cap aligned thereto showing both a pump motor and a brush motor;",
"FIG. 7A is a perspective view of the component board which is mounted in the handle housing;",
"FIG. 7B is a top cross-sectional view of the handle housing;",
"FIG. 7C is side cross-sectional view of the handle housing;",
"FIG. 8 is a cutaway perspective view of the dental hygiene device;",
"and, FIGS. 9A and 9B are schematic representations of the ball valve mechanism shown when the handle assembly is mounted on the docking base member 50 and when the handle assembly is removed from the docking base member assembly.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIGS. 1–8 and particularly with respect to FIGS. 1 and 8 , there is shown dental hygiene device 10 which is adapted to be mounted on base surface 100 .",
"In dental hygiene device 10 includes docking base member 50 in combination with fluid reservoir housing 55 as shown.",
"The combination of docking base member 50 and fluid reservoir housing 55 is substantially L-shaped in contour for permitting mounting of dental hygiene head 20 , handle housing 30 and telescoping handle chamber housing 40 in combination within a base portion of docking base member 50 all combined in a compact and volume efficient manner.",
"As is seen, fluid reservoir housing 55 contains fluid 15 which may be an antiseptic, antibacterial, fluoride, tartar control, whitening agent, or other prescription or over-the-counter fluid based medication, not important to the invention concept with the exception that fluid 15 be adapted to be emitted or passed through dental hygiene device 10 adjacent or through bristles 22 into the oral cavity of a user.",
"Docking base member 50 and fluid reservoir housing 55 may be formed of a plastic material composition or some like composition not important to the invention concept as herein detailed with the exception that fluid reservoir housing 55 and docking base member 50 be fluid tight to permit maintenance of fluid 15 within fluid reservoir housing 55 without external seepage.",
"Fluid 15 is shown in FIG. 1 to be partially loaded or filled within fluid reservoir chamber 102 .",
"It is to be further noted that fluid reservoir housing 55 may be transparent or translucent to permit a user to visually access fluid 15 within fluid reservoir housing 55 .",
"Docking base member 50 includes base actuation mechanism 80 which may be a simple on/off power switch well known in the art.",
"Docking base member 50 includes docking lower base surface 104 within which power mechanism or base actuation mechanism 80 is mounted.",
"Additionally, dental hygiene device 10 includes dental hygiene head 20 coupled to handle housing 30 and telescoping chamber housing 40 which define handle assembly 12 in combination.",
"As is seen in FIGS. 1 and 8 , handle assembly 12 is mounted within docking base member 50 and is insertable within U-shaped reservoir housing member 106 secured to an outer wall of fluid reservoir housing 55 .",
"In this manner, handle assembly 12 is releasably attached in a confined manner to docking base member 50 and fluid reservoir housing 55 when dental hygiene device 10 is not in use.",
"As shown in FIGS. 1 and 8 , dental hygiene head 20 , handle housing 30 and telescoping handle chamber housing 40 are docked or mounted in docking base member 40 which contains fluid reservoir chamber 102 .",
"Dental hygiene head 20 as shown includes bristles 22 and further includes fluid outlet nozzle 26 which may be mounted adjacent bristles 22 , interspersed within bristles 22 , or in some other location not important to the inventive concept as herein described with the exception that fluid 15 be passed from the area adjacent or within dental hygiene head 20 into the oral cavity during use.",
"The structure of dental hygiene head 20 , handle assembly 12 and telescoping handle chamber housing 40 may be formed of a lightweight composition such as a plastic composition or some light material not important to the inventive concept as herein described.",
"Fluid outlet nozzle 26 may be formed of plastic or some like material to allow emission of light around a nozzle opening.",
"Referring now to FIG. 8 , fluid 15 within fluid reservoir chamber 102 is passed from fluid reservoir chamber 102 into base pump 53 , first base conduit 108 , through pressure limit cutoff switch 54 B, through second base conduit 110 and eventually into telescoping handle chamber housing 40 to be described in detail in following paragraphs.",
"Referring now to FIG. 2 , handle assembly 12 is shown wherein dental hygiene head 20 is coupled to handle housing 30 which in turn is mounted to telescoping handle chamber housing 40 .",
"Fluid 15 which is contained within telescoping handle chamber 112 of telescoping handle chamber housing 40 is passed through siphon hose 45 A for fluid communication with a second fluid conduit 31 shown in FIG. 7A .",
"Fluid conduit 31 extends in an axial direction for fluid connection with piston fluid pump 33 shown in FIG. 7B within handle housing 30 .",
"As fluid 15 is charged or displaced from telescoping handle chamber housing 40 , handle housing piston end 37 is displaced along guide tracks 38 in a direction indicated by directional arrow 48 shown in FIG. 2 .",
"As seen in FIGS. 2 and 3B handle housing 12 includes control switch 35 A which is a depressible switch which may be simply a power on/off switch for activating displacement, oscillation and/or rotation of bristles 22 .",
"Control switch 35 B is a depressible switch member which can interrupt or allow fluid delivery to outlet nozzle 26 for passage of fluid into the oral cavity.",
"Referring now to FIG. 3A the dental hygiene head 20 is shown in a detached position with respect to handle housing 30 .",
"It is understood that in operation, dental hygiene head 20 is mounted to handle housing 30 in a manner wherein dental hygiene head 20 matingly engages first fluid conduit 24 within head opening 114 in a manner to provide fluid communication between dental hygiene head 20 and handle housing 30 for passage of fluid therethrough.",
"As provided in FIG. 7A , first fluid conduit 24 provides for a continuous flow of fluid through first fluid conduit 24 into dental hygiene head 20 for emission from fluid outlet nozzle 26 .",
"As seen in FIG. 7A , the fluid path extends from siphon tube 45 B through second fluid conduit 31 into first fluid conduit 24 ′ and then further into first fluid conduit 24 formed within dental hygiene head 20 .",
"Second fluid conduit 31 is in fluid communication with siphon tube 45 B shown in FIG. 7A and is mounted therein with an O-ring 60 which is used to prevent fluid leakage.",
"Actuation of bristles 22 is more clearly seen in FIG. 5 wherein driveshaft 29 (actuated by motor 34 shown in FIG. 3B ) rotates about an axial direction and is coupled to bristle head actuation member 116 which includes cam-like recess 118 which is coupled to driveshaft 29 .",
"As driveshaft 29 rotates about the axial direction, bristle head actuation member 116 causes a displacement of bristles 22 in a manner well known in the art.",
"Driveshaft 29 is coupled to motor 34 either directly or through a gear reduction system (not shown).",
"Driveshaft 29 shown in FIG. 5 is adapted to be coupled to driveshaft extension 29 ′ which in itself is coupled to motor 34 .",
"First fluid nozzle 24 includes at an end section O-ring 60 ′ shown in FIG. 5 for prevention of leakage of a fluid passing therethrough.",
"Referring now to FIG. 7A–C , component board 32 is provided in mounted fashion with siphon tube 45 B, second fluid conduit 31 and first fluid conduit 24 ′ for passage of fluid therethrough.",
"Each of the aforementioned elements are in fluid communication each with respect to the other.",
"Component board 32 includes motor 34 mounted thereon which, may be actuated by batteries 36 being electrically coupled to motor 34 and actuated in an on/off condition.",
"Motor 34 may be a standard motor which is well known in the commercial field for actuation of dental devices.",
"As is seen in FIG. 7B , motor 34 is coupled to piston 124 through motor gear 120 and motor bevel gear 122 wherein piston member 124 is mounted eccentrically on motor bevel gear 20 for providing linear reversible motion to piston 124 for driving fluid through piston pump 33 .",
"In overall context, the combination of motor gear 120 , and motor bevel gear 122 may be defined as cam piston coupling 340 .",
"In this manner, motor 34 upon actuation drives fluid through piston pump 33 for passage of fluid into first fluid conduit extension 24 ′ of dental hygiene head 20 .",
"Referring now to FIGS. 3A and 3B , telescoping handle chamber housing 30 includes siphon tube 45 B extending in an axial direction from a frontal surface of handle chamber housing 40 to a rear surface 126 which includes valve recess 41 formed within recess rear surface 126 .",
"Valve recess 41 contains therein a standard ball valve for insert of fluid into chamber 112 which is then passed into siphon tube 45 B subsequent to chamber 112 being filled.",
"In the embodiment shown in FIG. 3A , telescoping chamber housing 40 includes siphon hose 45 A which is coupled on opposing ends to siphon tube 45 B and inlet from second base conduit 110 .",
"In particular, fluid reservoir housing 55 of docking base member 50 is connected to fill the telescoping handle chamber 112 .",
"Guide tracks 37 are provided to constrain and facilitate the longitudinal sliding relationship as well as to avoid twisting of various tubes and elements as handle chamber 40 is either emptied or filled.",
"As may further be understood, either siphon hose 45 A shown in the embodiment provided in FIGS. 2 and 3B or siphon tube 45 B of the embodiment shown in FIGS. 3A and 4C transports fluid from the telescoping handle chamber housing to the second fluid conduit 31 and then into pump 33 in handle housing 30 .",
"Referring to FIGS. 4B and 4C such show the full condition and empting condition of telescoping handle chamber 40 with the handle piston end 37 substantially retracted in FIG. 4C where the fluid 15 is substantially filling the telescoping handle chamber housing 40 .",
"FIG. 4B is directed to the condition where there is substantially no fluid within telescoping handle chamber housing 40 and the piston end of the handle housing 37 is located at a distal end of the telescoping handle chamber housing.",
"O-rings 60 ′″ provide for fluid tight seal to maintain the fluid in a condition which is substantially leak proof with respect to telescoping handle chamber housing 40 .",
"FIG. 6 is directed to an embodiment wherein handle housing 30 is formed with a forward casing end cap 27 which is coupled to the front end of the handle housing 30 for permitting access to component board 32 .",
"Component board 32 is mounted internal handle housing 30 with projecting fluid conduit 24 and motor drive 29 that project through apertures in the formed through end cap of 27 for respective alignment of the elements and connection to the driveshaft 29 and first fluid conduit 24 of dental hygiene head 20 .",
"As shown in FIG. 6 , second fluid conduit 31 transports fluid from telescoping handle chamber of 40 to piston fluid pump 33 mounted on component board 32 .",
"Motor 34 A is coupled to clutch and gear mechanisms 35 mounted on component board 32 .",
"The motor and clutch and gear mechanism 35 are then coupled to an actuate piston pump 33 and motor driveshaft 25 .",
"Referring to FIG. 8 the dental hygiene device 10 with the handle assembly 12 is mounted in the docking base member 50 .",
"Microswitches are provided and includes magnetic relay switch 54 A and pressure limit cut-off switch 54 B formed in-line with the fluid conduit in docking base member 50 .",
"Base pump 53 is in fluid communication with fluid reservoir 50 at its outlet where tank release valve mechanism 58 controls flow of fluid 15 out of the reservoir 55 .",
"Base pump activation mechanism 80 is a global activation switch for turning on/off dental hygiene device 10 .",
"FIG. 9A and FIG. 9B are schematic diagrams of valve control mechanism 43 for controlling flow of fluid 15 from docking base member 50 to telescoping handle chamber housing 40 of a handle assembly 12 .",
"Valve mechanism 43 may be a standard check ball valve mechanism which includes ball member 128 mounted within valve housing 130 and having an inlet opening 132 for passage of liquid into chamber 112 .",
"Ball 128 is biased by spring member 134 and fluid 15 when assembly 12 is mounted on base 50 , shown in FIG. 9A and blocks opening 132 .",
"When assembly 12 is removed from base 50 , fluid flow into chamber 112 is terminated and fluid within chamber 12 may enter opening 136 for passage threrethrough to siphon tube 45 B or into siphon hose 45 A as shown respectively in FIGS. 3A and 3B .",
"When assembly 12 is mounted on base 50 , ball member 128 is forced upwardly to terminate any flow into assembly 12 but permit flow through conduit 138 and then further through opening 136 into chamber 112 .",
"Member 138 may simply be a conduit which extends from base 50 and is in fluid communication with second base conduit 110 .",
"Mounting of assembly 12 on base 50 permits locational displacement of ball 128 as has previously been described.",
"Thus, as is seen in FIGS. 9A and 9B , ball valve mechanism 43 is in physical cooperation with nipple-like projection 138 which extends from docking base member 50 and is received within valve recess 41 of telescoping handle chamber 40 which displaces the spring-biased ball to a closed position.",
"The displacement of ball 128 in an upward direction opens the aperture 136 within the wall of element 130 and provides an open passageway for fluid 15 to be transported from fluid reservoir 55 of the docking base member 50 into the telescoping handle chamber 40 .",
"Simultaneously, aperture 134 connecting fluid chamber 40 and siphon tube 45 B is closed by the displacement by the ball valve mechanism 43 preventing incoming fluid 15 from entering handle housing 30 .",
"Illumination mechanism for illuminating the oral cavity may be provided for dental hygiene device 10 .",
"Light emitting lamp 28 A may be mounted internal dental hygiene head 20 and powered by batteries 36 .",
"Light from emitting device 28 A is transmitted by fiber optic means that comprise a fiber optic bundle 25 A formed of an optically transmissive filament combination in alignment.",
"Such may be formed of glass or plastic filaments.",
"Fiber optic bundle 25 A and light therein thus extends axially through handle housing 30 , through dental hygiene head 20 and terminates adjacent to fluid outlet nozzle 26 and bristles 22 .",
"Thus, fluid outlet nozzle 26 may serve both as a light transmissive section surrounding a fluid outlet nozzle opening formed substantially at the center of the fluid outlet nozzle 26 .",
"The illumination of fluid reservoir 55 of docking base member 50 may be provided by a light emitting device 57 in the docking base member 50 either in close proximity to fluid reservoir 55 or in optical communication therewith.",
"Preferred light emitting devices 28 A and 57 may include light emitting diodes and/or diodes and/or incandescent and/or halogen light bulbs.",
"Although this invention has been described in connection with specific forms and embodiments thereof, it would be appreciated if various modifications other than those discussed above may be resorted to without the departing from the spirit or scope of the invention.",
"For example, equivalent elements may be substituted for those specifically shown and described, certain features may be used independently of other features, and in certain cases, particular locations of elements may be reversed or interposed, all without departing from the spirit or scope of the invention as defined in the appended claims."
] |
REFERENCE TO RELATED APPLICATIONS
This patent application is a continuation patent application from U.S. patent application Ser. No. 08/493,728, filed on Jun. 22, 1995, to issue as U.S. Pat. No. 5,835,897 on Nov. 10, 1998.
FIELD OF THE INVENTION
The present invention relates generally to computer-implemented methods for processing medical claims information. More particularly, the present invention relates to a computer-implemented method for receiving input data relating to a person s medical claim, establishing a management record for the person, establishing episode treatment groups to define groupings of medical episodes of related etiology, correlating subsequent medical claims events to an episode treatment group and manipulating episode treatment groups based upon time windows for each medical condition and co-morbidities.
BACKGROUND OF THE INVENTION
Due to an increase in health care costs and inefficiency in the health care system, health care providers and service management organizations need health care maintenance systems which receive input medical claim data, correlate the medical claim data and provide a means for quantitatively and qualitatively analyzing provider performance. Because of the complex nature of medical care service data, many clinicians and administrators are not able to efficiently utilize the data. A need exists for a computer program that transforms inpatient and out patient claim data to actionable information, which is logically understood by clinicians and administrators.
Performance is quickly becoming the standard by which health care purchasers and informed consumers select their health care providers. Those responsible for the development and maintenance of provider networks search for an objective means to measure and quantify the health care services provided to their clients. Qualitative and quantitative analysis of medical provider performance is a key element for managing and improving a health care network. Operating a successful health care network requires the ability to monitor and quantify medical care costs and care quality. Oftentimes, success depends on the providers' ability to identify and correct problems in their health care system. A need exists, therefore, for an analytical tool for identifying real costs in a given health care management system.
To operate a more efficient health care system, health care providers need to optimize health care services and expenditures. Many providers practice outside established utilization and cost norms. Systems that detect inappropriate coding, eliminate potentially inappropriate services or conduct encounter-based payment methodology are insufficient for correcting the inconsistencies of the health care system. When a complication or comorbidity is encountered during the course of treatment, many systems do not reclassify the treatment profile. Existing systems do not adjust for casemix, concurrent conditions or recurrent conditions. A system that compensates for casemix should identify the types of illnesses treated in a given population, determine the extent of resource application to specific types of illnesses, measure and compare the treatment patterns among individual and groups of health care providers and educate providers to more effectively manage risk. When profiling claims, existing systems establish classifications that do not contain a manageable number of groupings, are not clinically homogeneous or are not statistically stable. A need exists, therefore, for a patient classification system that accounts for differences in patient severity and establishes a clearly defined unit of analysis.
For many years, computer-implemented programs for increasing health care efficiency have been available for purchase. Included within the current patent literature and competitive information are many programs that are directed to the basic concept of health care systems.
The Mohlenbrock, et al. patent, U.S. Pat. No. 4,667,292, issued in 1987, discloses a medical reimbursement computer system which generates a list identifying the most appropriate diagnostic-related group (DRG) and related categories applicable to a given patient for inpatient claims only. The list is limited by a combination of the characteristics of the patient and an initial principal diagnosis. A physician can choose a new designation from a list of related categories while the patient is still being treated. The manually determined ICD-9 numbers can be applied to an available grouper computer program to compare the working DRG to the government's DRG.
The Mohlenbrock, et al. patent, U.S. Pat. No. 5,018,067, issued in 1991, discloses an apparatus and method for improved estimation of health resource consumption through the use of diagnostic and/or procedure grouping and severity of illness indicators. This system is a computer-implemented program that calculates the amount of payment to the health provider by extracting the same input data as that identified in the Mohlenbrock '292 Patent teaching the DRG System. The system calculates the severity of the patient's illness then classifies each patient into sub-categories of resource consumption within a designated DRG. A computer combines the input data according to a formula consisting of constants and variables. The variables are known for each patient and relate to the number of ICD codes and the government weighing of the codes. The software program determines a set of constants for use in the formula for a given DRG that minimizes variances between the actual known outcomes and those estimated by use of the formula. Because it is based upon various levels of illness severity within each diagnosis, the results of this system provide a much more homogenous grouping of patients than is provided by the DRGs. Providers can be compared to identify those providers whose practice patterns are of the highest quality and most cost efficient. A set of actual costs incurred can be compared with the estimated costs. After the initial diagnosis, the system determines the expected costs of treating a patient.
The Schneiderman patent, U.S. Pat. No. 5,099,424, issued in 1992, discloses a model user application system for clinical data processing that tracks and monitors a simulated out-patient medical practice using database management software. The system allows for a database of patients and the entry of EKG and/or chest x-ray (CXR) test results into separate EKG/CXR records as distinct logical entities. This system requires entry of test results that are not part of the medical claim itself. If not already present, the entry creates a separate lab record that may be holding blood work from the same lab test request. Portions of the information are transferred to the lab record for all request situations. Although the lab record data routine is limited to blood work, each time the routine is run, historical parameter data are sent to a companion lab record along with other data linking both record types. The system also includes a revision of the system's specialist record and the general recommendation from an earlier work for more explicit use in information management.
The Tawil patent, U.S. Pat. No. 5,225,976, issued in 1993, discloses an automated health benefit processing system. This system minimizes health care costs by informing the purchasers of medical services about market conditions of those medical services. A database includes, for each covered medical procedure in a specific geographic area, a list of capable providers and their charges. A first processor identifies the insured then generates a treatment plan and the required medical procedures. Next, the first processor retrieves information related to the medical procedures and appends the information to the treatment plan. A second processor generates an actual treatment record including the actual charges. A third processor compares the plan and the actual records to determine the amounts payable to the insured and the provider.
The Ertel patent, U.S. Pat. No. 5,307,262, issued in 1994, discloses a patient data quality review method and system. The system performs data quality checks and generates documents to ensure the best description of a case. The system provides file security and tracks the cases through the entire review process. Patient data and system performance data are aggregated into a common database that interfaces with existing data systems. Data profiles categorize data quality problems by type and source. Problems are classified as to potential consequences. The system stores data, processes it to determine misreporting, classifies the case and displays the case-specific patient data and aggregate patient data.
The Holloway, et al. patent, U.S. Pat. No. 5,253,164, issued in 1993, discloses a system and method for detecting fraudulent medical claims via examination of service codes. This system interprets medical claims and associated representation according to specific rules and against a predetermined CPT-4 code database. A knowledge base interpreter applies the knowledge base using the rules specified. The database can be updated as new methods of inappropriate coding are discovered. The system recommends appropriate CPT codes or recommends pending the claims until additional information is received. The recommendations are based on the decision rules that physician reviewers have already used on a manual basis.
The Cummings patent, U.S. Pat. No. 5,301,105, issued in 1994, discloses an all care health management system. The patient-based system includes an integrated interconnection and interaction of essential health care participants to provide patients with complete support. The system includes interactive participation with the patients employers and banks. The system also integrates all aspects of the optimization of health-inducing diet and life style factors and makes customized recommendations for health-enhancing practices. By pre-certifying patients and procedures, the system enhances health care efficiency and reduces overhead costs.
The Dome patent, U.S. Pat. No. 5,325,293, issued in 1994, discloses a system and method for correlating medical procedures and medical billing codes. After an examination, the system automatically determines raw codes directly associated with all of the medical procedures performed or planned to be performed with a particular patient. The system allows the physician to modify the procedures after performing the examination. By manipulating the raw codes, the system generates intermediate and billing codes without altering the raw codes.
The Kessler, et al. patent, U.S. Pat. No. 5,324,077, issued in 1994, discloses a negotiable medical data draft for tracking and evaluating medical treatment. This system gathers medical data from ambulatory visits using a medical data draft completed by the provider to obtain payment for services, to permit quality review by medical insurers. In exchange for immediate partial payment of services, providers are required to enter data summarizing the patient's visit on negotiable medical drafts. The partial payments are incentives to providers for participating in the system.
The Torma, et al. patent, U.S. Pat. No. 5,365,425, issued in 1994, discloses a method and system for measuring management effectiveness. Quality, cost and access are integrated to provide a holistic description of the effectiveness of care. The system compares general medical treatment databases and surveyed patient perceptions of care. Adjustments based on severity of illness, case weight and military costs are made to the data to ensure that all medical facilities are considered fairly.
Health Chex's PEER-A-MED computer program is a physician practice profiling system that provides case-mix adjusted physician analysis based on a clinical severity concept. The system employs a multivariate linear regression analysis to appropriately adjust for case-mix. After adjusting for the complexity of the physician's caseload, the system compares the relative performance of a physician to the performance of the peer group as a whole. The system also compares physician utilization performance for uncomplicated, commonly seen diagnosis. Because the full spectrum of clinical care that is rendered to a patient is not represented in its databases, the system is primarily used as an economic performance measurement tool. This system categorizes the claims into general codes including acute, chronic, mental health and pregnancy. Comorbidity and CPT-4 codes adjust for acuity level. The codes are subcategorized into twenty cluster groups based upon the level of severity. The system buckets the codes for the year and contains no apparent episode building methodology. While the PEER-A-MED system contains clinically heterogeneous groupings, the groupings are not episode-based and recurrent episodes cannot be accounted.
Ambulatory Care Groups (ACG) provides a patient-based system that uses the patient and the analysis unit. Patients are assigned to an diagnosis group and an entire year's claims are bucketed into thirty-one diagnosis groups. By pre-defining the diagnosis groups, this is a bucketing-type system and claim management by medical episode does not occur. The system determines if a claim is in one of the buckets. Because different diseases could be categorized into the same ACG, this system is not clinically homogeneous. An additional problem with ACGs is that too many diagnosis groups are in each ACG.
Ambulatory Patient Groups (APGs) are a patient classification system designed to explain the amount and type of resources used in an ambulatory visit. Patients in each APG have similar clinical characteristics and similar resource use and cost. Patient characteristics should relate to a common organ system or etiology. The resources used are constant and predictable across the patients within each APG. This system is an encounter-based system because it looks at only one of the patient's encounters with the health care system. This system mainly analyzes outpatient hospital visits and does not address inpatient services.
The GMIS system uses a bucketing procedure that profiles by clumps of diagnosis codes including 460 diagnostic episode clusters (DECs). The database is client specific and contains a flexible number and type of analytic data files. This system is episode-based, but it does not account for recurrent episodes, so a patient's complete data history within a one-year period is analyzed as one pseudo-episode. Signs and symptoms do not cluster to the actual disease state, e.g. abdominal pain and appendicitis are grouped in different clusters. This system does not use CPT-4 codes and does not shift the DEC to account for acuity changes during the treatment of a patient.
Value Health Sciences offers a value profiling system, under the trademark VALUE PROFILER, which utilizes a DB2 mainframe relational database with 1,800 groups. The system uses ICD9 and CPT-4 codes, which are bucket codes. Based on quality and cost-effectiveness of care, the system evaluates all claims data to produce case-mix-adjusted profiles of networks, specialties, providers and episodes of illness. The pseudo-episode building methodology contains clinically pre-defined time periods during which claims for a patient are associated with a particular condition and designated provider. The automated practice review system analyzes health care claims to identify and correct aberrant claims in a pre-payment mode (Value Coder) and to profile practice patterns in a post-payment mode (Value Profiler). This system does not link signs and symptoms and the diagnoses are non-comprehensive because the profiling is based on the exclusion of services. No apparent shifting of episodes occurs and the episodes can only exist for a preset time because the windows are not recurrent.
The medical claim profiling programs described in foregoing patents and non-patent literature demonstrate that, while conventional computer-implemented health care systems exist, they each suffer from the principal disadvantage of not identifying and grouping medical claims on an episodic basis or shifting episodic groupings based upon complications or co-morbidities. The present computer-implemented health care system contains important improvements and advances upon conventional health care systems by identifying concurrent and recurrent episodes, flagging records, creating new groupings, shifting groupings for changed clinical conditions, selecting the most recent claims, resetting windows, making a determination if the provider is an independent lab and continuing to collect information until an absence of treatment is detected.
SUMMARY OF THE INVENTION
Accordingly, it is a broad aspect of the present invention to provide a computer-implemented medical claims profiling system.
It is a further object of the present invention to provide a medical claims profiling system that allows an objective means for measuring and quantifying health care services.
It is a further object of the present invention to provide a medical claims profiling system that includes a patient classification system based upon episode treatment groups.
It is a further object of the present invention to provide a medical claims profiling system that groups claims to clinically homogeneous and statistically stable episode treatment groups.
It is a further object of the present invention to provide a medical claims profiling system that includes claims grouping utilizing service or segment-level claim data as input data.
It is a further object of the present invention to provide a medical claims profiling system that assigns each claim to an appropriate episode.
It is a further object of the present invention to provide a medical claims profiling system that identifies concurrent and recurrent episodes.
It is a further object of the present invention to provide a medical claims profiling system that shifts groupings for changed clinical conditions.
It is a further object of the present invention to provide a medical claims profiling system that employs a decisional tree to assign claims to the most relevant episode treatment group.
It is a further object of the present invention to provide a medical claims profiling system that resets windows of time based upon complications, co-morbidities or increased severity of clinical conditions.
It is a further object of the present invention to provide a health care system that continues to collect claim information and assign claim information to an episode treatment group until an absence of treatment is detected.
It is a further object of the present invention to provide a health care system that creates orphan records.
It is a further object of the present invention to provide a health care system that creates phantom records.
The foregoing objectives are met by the present system that allows an objective means for measuring and quantifying health care services based upon episode treatment groups (ETGs). An episode treatment group (ETG) is a clinically homogenous and statistically stable group of similar illness etiology and therapeutic treatment. ETG grouper method uses service or segment-level claim data as input data and assigns each service to the appropriate episode.
ETGs gather all in-patient, ambulatory and ancillary claims into mutually exclusive treatment episodes, regardless of treatment duration, then use clinical algorithms to identify both concurrent and recurrent episodes. ETG grouper method continues to collect information until an absence of treatment is detected for a predetermined period of time commensurate with the episode. For example, a bronchitis episode will have a sixty-day window, while a myocardial infarction may have a one-year window. Subsequent records of the same nature within the window reset the window for an additional period of time until the patient is asymptomatic for the pre-determined time period.
ETGs can identify a change in the patient's condition and shift the patient's episode from the initially defined ETG to the ETG that includes the change in condition. ETGs identify all providers treating a single illness episode, allowing the user to uncover specific treatment patterns. After adjusting for case-mix, ETGs measure and compare the financial and clinical performance of individual providers or entire networks.
Medical claim data is input as data records by data entry into a computer storage device, such as a hard disk drive. The inventive medical claims profiling system may reside in any of a number of computer system architectures, i.e., it may be run from a stand-alone computer or exist in a client-server system, for example a local area network (LAN) or wide area network (WAN).
Once relevant medical claim data is input, claims data is processed by loading the computer program into the computer system memory. During set-up of the program onto the computer system, the computer program will have previously set pointers to the physical location of the data files and look-up tables written to the computer storage device. Upon initialization of the inventive computer program, the user is prompted to enter an identifier for a first patient. The program then checks for open episodes for the identified patient, sets flags to identify the open episodes and closes any episodes based upon a predetermined time duration from date of episode to current date. After all open episodes for a patient are identified, the new claims data records are read to memory and validated for type of provider, CPT code and ICD-9 (dx) code, then identified as a management, surgery, facility, ancillary, drug or other record.
As used herein, “Management records” are defined as claims that represent a service by a provider engaging in the direct evaluation, management or treatment or a patient. Examples of management records include office visits and therapeutic services. Management records serve as anchor records because they represent focal points in the patient treatment as well as for related ancillary services.
“Ancillary records” are claims which represent services which are incidental to the direct evaluation, management and treatment of the patient. Examples of ancillary records include X-ray and laboratory tests.
“Surgery records” are specific surgical claims. Surgery records also serve as anchor records.
“Facility records” are claims for medical care facility usage. Examples of facility records include hospital room charges or outpatient surgical room charges.
“Drug records” are specific for pharmaceutical prescription claims. “Other records” are those medical claim records which are not management, surgery, ancillary, facility or drug records.
Invalid records are flagged and logged to an error output file for the user. Valid records are then processed by an ETG Assignor Sub-routine and, based upon diagnosis code, is either matched to existing open episodes for the patient or serve to create new episodes.
Management and surgery records serve as “anchor records.” An “anchor record” is a record which originates a diagnosis or a definitive treatment for a given medical condition. Management and surgery records serve as base reference records for facility, ancillary and drug claim records relating to the diagnosis or treatment which is the subject of the management or surgery record. Only management and surgery records can serve to start a given episode.
If the record is a management record or a surgery record, the diagnosis code in the claim record is compared with prior related open episodes in an existing look-up table for a possible ETG match. If more than one open episode exists, the program selects the most recent open episode. A positive match signifies that the current episode is related to an existing open episode. After the match is determined, the time window is reset for an additional period of time corresponding to the episode. A loop shifts the originally assigned ETG based on the additional or subsequent diagnoses. If any of the additional or subsequent diagnoses is a defined co-morbidity diagnosis, the patient's co-morbidity file updated. If no match between the first diagnosis code and an open episode is found, a new episode is created.
Grouping prescription drug records requires two tables, a NDC (National Drug Code) by GDC (Generic Drug Code) table and a GDC by ETG table. Because the NDC table has approximately 200,000 entries, it has been found impracticable to directly construct an NDC by ETG table. For this reason the NDC by GDC table serves as a translation table to translate NDCs to GDCs and construct a smaller table based upon GDCs. Reading, then from these tables, the NDC code in the claim data record is read and translated to a GDC code. The program then identifies all valid ETGs for the GDC codes in the claim data record then matches those valid ETGs with active episodes.
These and other objects, features and advantages of the present invention will become more apparent to those skilled in the art from the following more detailed description of the non-limiting preferred embodiment of the invention taken with reference to the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Briefly summarized, a preferred embodiment of the invention is described in conjunction with the illustrative disclosure thereof in the accompanying drawings, in which:
FIG. 1 is a diagrammatic representation of a computer system used with the computer-implemented method for analyzing medical claims data in accordance with the present invention.
FIG. 2 is a flow diagram illustrating the general functional steps of the computer implemented method for analyzing medical claims data in accordance with the present invention.
FIG. 3 is a flow diagram illustrating an Eligible Record Check routine which validates and sorts patient claim data records.
FIGS. 4A to 4 F are flow diagrams illustrating the Management Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.
FIGS. 5A-5D are flow diagrams illustrating a Surgery Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.
FIGS. 6A-6E are flow diagrams illustrating a Facility Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.
FIGS. 7A-B are flow diagrams illustrating an Ancillary Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.
FIGS. 8A-8C are flow diagrams illustrating a Drug Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.
FIG. 9 is a flow diagram illustrating the Episode Definer Routine in accordance with the computer-implemented method of the present invention.
FIG. 10 is diagrammatic timeline illustrating a hypothetical patient diagnosis and medical claims history during a one year period and grouping of claim records as management records and ancillary records with cluster groupings.
FIG. 11 is a diagrammatic representation of a I-9 Diagnosis Code (dx) X ETG table illustrating predetermined table values called by the Episode Definer Routine of the present invention.
FIG. 12 is a diagrammatic representation of an I-9 Diagnosis Code 9 (dx) X CPT Code table illustrating predetermined table values called by the Episode Definer Routine of the present invention.
FIG. 13 is a diagrammatic representation of a National Drug Code (NDC) to Generic Drug Code (GDC) conversion table illustrating predetermined Generic Drug Code values called by the Drug Record Grouping Sub-routine of the Episode Definer Routine of the present invention.
FIG. 14 is a diagrammatic representation of a Generic Drug Code (GDC) to Episode Treatment Group (ETG) table illustrating predetermined table values called by the Drug Record Grouping Sub-routine of the Episode Definer Routine of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to the accompanying drawings, the basic structural elements of a health care management system of the present invention are shown. Health care management system consists generally of a computer system 10 . Computer system 10 is capable of running a computer program 12 that incorporates the inventive method is shown in FIG. 1 . The computer system 10 includes a central processing unit (CPU) 14 connected to a keyboard 16 which allows the user to input commands and data into the CPU 14 . It will be understood by those skilled in the art that CPU 14 includes a microprocessor, random access memory (RAM), video display controller boards and at least one storage means, such as a hard disk drive or CD-ROM. The computer system 10 also contains a video display 18 which displays video images to a person using the computer system 10 . The video display screen 18 is capable of displaying video output in the form of text or other video images.
Episode Treatment Groups (ETGs) are used to define the basic analytical unit in the computer-implemented method of the present invention. ETGs are episode based and conceptually similar to Diagnostic Related Groups (DRGs), with a principal difference being that DRGs are inpatient only. ETGs encompass both inpatient and outpatient treatment.
Using ETGs as the basic episodic definer permits the present invention to track concurrently and recurrently occurring illnesses and correctly identify and assign each service event to the appropriate episode. Additionally, ETGs account for changes in a patient's condition during a course of treatment by shifting from the initially defined ETG to one which includes the changed condition once the changed condition is identified.
The inventive medical claims profiling system defines Episode Treatment Groups (ETGs). The number of ETGs may vary, depending upon the definitional specificity the health care management organization desires. Presently, the inventive system defines 558 ETGs, which are assigned ETG Numbers 1-900 distributed across the following medical areas: Infectious Diseases, Endocrinology, Hematology, Psychiatry, Chemical Dependency, Neurology, Ophthalmology, Cardiology, Otolaryngology, Pulmonology, Gastroenterology, Hepatology, Nephrology, Obstetrics, Gynecology, Dermatology, Orthopedics and Rheumatology, Neonatology, Preventative and Administrative and Signs and Isolated Signs, Symptoms and Non-Specific Diagnoses or Conditions. Under the presently existing system, ETG 900 is reserved to “Isolated Signs, Symptoms and Non-Specific Diagnoses or Conditions,” and is an ETG designation used where the diagnosis code is incapable of being assigned to another ETG. A listing of exemplary ETGs for typical episodes is found at Table 1, below. Those skilled in the art will understand, however, that the number of ETGs may change, the ETG numbering system is variable, the ETG classifications may be defined with relatively broader or narrower degrees of specificity and the range of medical specialties may be greater or fewer, as required may be require by the management organization in their medical claims data analysis protocols.
An episode may be considered a low outlier or high outlier. Low outliers are episodes with dollar values below the minimum amount which is specific to each ETG. Examples of low outliers include patients which drop from a plan during mid-episode and patients who use out-of-network providers and do not submit claims. High outliers are those episodes with high dollar values greater than the 75th percentile plus 2.5 times the interquartile range, based upon a predefined database. The low and high outlier points are pre-determined and hard-coded into the inventive system and will vary across analysis periods.
If no ICD-9 (diagnosis code) on a given record matches the CPT-4 code, i.e., a diagnosis of bronchitis and a CPT of knee x-ray, an invalid code segment results. The inventive system outputs invalid records and discontinues the processing of these records. An invalid ICD-9 code is assigned to ETG 997, an invalid CPT-4 code is assigned to ETG 996 and an invalid provider type is assigned to ETG 995. A sequential anchor count and a sequential episode count are incremented after each ETG assignment. Active open and closed ETG files include ETG number, sequential episode number, most recent anchor from date of service and most recent sequential anchor record count. An alternative embodiment creates a single record for each individual episode containing ETG number, patient age, patient sex, episode number, total charges, total payments, earlier anchor record, last anchor record, whether the episode was closed (“clean finish”), number of days between database start date and earliest anchor record, whether a number of days between database start date and earliest anchor record exceeds the ETG's days interval, patient identification, physician identification, management charges, management paid, surgery charges, surgery paid, ancillary charges and ancillary paid.
The inventive system uses clinical algorithms to identify both concurrent and recurrent episodes. Subsequent episodes of the same nature within a window reset the window for an additional period of time until the patient is asymptomatic for a pre-determined time period. If an ETG matches a prior ETG, a recurrent ETG is created and the window is reset. The most recent claim is selected if more than one matched claim exists. If the ETG does not match an active ETG, a new concurrent ETG is created.
Comorbidities, complications or a defining surgery could require an update of the patient's condition to an ETG requiring a more aggressive treatment profile. ETG's changes in the patient's clinical condition and shift the patient's episode from the initially defined ETG to an ETG which includes the change in clinical condition.
If the claim is an ancillary record and it does not match an active ETG it is designated an “orphan” ancillary record.
Termination of an episode is detected by an absence of treatment for a period of time commensurate with the episode.
If the claim is a prescription drug record, two pre-defined tables written to the computer data storage medium, are read. The first of the tables is a National Drug Code (NDC) by Generic Drug Code (GDC) table. The GDC code is equivalent to the Generic Drug Code table known in the art. This table acts as a translator table to translate a large number of NDCs to a smaller set of GCNs. A second pre-defined table is employed and is constructed as a GDC by ETG table. The GDC by ETG table is used, in conjunction with the NDC by GDC translator table, to identify all valid ETGs for a particular NDC code in the claim record.
To determine specific treatment patterns and performance contributions, the computer-implemented method identifies all providers treating a single illness episode. If a network of providers contains Primary Care Physicians (PCP), the ETGs clearly identify each treatment episode by PCP. Financial and clinical performance of individual providers or entire networks may be monitored and analyzed. To monitor health care cost management abilities of providers, components of a provider's treatment plan may be analyzed by uncovering casemix-adjusted differences in direct patient management, the use of surgery and the prescribing of ancillary services. By identifying excessive utilization and cost areas, continuous quality improvement protocols are readily engineered based on internally or externally derived benchmarks. After adjusting for location and using geographically derived normative charge information, ETG-based analysis compares the cost performance of providers or entire networks. By using geographically derived utilization norms, the present invention forms the methodology base for measuring both prevalence and incidence rates among a given population by quantifying health care demand in one population and comparing it to external utilization norms. This comparison helps to identify health care providers who practice outside established utilization or cost norms.
Turning now to FIG. 2, there is illustrated the general operation of the computer-implemented method of the present invention. Those skilled in the art will understand that the present invention is first read from a removable, transportable recordable medium, such as a floppy disk, magnetic tape or a CD-ROM onto a recordable, read-write medium, such as a hard disk drive, resident in the CPU 14 . Upon a user's entry of appropriate initialization commands entered via the keyboard 16 , or other input device, such as a mouse or trackball device, computer object code is read from the hard disk drive into the memory of the CPU 14 and the computer-implemented method is initiated. The computer-implemented method prompts the user by displaying appropriate prompts on display 18 , for data input by the user.
Those familiar with medical claims information processing will understand that medical claims information is typically received by a management service organization on paper forms. If this is the case, a user first manually sorts claim records by patient, then input patient data through interfacing with the CPU 14 through the keyboard 16 or other input device.
Prior to being submitted to the grouping algorithm, records must be sorted by patient by chronological date of service. An Eligible Record Check routine 48 to verify the validity and completeness of the input data. As each record is read by the software, it first checks the date of service on the record and compares it to the last service date of all active episodes to evaluate which episodes have expired in terms of an absence of treatment. These episodes are closed at step 50 . Next the record is identified as either a management 52 , surgery 54 , facility 56 , ancillary 58 or drug 60 record. These types of records are categorized as follows:
“Management records” are defined as claims which represent a service by a provider engaging in the direct evaluation, management or treatment or a patient. Examples of management records include office visits, surgeries and therapeutic services. Management records serve as anchor records because they represent focal points in the patient treatment as well as for related ancillary services.
“Ancillary records” are claims which represent services which are incidental to the direct evaluation, management and treatment of the patient. Examples of ancillary records include X-ray and laboratory tests.
“Surgery records” represent surgical procedures performed by physicians and other like medical allied personnel. Like management records, surgery records also serve as anchor records.
“Facility records” are claims for medical care facility usage. Examples of facility records include hospital room charges or ambulatory surgery room charges.
“Drug records” are specific for pharmaceutical prescription claims.
A “cluster” is a grouping of one, and only one, anchor record, management or surgery, and possibly ancillary, facility and/or drug records. A cluster represents a group of services in which the focal point, and therefore the responsible medical personnel, is the anchor record. An episode is made up of one or more clusters.
After the management, surgery, facility, ancillary and drug records are identified at steps 52 , 54 , 56 , 58 and 60 , respectively, an ETG Assignor Sub-routine is executed at step 62 . The ETG Assignor Sub-routine 62 assigns patient medical claims to ETGs based one or more cluster of services related to the same episode, and provides for ETG shifting upon encountering a diagnosis code or CPT code which alters the relationship between the diagnosis or treatment coded in the claim record and an existing ETG assignment. For example, ETG's may be shifted to account for changes in clinical severity, for a more aggressive ETG treatment profile if a complication or comorbidity is encountered during the course of treatment for a given ETG or where a defining surgery is encountered during the course of treatment for a given ETG.
When the last claim data record for a given patient is processed by the ETG Assignor Routine 62 , the Episode Definer Routine is executed at step 64 . Episode Definer Routine 64 identifies all open and closed ETG episodes for the patient and appropriately shifts any episodes to a different ETG if such ETG is defined by age and/or the presence or absence of a co-morbidity. The patient records are then output to a file with each record containing the ETG number, a sequential episode number, and a sequential cluster number. Upon input of an identifier for the next patient, the processing of medical claims for the next patient is initiated at step 66 by looping back to check for eligible records for the new patient at step 48 .
Operation of the Eligible Record Check routine 100 is illustrated in FIG. 3 . The patient records input by the user are read from the recordable read-write data storage medium into the CPU 14 memory in step 102 . From the patient records read to memory in step 102 , a record validation step 104 is carried out to check provider type, treatment code and diagnosis code against pre-determined CPT code and diagnosis code look up tables. The diagnosis code is preferably the industry standard ICD-9 code and the treatment code is preferably the industry standard CPT-4 code. All valid patient records are assigned as one of a) management record, b) ancillary record, c) surgery record, d) facility record, e) drug record or f other record, and coded as follows:
m=management record;
a=ancillary record;
s=surgery record;
f=facility record;
d=drug record; or
o=other record.
A sort of valid records 106 and invalid records 108 from step 104 is made. For valid records 106 in step 110 , patient age is then read to memory from the first patient record from step 106 . All valid records are then sorted by record type in step 112 , i.e., record type m, a, s, f, d or o by a date of service from date (DOS-from). A sort index of all record-type sorted records from step 116 is generated and written to the hard disk, and the ETG Assignor routine 120 is initialized.
For invalid records 108 identified at step 104 , the records are assigned ETG designations reserved for records having invalid provider data, invalid treatment code, or invalid diagnosis code, e.g., ETG 995, 996 and 997, respectively, at step 111 . An error log file is output identifying the invalid records by reserved ETG and written to disk or displayed for the user and processing of the invalid records terminates at step 113 .
The computer-implemented method of the present invention then initializes an Episode Assignor Routine 200 , the operation of which is illustrated in FIGS. 4A-8C. Episode Assignor Routine 200 consists generally of five Sub-routine modules for processing management records, surgery records, facility records, ancillary records and drug records and assigning claims to proper ETGs. FIGS. 4A-4F illustrate initial identification of records as management, surgery, facility ancillary and drug records and the Management Record Grouping Sub-Routine. FIGS. 5A-5E illustrate operation of the Surgery Record Grouping routine 400 for matching surgery claim records to proper ETGs. FIGS. 6A-6E illustrate operation of the Facility Record Grouping routine 500 for matching facilities records to proper ETGs. FIGS. 7A-7 illustrate operation of the Ancillary Record Grouping routine 600 for matching ancillary records to proper ETGs. Finally, FIGS. 8A-8C illustrate operation of the Drug Records Grouping routine 700 for matching drug records to proper ETGs.
Management Records
The Episode Assignor routine begins by executing a Management Records Grouping Sub-routine 200 , illustrated in FIGS. 4A-4F, first reads the input claim record for a given patient in step 202 . The first processing of the input claim record entails categorizing the record as a management, surgery, facility, ancillary or drug record at step 204 . A series of logical operands 208 , 210 , 212 and 214 , read the record and determine whether the record is a management record at step 204 , a surgery record at step 208 , a facility record at step 210 , an ancillary record at step 212 or a drug record at step 214 . If an affirmative response is returned in response to logical operand 204 , grouping of the management record to an ETG is initialized and processing of the management record proceeds to step 215 . If, however, a negative response is returned in response to the logical operand 206 , logical operand 208 is executed to determine whether the record is a surgery record. If an affirmative response is returned from logical operand 208 , the Surgery Record Grouping routine 400 is initialized. If, however, a negative response to logical operand 208 is returned, logical operand 210 is executed to determine whether the record is a facility record. If an affirmative response is returned in response to logical operand 210 , the Facility Record Grouping Sub-routine 500 is executed. If, however, a negative response is returned in response to the logical operand 210 , logical operand 212 is executed to determine whether the record is an ancillary record. If an affirmative response is returned from logical operand 212 , the Ancillary Record Grouping Sub-routine 600 is executed. If, however, a negative response to logical operand 212 is returned, logical operand 214 is executed to determine whether the record is a facility record. At this point all records except drug records have been selected. Thus, all the remaining records are drug records and the Drug Record Grouping Sub-routine 700 is executed.
Returning now to the initialization of the Management Record Grouping routine 200 , and in particular to step 215 . Once the record has been categorized as a management record in step 206 , the DOS-to value is compared to active episodes for the patient to determine if any active episodes should be closed. Closed episodes are moved to an archive created on the storage means, such as a hard disk or CD-ROM.
The management record is examined and the first diagnosis code on record is read, a diagnosis code (dx) by ETG table 201 is read from the storage means and all valid ETGs for the first diagnosis code on record are identified at step 216 . The dx by ETG table 201 consists of a table matrix having diagnosis codes on a first table axis and ETG numbers on a second table axis. At intersection cells of the dx by ETG table are provided table values which serve as operational flags for the inventive method. In accordance with the preferred embodiment of the invention, dx by ETG table values are assigned as follows:
P=primary, with only one P value existing per ETG;
S=shift;
I=incidental;
A=shift to ETG with C value; and
C=P, where P′ is a shiftable primary value.
An illustrative example of a section of a dx by ETG table is found at FIG. 11 .
ETG validation in step 216 occurs where for a given diagnosis code on record, the code has either a P, S, I, A or C dx-ETG table value. The ETGs identified as valid for the first diagnosis code on record in step 216 , are then matched with active open ETGs in step 217 by comparing the valid ETGs with the open ETGs identified in step 215 . A logical operand is then executed at step 218 to determine whether a match exists between the valid ETG from the management record and any open ETGs. A negative response at step 218 causes execution of another logical operand at step 220 to determine whether for the first diagnosis code is the P value in the dx-ETG table equal to the ETG for non-specific diagnosis, i.e., ETG 900. If an affirmative response is returned at step 216 , ETG identifiers for the second to the fourth diagnosis codes in the management record are established from the dx-ETG table and the ETG identifier value is matched to active specific ETGs in step 222 and execution of the program continues as represented by designator AA 236 bridging to FIG. 5 B. If, however, a negative response is returned from logical operand 220 , a value of one is added to the management record or anchor count and to the episode count and the ETG with a P value on the dx-ETG table is selected and a new episode is initialized. Further processing of the new episode by the program continues as represented by designator F 236 bridging to FIG. 5 C.
If an affirmative response is returned at logical operand step 218 , the matched active ETG with the most recent DOS-to are selected at step 230 . If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. A value of one is then added to the management record or anchor record counter at step 232 and further processing continues as represented by designator G 238 bridging to FIG. 5 C.
Turning now to FIG. 4B, which is a continuation from designator AA 236 of FIG. 4A, identifier ETGs for the second to fourth diagnoses in the management record are matched to active ETGs in logical operand 237 . If an affirmative response is returned in response to logical operand 237 , the matched active ETG with the most recent DOS-to is selected in step 240 . If there is a tie between two or more ETGs with the most recent DOS-to value, the most recent DOS-from ETG is selected. If, however, there is a tie between two or more active ETGs with the most recent DOS-from value, then the first encountered ETG is selected in step 240 . A value of one is then added to the sequential anchor record counter in step 241 and operation of the computer-implemented method continues as indicated by designator G 243 bridging to FIG. 5 C.
From logical step 237 , if a negative response is returned, the ETG with the second diagnosis value of P is selected at step 242 , then a logical query is made to determine whether the selected ETG is a non-specific ETG, i.e., ETG 900 at step 244 . A negative response to logical query 244 causes a value of one to be added to the sequential anchor count and to the sequential episode count at step 254 . If an affirmative response to logical query 244 is returned, logical queries 246 and 248 are sequentially executed to select ETGs with the third and fourth diagnosis values of P from the dx-ETG table written on the storage means, respectively, and logical query 244 is executed to determine whether the selected ETG is the non-specific ETG, i.e., ETG 900. If a negative response is returned to logical query 244 for the ETG selected in step 248 , a value of one is added to the sequential anchor count and to the sequential episode count in step 254 . If an affirmative response is returned from logical query 244 , a value of one is added to the sequential anchor count and the sequential episode count at step 250 .
From step 250 , the non-specific ETG, i.e., ETG 900 is selected and a new episode is started in the active ETG file. The updated sequential episode number, the updated sequential anchor count, the DOS-from and the DOS-to from the record are written to the new episode in the active ETG file in step 252 .
From step 254 , the ETG with a dx-ETG table value of P is selected and a new episode is started in the active ETG file. The updated sequential episode number, the updated sequential anchor count, the DOS-from and the DOS-to from the record are written to the new episode in the active ETG file in step 256 . A comorbidity file written on the storage means is then updated with all the dx codes in the management record in step 258 .
From each of steps 252 and steps 258 a check is made to determine whether the processed management record is the last record for the patient at logical step 260 . An affirmative response returned to logical step 260 prompts the program operation to the Episode Definer Sub-routine 264 , bridging to FIG. 9 with identifier GG, while a negative response to logical step 260 returns program operation to the beginning of the ETG Assignor routine 200 and the next patient record is read at step 262 .
Turning now to FIG. 4C, the bridge reference G 238 is continued from FIG. 4 A. For those records having a match with an open ETG, a query is made at step 270 of the dx-ETG table 201 to determine the table value of the dx code for the selected ETG. Again, valid table values are one of P, S, I, A, or C. If the table value returned from step 270 is A, the selected ETG in the active file is changed at step 272 to the ETG number having an equivalent table value of C for the diagnosis on record. If the table value returned from step 270 is S, the selected ETG in the active file is shifted at step 274 to an ETG value having a table value of P for the diagnosis code on record. If the table value is one of P, I or C, the ETG remains the same and the selected active ETG's most recent DOS-to is updated by writing the record date to the ETG DOS-to field, and the sequential anchor count in the selected active ETG is updated to reflect writing of the record to the ETG at step 276 .
At step 278 , the record is then written with a sequential episode number and the sequential anchor count of the selected ETG from the selected active ETG. In this manner, the record is identified with the ETG and the specific episode. The patient's co-morbidity file is flagged with the output read from bridge designator F at step 234 . A patient's comorbidity file is a predefined list of diagnoses which have been identified as comorbidities. If during the course of grouping a patient's records, a management record is encountered which is a comorbidity diagnosis, the ETG for that diagnosis is flagged or “turned on” in the comorbidity file. Then, during the execution of the Episode Definer Routine, all the patient's episodes with an ETG which can shift based on the presence of a comorbidity and which are “turned on” are appropriately shifted to the ETG “with comorbidity”.
A loop beginning at step 282 is then executed to determine whether the ETG assigned by the first diagnosis code should be shifted to another ETG based upon the second, third and fourth diagnoses on record. At step 282 , the second diagnosis is read from the patient's claim record and all valid ETGs for the second diagnosis are read from the dx-ETG table 201 . A logical operand 284 is executed to determine whether one of the valid ETGs for the second diagnosis matches the primary diagnosis ETG. If a negative response is returned to logical operand 284 , a loop back at step 285 is executed to step 282 for the next sequential diagnosis code on record, i.e., the third and forth diagnosis codes on record. If an affirmative response is returned to the logical operand 284 , the a logical operand 286 queries the table value of the matched ETG to determine if a value of A is returned from the dx-ETG table. If a negative response is returned, the loop back step 285 is initialized. If an affirmative response is returned, the first dx ETG is flagged for change to a second dx ETG having an equivalent table value of C for the second diagnosis code on record at step 288 and all valid ETGs for the current diagnosis code on record are identified at step 290 from the dx-ETG table. The identified C-value ETG is then matched with any open active ETGs at step 292 . Program operation then continues at bridge H 292 to FIG. 4 D.
At FIG. 4D the continued operation of the Management Grouping Sub-routine from bridge H 292 of FIG. 4 C. Logical operand 296 queries the open active ETGs to determine whether a valid match with the identified C-value ETG exists. If a negative response is returned to logical operand 296 , a value of 1 is added to the sequential episode count at step 297 and a new episode having a P value ETG is started in the patient's master active ETG file at step 299 . The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom management record. A phantom record is an anchor record, management or surgery, with more than one diagnosis, which is assigned to one episode and its corresponding ETG based on one diagnosis, but can start a new episode(s) or update the most recent date of another active episode(s) based on other diagnoses on the record.
If an affirmative response is returned from logical operand 296 , the matched active ETG with the most recent DOS-to value is selected at step 298 . If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 300 .
For either the new episode created at step 299 or the updated ETG from step 300 , the patient's co-morbidity file is then updated with the second diagnosis code on-record at step 302 . Processing then continues to identify all valid ETGs for a third diagnosis code on record at step 304 and the identified valid ETGs from step 304 are compared to the active ETGs in the patient's master active ETG file in step 306 .
Bridge I 308 continues to FIG. 4E, and a logical operand 310 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 304 with any active ETG from the patients master active ETG file. If a negative response is returned to logical operand 310 , a value of 1 is added to the sequential episode count at step 311 and a new episode having a P value ETG is started in the patient's master active ETG file at step 313 . The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom management record.
If an affirmative response is returned from logical operand 310 , the matched active ETG with the most recent DOS-to value is selected at step 312 . Again a decisional hierarchy is executed. If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 314 .
For either the new episode created at step 311 or the updated ETG from step 314 , the patient's co-morbidity file is then updated with the third diagnosis code on-record at step 316 . Processing then continues to identify all valid ETGs for a fourth diagnosis code on record at step 318 and the identified valid ETGs from step 3318 are compared to the active ETGs in the patient's master active ETG file in step 320 . Bridge reference I 322 , bridges to FIG. 4 F.
Turning to FIG. 4F, a logical operand 324 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 320 with any active ETG from the patients master active ETG file. If a negative response is returned to logical operand 324 , a value of 1 is added to the sequential episode count at step 325 and a new episode having a P value ETG is started in the patient's master active ETG file at step 337 . The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom management record.
If an affirmative response is returned from logical operand 324 , the matched active ETG with the most recent DOS-to value is selected at step 326 . Again a decisional hierarchy is executed. If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 328 .
For either the new episode created at step 337 or the updated ETG from step 324 , the patient's co-morbidity file is then updated with the fourth diagnosis code on-record at step 330 . A check is then made to determine whether the processed record is the last record for the patient by execution of logical operand 332 and reading the input claim records from the storage means. If logical operand 332 returns an affirmative value, the ETG Definer Sub-routine is called at step 334 , as represented by bridge reference GG. If, however, a negative response is returned to logical operand 332 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means.
Surgery Records
Grouping of Surgery Records to ETGs is governed by the Surgery Record Grouping Sub-routine 400 , the operation of which is illustrated in FIGS. 5A-5D.
For those patient claim records identified as Surgery Records at step 208 , the DOS-from value on-record is compared with the DOS-to value read from the patient master active ETG file at step 402 . This identifies and flags those active ETGs which are to be closed, the flagged ETGs are then moved to the patient master closed ETG file. The first diagnosis code on-record is then read and compared to the dx-ETG table 201 to identify all possible valid ETGs for the first diagnosis code on-record in step 404 .
Surgery records are coded with treatment codes (CPT codes). Each surgery record has a single CPT code value. The CPT code on-record is then read, and compared to a CPT by ETG table 401 previously written to the storage means. The CPT-ETG table will have pre-determined table values. For example, in accordance with the preferred embodiment of the invention, the CPT-ETG table 401 has table values of R, W and X, where R is a value shiftable to W and X is a validator value. All valid ETGs for the on-record CPT code are identified by this comparison at step 406 . A logical operand 408 is then executed to determine whether there is a match of valid ETGs returned from the dx-ETG table 201 and the CPT-ETG table 401 . If an affirmative response is returned to logical operand 408 , a second logical operand 410 is executed to determine whether a match of valid specific ETGs exists. Again, if an affirmative response is returned from second logical operand 410 , the valid specific ETGs matched in step 410 are then compared at step 414 with the open active ETGs for the patient read from the patient's master active ETG file at step 412 . If an affirmative response is returned from step 414 , the matched ETG with the most recent DOS-to is selected at step 416 and a value of 1 is added to the sequential anchor count in the selected ETG at step 418 . In step 416 , if a tie is found based upon most recent DOS-to values, then a decisional hierarchy is followed to select the most recent DOS-from value for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.
If a negative response is returned to any of logical operands 408 , 410 or 414 , second, third and fourth dx codes on-record are read and all possible valid ETGs are read in step 411 from the dx-ETG table 201 . Further processing of the valid ETGs output from step 411 is continued at FIG. 5B identified by bridge reference P, 413 .
Turning to FIG. 5B, a logical operand 415 compares the valid ETGs for the second, third and fourth dx codes with the valid ETGs for the CPT code on-record in step 411 . If a negative response is returned from logical operand 415 , the patient claim record is assigned to an ETG reserved for match errors between dx code and CPT code, e.g., ETG 998, and further processing of the match error ETG bridges at reference R, 431 , to FIG. 5 D.
If an affirmative response is returned from logical operand 415 , the matched ETGs are compared with active ETGs read from the patient master active ETG file at step 417 and logical operand 419 is executed at step 419 to determine whether any valid matches between matched ETGs and active ETGs. If a negative response is returned to logical operand 419 , a value of 1 is added to the sequential anchor count and to the sequential episode count at step 425 and a new episode is started at step 437 with the first dx code on-record having a P value for a specific ETG in the dx-ETG table 201 . If no specific ETG has a P value, a non-specific ETG having a P value for the dx code on record is used to start the new episode. The new episode is started by writing the sequential episode number, the sequential anchor count, the DOS-from and the DOS-to values on the record.
If an affirmative response is returned from logical operand 419 , the matched specific ETG with the most recent DOS-to is selected at step 421 . If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. A value of 1 is added to the sequential anchor count at step 423 . Processing the new episode started at step 427 or of the selected matched specific ETG at step 421 continues to bridge Q, 420 , continued at FIG. 5 C.
Turning to FIG. 5C, bridged from reference Q, 420 , logical operand 422 is executed which reads the CPT-ETG table 401 and determines the table value of the selected ETG from step 421 and step 427 based on the CPT value on-record. If a table value of R is returned from the read of the CPT-ETG table 401 at step 422 , the matched ETG in the master active ETG file is shifted at step 424 to the ETG with an equivalent value of W for the CPT code on-record. If a table value of X or W is returned from step 422 or from step 242 , the dx-ETG table 201 is read at step 426 and the dx code for the selected matched ETG from the CPT-ETG table 401 or the shifted ETG from step 424 is read. From the dx-ETG table 201 , if a value of S is returned, the matched ETG in the patient master active ETG file is shifted at step 428 to the ETG with a table value of P for the dx code on-record. If a table value of A is returned, the matched ETG in the patient master active ETG file is changed in step 430 to an equivalent value of C for the dx code on-record. If a table value of P, I or C is returned either from logical operand 426 , or from the ETG change step 428 or the ETG shift step 430 , the DOS-to and the sequential anchor count of the ETG in the patient master active ETG file are updated in step 432 . The patient claim record is then assigned and written with the sequential episode number and the sequential anchor count of the selected ETG at step 434 . The patient co-morbidity file is then updated with all diagnosis codes on-record at step 436 .
FIG. 5D bridges from FIG. 5C with bridge reference BB, 438 . In FIG. 5D, the diagnosis codes on-record which were not used in the ETG selection described above, are then read from the patient claim record to identify all possible valid ETGs in the dx-ETG table 201 . The identified possible valid ETGs are then matched against the patient master active ETG file in step 442 and logical operand 444 is executed to validate the matches. If an affirmative response is returned to logical operand 444 , for each matched dx code on-record, the matched active ETG with the most recent DOS-to is selected at step 446 . If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The selected ETG's most recent DOS-to value is updated to the date of the patient medical claim, and the sequential anchor count in the active ETG is updated in step 448 .
If a negative response is returned to logical operand 444 , a value of 1 is added to sequential episode count at step 456 and a new episode having a P value ETG is started in the patient's master active ETG file at step 458 . The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom surgery record. If an affirmative response is returned to logical operand 444 , the matched active ETG for each diagnosis code is selected at step 446 on the basis of the most recent DOS-to value. If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The DOS-to field of the selected ETG from step 446 is updated in step 448 to the date of service on-record and the sequential anchor count in the active ETG file is updated. From either step 458 or from step 448 , the patient co-morbidity file is updated to reference the selected ETG and a check is made to determine whether the patient claim record processed in step 429 , which assigned an invalid dx-CPT code match to the record, or from step 450 , which updated the co-morbidity file, is the last record for the patient at logical operand 462 . If an affirmative response is returned to logical operand 462 , record processing proceeds to the Episode Definer Sub-routine at step 464 , bridged by reference GG, to FIG. 9 . If, however, a negative response is returned to logical operand 462 , a loop back 468 to the beginning of the ETG Assigner routine 200 is executed and the next patient claim record is read.
Facility Records
The Facility Record Grouping Sub-routine 500 assigns facility records to ETGs on the basis of diagnosis codes on-record. The patient claim record is read and the first diagnosis code on-record is read to the dx-ETG table 201 to identify all valid ETGs for the first dx code at step 502 . The identified valid ETGs are then compared to the open active ETGs in the patient master active ETG file in step 504 . Logical operand 506 executes to determine whether any valid matches exist between identified ETGs for the dx code and the active ETGs for the patient. If a negative response is returned to step 506 , a value of 1 is added to the sequential episode count at step 507 and a new episode is started in step 509 in the patient active ETG file with the ETG corresponding to the dx-ETG table value of P. If logical operand 507 returns an affirmative response, a query of the matched ETG value is made at step 508 to determine whether the matched ETG has a table value of P, C, A or S. If a negative response is returned to step 508 , the matched active ETG with the most recent DOS-from value is selected at step 511 . If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. If an affirmative response is returned at step 508 , the table value of the matched ETG table value is identified at step 510 . If the table value for the matched ETG in the dx-ETG table 201 is S, the matched ETG is shifted at step 514 to the ETG having a table value of P for the dx code. If the table value for the matched ETG returns a value of A, the matched ETG in the patient master active ETG file is changed at step 512 to an ETG having an equivalent table value of C for the dx code. If a table value of either P or C is returned at step 510 , the most recent DOS-to is updated at step 516 in the ETG to the on-record claim date. Further processing of the claim record from steps 509 , 511 and 516 bridges at reference 1 , 520 , to FIG. 6 B.
Turning to FIG. 6B, bridged from reference 1 , 520 , in FIG. 6A, the patient's co-morbidity file is updated with the first dx code at step 522 . A loop beginning at step 524 is then executed to determine whether the ETG assigned by the first diagnosis code should be shifted to another ETG based upon the second, third and fourth diagnoses on record. At step 524 , the second diagnosis is read from the patient's claim record and all valid ETGs for the second diagnosis are read from the dx-ETG table 201 . A logical operand 526 is executed to determine whether one of the valid ETGs for the second diagnosis matches the primary diagnosis ETG. If a negative response is returned to logical operand 526 , a loop back at step 527 is executed to step 524 for the next sequential diagnosis code on record, i.e., the third and forth diagnosis codes on record. If an affirmative response is returned to the logical operand 524 , the logical operand 528 queries the table value of the matched ETG to determine if a value of A is returned from the dx-ETG table. If a negative response is returned, the loop back step 527 is initialized. If an affirmative response is returned, the first dx ETG is flagged for change to a second dx ETG having an equivalent table value of C for the second diagnosis code on record at step 530 . All valid ETGs for the second diagnosis code on record are identified at step 532 from the dx-ETG table. The identified ETGs are then matched with any open active ETGs at step 532 . Program operation then continues at bridge 2 , 536 to FIG. 6 C.
At FIG. 6C the continued operation of the Facility Record Grouping Sub-routine 500 from bridge 2 of FIG. 6 b is illustrated. Logical operand 538 queries the open active ETGs to determine whether a valid match with the identified ETGs exists. If a negative response is returned to logical operand 538 , the patient co-morbidity file is updated with the second diagnosis code at step 544 . If an affirmative response is returned from logical operand 538 , the matched active ETG with the most recent DOS-to value is selected at step 540 . If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 542 .
Processing then continues to identify all valid ETGs for a third diagnosis code on record at step 546 and the identified valid ETGs from step 546 are compared to the active ETGs in the patient's master active ETG file in step 548 .
Bridge 3 , 550 , continues to FIG. 6D, and a logical operand 552 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 548 with any active ETG from the patients master active ETG file. If a negative response is returned to logical operand 538 , the patient's comorbidity file is updated with the third diagnosis code at 558 .
If an affirmative response is returned from logical operand 552 , the matched active ETG with the most recent DOS-to value is selected at step 554 . Again a decisional hierarchy is executed. If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.
The patient's co-morbidity file is then updated with the third diagnosis code on-record at step 558 . Processing then continues to identify all valid ETGs for a fourth diagnosis code on record at step 560 and the identified valid ETGs from step 3318 are compared to the active ETGs in the patient's master active ETG file in step 562 . Bridge reference 4 , 564 , bridges to FIG. 6 D.
Turning to FIG. 6D, a logical operand 566 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 562 with any active ETG from the patients master active ETG file. If a negative response is returned to logical operand 566 , the patient's comorbidity file is updated with the fourth diagnosis code.
If an affirmative response is returned from logical operand 566 , the matched active ETG with the most recent DOS-to value is selected at step 568 . In the event of a tie, a decisional hierarchy is executed. If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched. The selected ETG's most recent DOS-to are updated in the patient's master active ETG file in step 570 and the patient's co-morbidity file is then updated with the fourth diagnosis code on-record at step 572 . A check is then made to determine whether the processed record is the last record for the patient by execution of logical operand 574 and reading the input claim records from the storage means. If logical operand 574 returns an affirmative value, the ETG Definer Sub-routine is called at step 576 , as represented by bridge reference GG. If, however, a negative response is returned to logical operand 574 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means at step 578 .
Ancillary Records
Operation of the Ancillary Record Grouping Sub-routine 600 is illustrated in FIGS. 7A-7B. Like surgery records, ancillary records are grouped to ETGs on the basis of both dx codes and CPT code on record. First all valid ETGs for the treatment or CPT code on-record are identified in step 602 from the CPT-ETG table 401 . Then all valid ETGs for the first dx code on record are identified in step 604 from the dx-ETG table 201 . The ETGs from the CPT-ETG table 401 are then compared at step 606 to the ETGs from the dx-ETG table 201 and a logical operand 608 determines whether there is an ETG match. An affirmative response returned from logical operand 608 continues record processing at bridge D, 610 , which continues on FIG. 7B. A negative response returned from logical operand 608 prompts a look up on the dx-ETG table to determine all valid ETGs for the second diagnosis code on record in step 611 . Step 613 again compares the valid ETGs for the CPT code on record and with the valid ETGs for the second dx code on record and a logical operand 614 is executed to match the second dx code ETG with the CPT code ETG. Again, an affirmative response returned from logical operand 614 continues record processing at bridge D, 610 , which continues on FIG. 7 B. If a negative response is returned to logical operand 614 , a look up on the dx-ETG table occurs to determine all valid ETGs for the third diagnosis code on record in step 615 . Step 616 again compares the valid ETGs for the CPT code on record and with the valid ETGs for the third dx code on-record, which bridges E, 619 , to FIG. 7B for identification of all valid ETGs for the fourth dx code on-record at step 625 .
Step 627 then compares the valid ETGs for the CPT code on record and with the valid ETGs for the fourth dx code on record and a logical operand 629 is executed to match the fourth dx code ETG with the CPT code ETG. An affirmative response returned from logical operand 629 continues to step 616 which compares the matched ETGs with the ETGs in the patient master active ETG file and a query is made at logical operand 618 to determine whether any valid matches exist. If a negative response is returned to logical operand 629 , the record is output to the ETG reserved for a CPT code-dx code mismatch at step 631 and a check is made at step 635 to determine whether the record is the last record for the patient.
If a match is found between the matched ETGs from the dx code-CPT code comparison in step 616 . The matched active ETG with the most recent DOS-to value is selected. In the event of a tie, a decisional hierarchy is executed. If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs. If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected. The sequential episode number of the selected ETG is assigned to the record and the most recent sequential anchor count of the episode from the active ETG file is assigned to the record at step 622 .
If the response to logical operand 618 is negative, the record is assigned to an orphan record ETG at step 633 and maintained in the claims records until subsequent record processing either matches the record to an ETG or the orphan record DOS-from exceeds a one-year time period, at which time the record is output to an error log file.
A check is then made to determine whether this record is the last record for the patient at step 635 . If logical operand 635 returns an affirmative value, the ETG Definer Sub-routine is called at step 642 , as represented by bridge reference GG. If, however, a negative response is returned to logical operand 635 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means at step 644 .
Prescription Drug Records
FIGS. 8A-8C illustrate the operation of the Drug Record Grouping Sub-routine 700 . Drug Record Grouping Sub-routine 700 references two predetermined tables previously written to the storage means. The first of the tables is a National Drug Code (NDC) by Generic Drug Code (GDC) table 800 . This table acts as a translator table to translate a large number of NDCs to a smaller set of GDCs. A second pre-defined table is employed and is constructed as a GDC by ETG table 900 . The GDC by ETG table is used, in conjunction with the NDC by GDC translator table, to identify all valid ETGs for a particular NDC code in the claim record.
Once identified as a drug record in the initial operation of the Episode Assignor Routine 200 , the drug record is read from storage to memory in step 702 . The NDC code on-record is converted to a GDC code by reading from the NDC-GDC table 800 in step 704 . Using the GDC number so identified, all possible valid ETGs for the GDC code are identified in step 706 . The possible valid ETGs for the GDC code are then compared to the patient master active ETG file in step 708 . Following bridge LL, 710 , to FIG. 8B, a logical operand is executed in step 712 based upon the comparison executed in step 708 , to determine whether a match occurs having a table value of P, A, C or S.
If a negative response is returned to logical operand 712 , a check is made to determine whether a match having table value I in the GDC-ETG table 900 exists in step 713 . If another negative response is returned to logical operand 713 , the record is flagged an orphan drug record and assigned to an orphan drug record ETG in step 715 . If an affirmative response is returned to logical operand 713 , the ETG with the highest second value is selected in step 718 (e.g. I 1 , I 2 , I 3 and so on). If more than one ETG having the highest second value exists, the ETG having the most recent DOS-from value is selected. If a tie is again encountered, the first encountered ETG is selected. A sequential episode number and the most recent sequential anchor count of the episode from the patient master active ETG file is assigned to the drug record for the selected ETG in step 720 .
If an affirmative response is returned to logical operand 712 , the ETG having the highest second value, in order of P, S, A, C is selected in step 714 (e.g. P 1 , then P 2 . . . then S 1 , then S 2 . . . and so on). The record is then assigned a sequential episode number of the selected ETG and the most recent sequential anchor count of the episode from the patient master active ETG file in step 716 .
Further processing of the drug record continues from steps 716 , 715 and 720 through bridge MM, 724 and is described with reference to FIG. 8C. A check is made in step 726 to determine whether the drug record is the last drug record for the patient on the record date. If a negative response is returned, a loop back to the top of the Drug Record Grouping Sub-routine 700 is executed. If an affirmative response is returned at step 726 , a check is made to determine whether the drug record is the last record for the patient in step 728 . If logical operand 728 returns an affirmative value, the ETG Definer Sub-routine is called at step 732 , as represented by bridge reference GG. If, however, a negative response is returned to logical operand 728 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means at step 730 .
The Episode Definer Sub-routine is illustrated with reference to FIG. 9 . Episode Definer Routine 118 is employed to assign all non-specific claims records, i.e., those initially assigned to ETG 900, to specific more appropriate ETGs. Episode Definer routine 750 . Once all episodes have been grouped to ETGs, all ETG episodes in both active and closed ETGs are then identified in step 752 by patient age and presence or absence of a comorbidity. The ETG number for each episode is then shifted and re-written to an ETG appropriate for the patient age and/or presence or absence of a comorbidity in step 754 . All patient records are then output in step 756 to the display, to a file or to a printer, along with their shifted ETG number, sequential episode number of the record and in patient master active and closed ETG file for the patient. The Episode Definer routine 750 then writes a single record at step 758 for each episode containing key analytical information, for example: the ETG number, patient age, patient sex, the sequential episode number, the total sum charges, the total sum paid, the earliest anchor record DOS-from value, the last anchor record DOS-to value, patient identification, physician identification, management charges, management charges paid, surgery charges, surgery charges paid, ancillary charges, and ancillary charges paid.
After the single record for each episode is written in step 758 for the patient, processing for the next patient begins by initialization of the next patient master active and closed ETG file, the next patient co-morbidity file, and the patient age file in step 760 and the Eligible Record Check Routine is re-initiated for processing claims records for the next patient at step 762 .
EXAMPLE
FIG. 10 provides an example of Management and Ancillary record clustering over a hypothetical time line for a single patient over a one year period from January, 1995 to December, 1995. FIG. 10 depicts time frames of occurrences for claims classified as management records, i.e., office visit 84 , hospital or emergency room visit 85 , and surgery and surgical follow-up 86 and for claims records classified as ancillary records, i.e., laboratory tests 87 , X-ray and laboratory tests 88 and x-ray 89 . Two time lines are provided. A first timeline 71 includes the diagnosis and the time duration of the diagnosed clinical condition. A second timeline 72 includes the claim events which gave rise to the medical claims. Where claim events occur more than once, an alphabetic designator is added to the reference numeral to denote chronological order of the event. For example, the first office visit is denoted 84 a , the second office visit is denoted 84 b , the third denoted 84 c , etc. Vertical broken lines denote the beginning and end of each Episode Treatment Group 90 , and facilitate correlation of the episode event, e.g., office visit, with the resulting diagnosis, e.g., bronchitis.
A first office visit 84 a resulted in a diagnosis of bronchitis 76 . Office visit 84 a started an episode 90 a for this patient based upon the bronchitis diagnosis 76 . A second office visit 84 b occurred concurrently with the bronchitis episode 90 a , but resulted in a diagnosis of eye infection 77 . Because the eye infection 77 is unrelated to the open bronchitis episode ETG 90a, a new eye infection episode ETG 90 b is started. An X-ray and lab test 88 was taken during the time frame of each of the bronchitis episode 90 a and the eye infection 90 b . Based upon the CPT-ETG table, discussed above, the X-ray and lab test 88 is assigned to the eye infection episode 90 b . A third office visit 84 c and x-ray 89 a occured and related to the bronchitis episode 90 a rather than the eye infection episode 90 b.
A fourth office visit 84 d occured and resulted in a diagnosis of major infection 78 unrelated to the bronchitis diagnosis 76 . Because the major infection 78 is unrelated to the bronchitis, the fourth office visit 84 d opened a new ETG 90 c . Two subsequent lab tests 87 a and 87 b were both assigned to the only open episode, i.e., ETG 90 c .
A fifth office visit 84 e resulted in a diagnosis of benign breast neoplasm 79 , which is unrelated to the major infection ETG 90 c . A fifth office visit 84 e opened a new ETG 90 d because the benign breast neoplasm is unrelated to either the bronchitis episode ETG 90 a , the eye infection episode ETG 90 b , or the major infection episode 90 c . Sixth office visit 84 f was assigned then to the only open episode, i.e., ETG 90 d . Similarly, the surgery and follow-up records 86 a and 86 b related to the benign neoplasm ETG 90 d and are grouped to that ETG.
Some months later, the patient has a seventh office visit 84 g which resulted in a diagnosis of bronchitis 80 . However, because the time period between the prior bronchitis episode 76 and the current bronchitis episode 80 exceeds a pre-determined period of time in which there was an absence of treatment for bronchitis, the bronchitis episode 90 a is closed and the bronchitis episode 90 e is opened. A hospital record 85 occurs as a result of an eye trauma and eye trauma 81 is the resulting diagnosis. Because the eye trauma 85 is unrelated to the bronchitis 80 , a new eye trauma ETG 90 f is started which is open concurrently with the bronchitis ETG 90 e . An eighth office visity 84 h occurs during the time when both ETG 90 e and ETG 90 f are open. Eighth office visity 84 h is, therefore, grouped to the ETG most relevant to the office visity 84 h , i.e., ETG 90 e . A subsequent x-ray record 89 b occurs and is related to the eye trauma diagnosis and is, therefore, grouped to ETG 90 f . Because and absence of treatment has occured for the bronchitis ETG 90 e , that ETG 90 e is closed.
Finally, while the eye trauma ETG 90 f is open, the patient has a routine office visit 84 h which is unrelated to the open ETG 90 f for the eye trauma diagnosis 91 . Because it is unrelated to the open ETG 90 f , the routine office visity 84 i starts and groups to a new episode 90 g which contains only one management record 84 i . An x-ray record 89 c occurs after and is unrelated to the routine office visity 84 i . The only open episode is the eye trauma episode 90 f and the x-ray record 89 c is, therefore, grouped to the eye trauma episode 90 f . At the end of the year, all open episodes, i.e., the eye trauma ETG 90 f are closed.
It will be apparent to those skilled in the art, that the foregoing detailed description of the preferred embodiment of the present invention is representative of a type of health care system within the scope and spirit of the present invention. Further, those skilled in the art will recognize that various changes and modifications may be made without departing from the true spirit and scope of the present invention. Those skilled in the art will recognize that the invention is not limited to the specifics as shown here, but is claimed in any form or modification falling within the scope of the appended claims. For that reason, the scope of the present invention is set forth in the following claims.
TABLE 1
ETG
DESCRIPTION
1
AIDS with major infectious complication
2
AIDS with minor infectious complication
3
AIDS with inflammatory complication
4
AIDS with neoplastic complication, with surgery
5
AIDS with neoplastic complication, w/o surgery
6
HIV sero-positive without AIDS
7
Major infectious disease except HIV, with comorbidity
8
Septicemia, w/o comorbidity
9
Major infectious disease except HIV and septicemia,
w/o comorbidity
10
Minor infectious disease
11
Infectious disease signs & symptoms
20
Diseases of the thyroid gland, with surgery
21
Hyper-functioning thyroid gland
22
Hypo-functioning thyroid gland
23
Non-toxic goiter
24
Malignant neoplasm of the thyroid gland
25
Benign neoplasm of the thyroid gland
26
Other diseases of the thyroid gland
27
Insulin dependent diabetes, with comorbidity
28
Insulin dependent diabetes, w/o comorbidity
29
Non-insulin dependent diabetes, with comorbidity
30
Non-insulin dependent diabetes, w/o comorbidity
31
Malignant neoplasm of the pancreatic gland
32
Benign endocrine disorders of the pancreas
33
Malignant neoplasm of the pituitary gland
34
Benign neoplasm of the pituitary gland
35
Hyper-functioning adrenal gland
36
Hypo-functioning adrenal gland
37
Malignant neoplasm of the adrenal gland
38
Benign neoplasm of the adrenal gland
39
Hyper-functioning parathyroid gland
40
Hypo-functioning parathyroid gland
41
Malignant neoplasm of the parathyroid gland
42
Benign neoplasm of the parathyroid gland
43
Female sex gland disorders
44
Male sex gland disorders
45
Nutritional deficiency
46
Gout
47
Metabolic deficiency except gout
48
Other diseases of the endocrine glands or metabolic disorders,
with surgery
49
Other diseases of the endocrine glands or metabolic disorders,
w/o surgery
50
Endocrine disease signs & symptoms
70
Leukemia with bone marrow transplant
71
Leukemia with splenectomy
72
Leukemia w/o splenectomy
73
Neoplastic disease of blood and lymphatic system except Leukemia
74
Non-neoplastic blood disease with splenectomy
75
Non-neoplastic blood disease, major
76
Non-neoplastic blood disease, minor
77
Hematology signs & symptoms
90
Senile or pre-senile mental condition
91
Organic drug or metabolic disorders
92
Autism and childhood psychosis
93
Inorganic psychoses except infantile autism
94
Neuropsychological & behavioral disorders
95
Personality disorder
96
Mental disease signs & symptoms
110
Cocaine or amphetamine dependence with complications age
less than 16
111
Cocaine or amphetamine dependence with complications
age 16+
112
Cocaine or amphetamine dependence w/o complications age less
than 16
113
Cocaine or amphetamine dependence w/o complications age 16+
114
Alcohol dependence with complications, age less than 16
115
Alcohol dependence with complications, age 16+
116
Alcohol dependence w/o complications, age less than 16
117
Alcohol dependence w/o complications, age 16+
118
Opioid and/or barbiturate dependence, age less than 16
119
Opioid and/or barbiturate dependence, age 16+
120
Other drug dependence, age less than 16
121
Other drug dependence, age 16+
140
Viral meningitis
141
Bacterial and fungal meningitis
142
Viral encephalitis
143
Non-viral encephalitis
144
Parasitic encephalitis
145
Toxic encephalitis
146
Brain abscess, with surgery
147
Brain abscess, w/o surgery
148
Spinal abscess
149
Inflammation of the central nervous system, with surgery
150
Inflammation of the central nervous system, w/o surgery
151
Epilepsy, with surgery
152
Epilepsy, w/o surgery
153
Malignant neoplasm of the central nervous system, with surgery
154
Malignant neoplasm of the central nervous system, w/o surgery
155
Benign neoplasm of the central nervous system, with surgery
156
Benign neoplasm of the central nervous system, w/o surgery
157
Cerebral vascular accident, hemorrhagic, with surgery
158
Cerebral vascular accident, hemorrhagic, w/o surgery
159
Cerebral vascular accident, non-hemorrhagic, with surgery
160
Cerebral vascular accident, non-hemorrhagic, w/o surgery
161
Major brain trauma, with surgery
162
Major brain trauma, w/o surgery
163
Minor brain trauma
164
Spinal trauma, with surgery
165
Spinal trauma, w/o surgery
166
Hereditary and degenerative diseases of the central nervous system,
with surgery
167
Hereditary and degenerative diseases of the central nervous system,
w/o surgery
168
Migraine headache, non-intractable
169
Migraine headache, intractable
170
Congenital and other disorders of the central nervous system,
with surgery
171
Congenital and other disorders of the central nervous system,
w/o surgery
172
Inflammation of the cranial nerves, with surgery
173
Inflammation of the cranial nerves, w/o surgery
174
Carpal tunnel syndrome, with surgery
175
Carpal tunnel syndrome, w/o surgery
176
Inflammation of the non-cranial nerves, except carpal tunnel,
with surgery
177
Inflammation of the non-cranial nerves, except carpal tunnel,
w/o surgery
178
Peripheral nerve neoplasm, with surgery
179
Peripheral nerve neoplasm, w/o surgery
180
Traumatic disorder of the cranial nerves, with surgery
181
Traumatic disorder of the cranial nerves, w/o surgery
182
Traumatic disorder of the non-cranial nerves, with surgery
183
Traumatic disorder of the non-cranial nerves, w/o surgery
184
Congenital disorders of the peripheral nerves
185
Neurological disease signs & symptoms
200
Internal eye infection with surgery
201
Internal eye infection w/o surgery
202
External eye infection, with surgery
203
External eye infection, except conjunctivitis, w/o surgery
204
Conjunctivitis
205
Inflammatory eye disease, with surgery
206
Inflammatory eye disease, w/o surgery
207
Malignant neoplasm of the eye, internal, with surgery
208
Malignant neoplasm of the eye, internal, w/o surgery
209
Malignant neoplasm of the eye, external
210
Benign neoplasm of the eye, internal
211
Benign neoplasm of the eye, external
212
Glaucoma, closed angle with surgery
213
Glaucoma, closed angle w/o surgery
214
Glaucoma, open angle, with surgery
215
Glaucoma, open angle, w/o surgery
216
Cataract, with surgery
217
Cataract, w/o surgery
218
Trauma of the eye, with surgery
219
Trauma of the eye, w/o surgery
220
Congenital anomaly of the eye, with surgery
221
Congenital anomaly of the eye, w/o surgery
222
Diabetic retinopathy, with surgery
223
Diabetic retinopathy, w/o surgery with comorbidity
224
Diabetic retinopathy, w/o surgery w/o comorbidity
225
Non-diabetic vascular retinopathy, with surgery
226
Non-diabetic vascular retinopathy, w/o surgery
227
Other vascular disorders of the eye except retinopathies,
with surgery
228
Other vascular disorders of the eye except retinopathies,
w/o surgery
229
Macular degeneration, with surgery
230
Macular degeneration, w/o surgery
231
Non-macular degeneration, with surgery
232
Non-macular degeneration, w/o surgery
233
Major visual disturbances, with surgery
234
Major visual disturbances, w/o surgery
235
Minor visual disturbances, with surgery
236
Minor visual disturbances, w/o surgery
237
Other diseases and disorders of the eye and adnexa
250
Heart transplant
251
AMI, with coronary artery bypass graft
252
AMI or acquired defect, with valvular procedure
253
AMI, with angioplasty
254
AMI, with arrhythmia, with pacemaker implant
255
AMI, with cardiac catheterization
256
AMI, anterior wall with complication
257
AMI, anterior wall w/o complication
258
AMI, inferior wall with complication
259
AMI, inferior wall w/o complication
260
Ischemic heart disease, w/o AMI, with coronary artery bypass graft
261
Ischemic heart disease, w/o AMI, with valvular procedure
262
Ischemic heart disease, w/o AMI, with angioplasty
263
Ischemic heart disease, w/o AMI, with arrhythmia, with
pacemaker implant
264
Ischemic heart disease, w/o AMI, with cardiac catheterization
265
Ischemic heart disease, w/o AMI
266
Pulmonary heart disease, w/o AMI
267
Aortic aneurysm, with surgery
268
Aortic aneurysm, w/o surgery
269
Cardiac infection, with surgery
270
Cardiac infection, w/o surgery
271
Valvular disorder, with complication
272
Valvular disorder, w/o complication
273
Major conduction disorder, with pacemaker/defibrillator implant
274
Major conduction disorder, w/o pacemaker/defibrillator implant
275
Minor conduction disorder
276
Malignant hypertension with comorbidity
277
Malignant hypertension w/o comorbidity
278
Benign hypertension with comorbidity
279
Benign hypertension w/o comorbidity
280
Cardiac congenital disorder, with surgery
281
Cardiac congenital disorder, w/o surgery
282
Major cardiac trauma, with surgery
283
Major cardiac trauma, w/o surgery
284
Minor cardiac trauma
285
Other cardiac diseases
286
Arterial inflammation, with surgery
287
Major arterial inflammation, w/o surgery
288
Minor arterial inflammation, w/o surgery
289
Major non-inflammatory arterial disease with surgery
290
Arterial embolism/thrombosis, w/o surgery
291
Major non-inflammatory arterial disease, except embolism/-
thrombosis, w/o surgery
292
Atherosclerosis, with surgery
293
Atherosclerosis, w/o surgery
294
Arterial aneurysm, except aorta, with surgery
295
Arterial aneurysm, except aorta, w/o surgery
296
Other minor non-inflammatory arterial disease, with surgery
297
Other minor non-inflammatory arterial disease, w/o surgery
298
Arterial trauma, with surgery
299
Arterial trauma, w/o surgery
300
Vein inflammation, with surgery
301
Embolism and thrombosis of the veins
302
Disorder of the lymphatic channels
303
Phlebitis and thrombophlebitis of the veins
304
Varicose veins of the lower extremity
305
Other minor inflammatory disease of the veins
306
Venous trauma, with surgery
307
Venous trauma, w/o surgery
308
Other diseases of the veins
309
Cardiovascular disease signs & symptoms
320
Infection of the oral cavity
321
Inflammation of the oral cavity, with surgery
322
Inflammation of the oral cavity, w/o surgery
323
Trauma of the oral cavity, with surgery
324
Trauma of the oral cavity, w/o surgery
325
Other diseases of the oral cavity, with surgery
326
Other diseases of the oral cavity, w/o surgery
327
Otitis media, with major surgery
328
Otitis media, with minor surgery
329
Otitis media, w/o surgery
330
Tonsillitis, adenoiditis or pharyngitis, with surgery
331
Tonsillitis, adenoiditis or pharyngitis, w/o surgery
332
Sinusitis and Rhinitis, with surgery
333
Sinusitis and Rhinitis, w/o surgery
334
Other ENT infection, with surgery
335
Other ENT infection, w/o surgery
336
Major ENT inflammatory conditions with surgery
337
Major ENT inflammatory conditions w/o surgery
338
Minor ENT inflammatory conditions with surgery
339
Minor ENT inflammatory conditions w/o surgery
340
ENT malignant neoplasm, with surgery
341
ENT malignant neoplasm, w/o surgery
342
ENT benign neoplasm, with surgery
343
ENT benign neoplasm, w/o surgery
344
ENT congenital anomalies, with surgery
345
ENT congenital anomalies, w/o surgery
346
Hearing disorders, with surgery
347
Hearing disorders, w/o surgery
348
ENT trauma, with surgery
349
ENT trauma, w/o surgery
350
Other ENT disorders, with surgery
351
Other ENT disorders, w/o surgery
352
Otolaryngology disease signs & symptoms
371
Viral pneumonia, with comorbidity
372
Viral pneumonia, w/o comorbidity
373
Bacterial lung infections, with comorbidity
374
Bacterial lung infections, w/o comorbidity
375
Fungal and other pneumonia, with comorbidity
376
Fungal and other pneumonia, w/o comorbidity
377
Pulmonary TB with comorbidity
378
Pulmonary TB w/o comorbidity
379
Disseminated TB with comorbidity
380
Disseminated TB w/o comorbidity
381
Acute bronchitis, with comorbidity, age less than 5
382
Acute bronchitis, with comorbidity, age 5+
383
Acute bronchitis, w/o comorbidity, age less than 5
384
Acute bronchitis, w/o comorbidity, age 5+
385
Minor infectious pulmonary disease other than acute bronchitis
386
Asthma with comorbidity, age less than 18
387
Asthma with comorbidity, age 18+
388
Asthma w/o comorbidity, age less than 18
389
Asthma w/o comorbidity, age 18+
390
Chronic bronchitis, with complication with comorbidity
391
Chronic bronchitis with complication w/o comorbidity
392
Chronic bronchitis, w/o complication with comorbidity
393
Chronic bronchitis w/o complication w/o comorbidity
394
Emphysema, with comorbidity
395
Emphysema w/o comorbidity
396
Occupational and environmental pulmonary diseases,
with comorbidity
397
Occupational and environmental pulmonary diseases,
w/o comorbidity
398
Other inflammatory lung disease, with surgery
399
Other inflammatory lung disease, w/o surgery
400
Malignant pulmonary neoplasm, with surgery
401
Malignant pulmonary neoplasm, w/o surgery
402
Benign pulmonary neoplasm, with surgery
403
Benign pulmonary neoplasm, w/o surgery
404
Chest trauma, with surgery
405
Chest trauma, open, w/o surgery
406
Chest trauma, closed, w/o surgery
407
Pulmonary congenital anomalies, with surgery
408
Pulmonary congenital anomalies, w/o surgery
409
Other pulmonary disorders
410
Pulmonology disease signs & symptoms
430
Infection of the stomach and esophagus with comorbidity
431
Infection of the stomach and esophagus w/o comorbidity
432
Inflammation of the esophagus, with surgery
433
Inflammation of the esophagus, w/o surgery
434
Gastritis and/or duodenitis, complicated
435
Gastritis and/or duodenitis, simple
436
Ulcer, complicated with surgery
437
Ulcer, complicated w/o surgery
438
Ulcer, simple
439
Malignant neoplasm of the stomach and esophagus, with surgery
440
Malignant neoplasm of the stomach and esophagus, w/o surgery
441
Benign neoplasm of the stomach and esophagus, with surgery
442
Benign neoplasm of the stomach and esophagus, w/o surgery
443
Trauma or anomaly of the stomach or esophagus, with surgery
444
Trauma of the stomach or esophagus, w/o surgery
445
Anomaly of the stomach or esophagus, w/o surgery
446
Appendicitis, with rupture
447
Appendicitis, w/o rupture
448
Diverticulitis, with surgery
449
Diverticulitis, w/o surgery
450
Other infectious diseases of the intestines and abdomen
451
Inflammation of the intestines and abdomen with surgery
452
Inflammation of the intestines and abdomen, w/o surgery
453
Malignant neoplasm of the intestines and abdomen, with surgery
454
Malignant neoplasm of the intestines and abdomen, w/o surgery
455
Benign neoplasm of the intestines and abdomen, with surgery
456
Benign neoplasm of the intestines and abdomen, w/o surgery
457
Trauma of the intestines and abdomen, with surgery
458
Trauma of the intestines and abdomen, w/o surgery
459
Congenital anomalies of the intestines and abdomen, with surgery
460
Congenital anomalies of the intestines and abdomen, w/o surgery
461
Vascular disease of the intestines and abdomen
462
Bowel obstruction with surgery
463
Bowel obstruction w/o surgery
464
Irritable bowel syndrome
465
Hernias, except hiatal, with surgery
466
Hernias, except hiatal, w/o surgery
467
Hiatal hernia, with surgery
468
Hiatal hernia, w/o surgery
469
Other diseases of the intestines and abdomen
470
Infection of the rectum or anus, with surgery
471
Infection of the rectum or anus, w/o surgery
472
Hemorrhoids, complicated, with surgery
473
Hemorrhoids, complicated, w/o surgery
474
Hemorrhoids, simple
475
Inflammation of the rectum or anus, with surgery
476
Inflammation of the rectum or anus, w/o surgery
477
Malignant neoplasm of the rectum or anus, with surgery
478
Malignant neoplasm of the rectum or anus, w/o surgery
479
Benign neoplasm of the rectum or anus, with surgery
480
Benign neoplasm of the rectum or anus. w/o surgery
481
Trauma of the rectum or anus, open, with surgery
482
Trauma of the rectum or anus, open, w/o surgery
483
Trauma of the rectum or anus, closed
484
Other diseases and disorders of the rectum and anus, with surgery
485
Other diseases and disorders of the rectum and anus, w/o surgery
486
Gastroenterology disease signs & symptoms
510
Liver Transplant
511
Infectious hepatitis, high severity with comorbidity
512
Infectious hepatitis, high severity w/o comorbidity
513
Infectious hepatitis, low severity with comorbidity
514
Infectious hepatitis, low severity w/o comorbidity
515
Non-infectious hepatitis, with complications
516
Non-infectious hepatitis, w/o complications
517
Cirrhosis, with surgery
518
Cirrhosis, w/o surgery
519
Acute pancreatitis
520
Chronic pancreatitis
521
Cholelithiasis, complicated
522
Cholelithiasis, simple, with surgery
523
Cholelithiasis, simple, w/o surgery
524
Malignant neoplasm of the hepato-biliary system, with surgery
525
Malignant neoplasm of the hepato-biliary system, w/o surgery
526
Benign neoplasm of the hepato-biliary system, with surgery
527
Benign neoplasm of the hepato-biliary system, w/o surgery
528
Trauma of the hepato-biliary system, complicated, with surgery
529
Trauma of the hepato-biliary system, complicated, w/o surgery
530
Trauma of the hepato-biliary system, simple
531
Other diseases of the hepato-biliary system, with surgery
532
Other diseases of the hepato-biliary system, w/o surgery
533
Hepatology disease signs & symptoms
550
Kidney Transplant
551
Acute renal failure, with comorbidity
552
Acute renal failure, w/o comorbidity
553
Chronic renal failure, with ESRD
554
Chronic renal failure, w/o ESRD
555
Acute renal inflammation, with comorbidity
556
Acute renal inflammation, w/o comorbidity
557
Chronic renal inflammation, with surgery
558
Chronic renal inflammation, w/o surgery
559
Nephrotic syndrome, minimal change
560
Nephrotic syndrome
561
Other renal conditions
562
Nephrology disease signs & symptoms
570
Infection of the genitourinary system with surgery
571
Infection of the genitourinary system w/o surgery
572
Sexually transmitted infection of the lower genitourinary system
573
Infection of the lower genitourinary system, not sexually
transmitted
574
Kidney stones, with surgery with comorbidity
575
Kidney stones, with surgery w/o comorbidity
576
Kidney stones, w/o surgery with comorbidity
577
Kidney stones, w/o surgery w/o comorbidity
578
Inflammation of the genitourinary tract except kidney stones,
with surgery
579
Inflammation of the genitourinary tract except kidney stones,
w/o surgery
580
Malignant neoplasm of the prostate, with surgery
581
Malignant neoplasm of the prostate, w/o surgery
582
Benign neoplasm of the prostate, with surgery
583
Benign neoplasm of the prostate, w/o surgery
584
Malignant neoplasm of the genitourinary tract, except prostate,
with surgery
585
Malignant neoplasm of the genitourinary tract, except prostate,
w/o surgery
586
Benign neoplasm of the genitourinary tract, except prostate
with surgery
587
Benign neoplasm of the genitourinary tract, except prostate,
w/o surgery
588
Trauma to the genitourinary tract, with surgery
589
Trauma to the genitourinary tract, w/o surgery
590
Urinary incontinence, with surgery
591
Urinary incontinence, w/o surgery
592
Other diseases of the genitourinary tract, with surgery
593
Other diseases of the genitourinary tract, w/o surgery
594
Urological disease signs & symptoms
610
Normal pregnancy, normal labor & delivery, with cesarean section
611
Normal pregnancy, normal labor & delivery, w/o cesarean section
612
Complicated pregnancy, with cesarean section
613
Complicated pregnancy, w/o cesarean section
614
Hemorrhage during pregnancy, with cesarean section
615
Hemorrhage during pregnancy, w/o cesarean section
616
Other condition during pregnancy, with cesarean section
617
Other condition during pregnancy, w/o cesarean section
618
Fetal problems during pregnancy, with cesarean section
619
Fetal problems during pregnancy, w/o cesarean section
620
Ectopic pregnancy, with surgery
621
Ectopic pregnancy, w/o surgery
622
Spontaneous abortion
623
Non-spontaneous abortion
624
Obstetric signs & symptoms
630
Infection of the ovary and/or fallopian tube, with surgery
631
Infection of the ovary and/or fallopian tube, w/o surgery,
with comorbidity
632
Infection of the ovary and/or fallopian tube, w/o surgery,
w/o comorbidity
633
Infection of the uterus, with surgery
634
Infection of the uterus, w/o surgery, with comorbidity
635
Infection of the uterus, w/o surgery, w/o comorbidity
636
Infection of the cervix, with surgery
637
Infection of the cervix, w/o surgery
638
Vaginal infection, with surgery
639
Monilial infection of the vagina (yeast)
640
Infection of the vagina except monilial
641
Inflammation of the female genital system, with surgery
642
Endometriosis, w/o surgery
643
Inflammatory condition of the female genital tract except
endometriosis, w/o surgery
644
Malignant neoplasm of the female genital tract, with surgery
645
Malignant neoplasm of the female genital tract, w/o surgery
646
Benign neoplasm of the female genital tract, with surgery
647
Benign neoplasm of the female genital tract, w/o surgery
648
Conditions associated with menstruation, with surgery
649
Conditions associated with menstruation, w/o surgery
650
Conditions associated with female infertility, with surgery
651
Conditions associated with female infertility, w/o surgery
652
Other diseases of the female genital tract, with surgery
653
Other diseases of the female genital tract, w/o surgery
654
Malignant neoplasm of the breast, with surgery
655
Malignant neoplasm of the breast, w/o surgery
656
Benign neoplasm of the breast, with surgery
657
Benign neoplasm of the breast, w/o surgery
658
Other disorders of the breast, with surgery
659
Other disorders of the breast, w/o surgery
660
Gynecological signs & symptoms
670
Major bacterial infection of the skin, with surgery
671
Major bacterial infection of the skin, w/o surgery
672
Minor bacterial infection of the skin
673
Viral skin infection
674
Fungal skin infection, with surgery
675
Fungal skin infection, w/o surgery
676
Parasitic skin infection
677
Major inflammation of skin & subcutaneous tissue
678
Minor inflammation of skin & subcutaneous tissue
679
Malignant neoplasm of the skin, major, with surgery
680
Malignant neoplasm of the skin, major, w/o surgery
681
Malignant neoplasm of the skin, minor
682
Benign neoplasm of the skin
683
Major burns, with surgery
684
Major burns, w/o surgery
685
Major skin trauma, except bums, with surgery
686
Major skin trauma, except burns, w/o surgery
687
Minor burn
688
Minor trauma of the skin except burn, with surgery
689
Open wound of the skin, w/o surgery
690
Minor trauma of the skin except burn and open wound, w/o surgery
691
Other skin disorders
692
Dermatological signs & symptoms
710
Infection of the large joints with comorbidity
711
Infection of the large joints w/o comorbidity
712
Infection of the small joints with comorbidity
713
Infection of the small joints w/o comorbidity
714
Degenerative orthopedic diseases with hip or spine surgery
715
Degenerative orthopedic diseases with large joint surgery
716
Degenerative orthopedic diseases with hand or foot surgery
717
Juvenile rheumatoid arthritis with complication with comorbidity
718
Juvenile rheumatoid arthritis with complication w/o comorbidity
719
Juvenile rheumatoid arthritis w/o complication with comorbidity
720
Juvenile rheumatoid arthritis w/o complication w/o comorbidity
721
Adult rheumatoid arthritis with complication with comorbidity
722
Adult rheumatoid arthritis with complication w/o comorbidity
723
Adult rheumatoid arthritis w/o complication with comorbidity
724
Adult rheumatoid arthritis w/o complication w/o comorbidity
725
Lupus, with complication
726
Lupus, w/o complication
727
Autoimmune rheumatologic disease except lupus
728
Inflammation of the joints other than rheumatoid arthritis, with
comorbidity
729
Inflammation of the joints other than rheumatoid arthritis, w/o
comorbidity
730
Degenerative joint disease, generalized
731
Degenerative joint disease, localized with comorbidity
732
Degenerative joint disease, localized w/o comorbidity
733
Infections of bone, with surgery
734
Infections of bone, w/o surgery
735
Maxillofacial fracture or dislocation, with surgery
736
Maxillofacial fracture or dislocation, w/o surgery
737
Pelvis fracture or dislocation, with surgery
738
Pelvis fracture or dislocation, w/o surgery
739
Hip and/or femur fracture or dislocation, with surgery
740
Hip and/or femur fracture or dislocation, open, w/o surgery
741
Hip and/or femur fracture or dislocation, closed, w/o surgery
742
Upper extremity fracture or dislocation, with surgery
743
Upper extremity fracture or dislocation, open, w/o surgery
744
Upper extremity fracture or dislocation, closed, w/o surgery
745
Lower extremity fracture or dislocation, with surgery
746
Lower extremity fracture or dislocation, open, w/o surgery
747
Lower extremity fracture or dislocation, closed, w/o surgery
748
Trunk fracture or dislocation, with surgery
749
Trunk fracture or dislocation, open, w/o surgery
750
Trunk fracture or dislocation, closed, w/o surgery
751
Malignant neoplasm of the bone and connective tissue, head
and neck
752
Malignant neoplasm of the bone and connective tissue other than
head and neck
753
Benign neoplasm of the bone and connective tissue, head and neck
754
Benign neoplasm of the bone and connective tissue other than
head and neck
755
Internal derangement of joints, with surgery
756
Internal derangement of joints, w/o surgery
757
Major orthopedic trauma other than fracture or dislocation,
with surgery
758
Major orthopedic trauma other than fracture or dislocation,
w/o surgery
759
Major neck and back disorders, with surgery
760
Major neck and back disorders, w/o surgery
761
Bursitis and tendinitis, with surgery
762
Bursitis and tendinitis, w/o surgery
763
Minor orthopedic disorder except bursitis and tendinitis,
with surgery
764
Minor neck and back disorder, except bursitis and tendinitis,
w/o surgery
765
Minor orthopedic disorder other than neck and back, except bursitis
and tendinitis, w/o surgery
766
Orthopedic congenital and acquired deformities, with surgery
767
Orthopedic congenital and acquired deformities, w/o surgery
768
Orthopedic and rheumatological signs & symptoms
780
Uncomplicated neonatal management
781
Chromosomal anomalies
782
Metabolic related disorders originating the antenatal period
783
Chemical dependency related disorders originating in the
antenatal period
784
Mechanical related disorders originating in the antenatal period
785
Other disorders originating in the antenatal period
786
Other major neonatal disorders, perinatal origin
787
Other minor neonatal disorders, perinatal origin
788
Neonatal signs & symptoms
796
Exposure to infectious diseases
791
Routine inoculation
792
Non-routine inoculation
793
Prophylactic procedures other than inoculation and exposure to
infectious disease
794
Routine exam
795
Contraceptive management, with surgery
796
Contraceptive management, w/o surgery
797
Conditional exam
798
Major specific procedures not classified elsewhere
799
Minor specific procedures not classified elsewhere
800
Administrative services
801
Other preventative and administrative services
810
Late effects and late complications
811
Environmental trauma
812
Poisonings and toxic effects of drugs
900
Isolated signs, symptoms and non-specific diagnoses or conditions
990
Drug record, no drug module
991
Orphan drug record
992
Non-Rx NDC code
993
Invalid NDC code
994
Invalid provider type, e.g., dentist
995
Record outside date range
996
Invalid CPT-4 code
997
Invalid Dx code
998
Inappropriate Dx-CPT-4 matched record
999
Orphan record | A computer-implemented method for profiling medical claims to assist health care managers in determining the cost-efficiency and service quality of health care providers. The method allows an objective means for measuring and quantifying health care services. An episode treatment group (ETG) is a patient classification unit, which defines groups that are clinically homogenous (similar cause of illness and treatment) and statistically stable. The ETG grouper methodology uses service or segment-level claim data as input data and assigns each service to the appropriate episode. The program identifies concurrent and recurrent episodes, flags records, creates new groupings, shifts groupings for changed conditions, selects the most recent claims, resets windows, makes a determination if the provider is an independent lab and continues to collect information until an absence of treatment is detected. | Provide a concise summary of the essential information conveyed in the context. | [
"REFERENCE TO RELATED APPLICATIONS This patent application is a continuation patent application from U.S. patent application Ser.",
"No. 08/493,728, filed on Jun. 22, 1995, to issue as U.S. Pat. No. 5,835,897 on Nov. 10, 1998.",
"FIELD OF THE INVENTION The present invention relates generally to computer-implemented methods for processing medical claims information.",
"More particularly, the present invention relates to a computer-implemented method for receiving input data relating to a person s medical claim, establishing a management record for the person, establishing episode treatment groups to define groupings of medical episodes of related etiology, correlating subsequent medical claims events to an episode treatment group and manipulating episode treatment groups based upon time windows for each medical condition and co-morbidities.",
"BACKGROUND OF THE INVENTION Due to an increase in health care costs and inefficiency in the health care system, health care providers and service management organizations need health care maintenance systems which receive input medical claim data, correlate the medical claim data and provide a means for quantitatively and qualitatively analyzing provider performance.",
"Because of the complex nature of medical care service data, many clinicians and administrators are not able to efficiently utilize the data.",
"A need exists for a computer program that transforms inpatient and out patient claim data to actionable information, which is logically understood by clinicians and administrators.",
"Performance is quickly becoming the standard by which health care purchasers and informed consumers select their health care providers.",
"Those responsible for the development and maintenance of provider networks search for an objective means to measure and quantify the health care services provided to their clients.",
"Qualitative and quantitative analysis of medical provider performance is a key element for managing and improving a health care network.",
"Operating a successful health care network requires the ability to monitor and quantify medical care costs and care quality.",
"Oftentimes, success depends on the providers'",
"ability to identify and correct problems in their health care system.",
"A need exists, therefore, for an analytical tool for identifying real costs in a given health care management system.",
"To operate a more efficient health care system, health care providers need to optimize health care services and expenditures.",
"Many providers practice outside established utilization and cost norms.",
"Systems that detect inappropriate coding, eliminate potentially inappropriate services or conduct encounter-based payment methodology are insufficient for correcting the inconsistencies of the health care system.",
"When a complication or comorbidity is encountered during the course of treatment, many systems do not reclassify the treatment profile.",
"Existing systems do not adjust for casemix, concurrent conditions or recurrent conditions.",
"A system that compensates for casemix should identify the types of illnesses treated in a given population, determine the extent of resource application to specific types of illnesses, measure and compare the treatment patterns among individual and groups of health care providers and educate providers to more effectively manage risk.",
"When profiling claims, existing systems establish classifications that do not contain a manageable number of groupings, are not clinically homogeneous or are not statistically stable.",
"A need exists, therefore, for a patient classification system that accounts for differences in patient severity and establishes a clearly defined unit of analysis.",
"For many years, computer-implemented programs for increasing health care efficiency have been available for purchase.",
"Included within the current patent literature and competitive information are many programs that are directed to the basic concept of health care systems.",
"The Mohlenbrock, et al.",
"patent, U.S. Pat. No. 4,667,292, issued in 1987, discloses a medical reimbursement computer system which generates a list identifying the most appropriate diagnostic-related group (DRG) and related categories applicable to a given patient for inpatient claims only.",
"The list is limited by a combination of the characteristics of the patient and an initial principal diagnosis.",
"A physician can choose a new designation from a list of related categories while the patient is still being treated.",
"The manually determined ICD-9 numbers can be applied to an available grouper computer program to compare the working DRG to the government's DRG.",
"The Mohlenbrock, et al.",
"patent, U.S. Pat. No. 5,018,067, issued in 1991, discloses an apparatus and method for improved estimation of health resource consumption through the use of diagnostic and/or procedure grouping and severity of illness indicators.",
"This system is a computer-implemented program that calculates the amount of payment to the health provider by extracting the same input data as that identified in the Mohlenbrock '292 Patent teaching the DRG System.",
"The system calculates the severity of the patient's illness then classifies each patient into sub-categories of resource consumption within a designated DRG.",
"A computer combines the input data according to a formula consisting of constants and variables.",
"The variables are known for each patient and relate to the number of ICD codes and the government weighing of the codes.",
"The software program determines a set of constants for use in the formula for a given DRG that minimizes variances between the actual known outcomes and those estimated by use of the formula.",
"Because it is based upon various levels of illness severity within each diagnosis, the results of this system provide a much more homogenous grouping of patients than is provided by the DRGs.",
"Providers can be compared to identify those providers whose practice patterns are of the highest quality and most cost efficient.",
"A set of actual costs incurred can be compared with the estimated costs.",
"After the initial diagnosis, the system determines the expected costs of treating a patient.",
"The Schneiderman patent, U.S. Pat. No. 5,099,424, issued in 1992, discloses a model user application system for clinical data processing that tracks and monitors a simulated out-patient medical practice using database management software.",
"The system allows for a database of patients and the entry of EKG and/or chest x-ray (CXR) test results into separate EKG/CXR records as distinct logical entities.",
"This system requires entry of test results that are not part of the medical claim itself.",
"If not already present, the entry creates a separate lab record that may be holding blood work from the same lab test request.",
"Portions of the information are transferred to the lab record for all request situations.",
"Although the lab record data routine is limited to blood work, each time the routine is run, historical parameter data are sent to a companion lab record along with other data linking both record types.",
"The system also includes a revision of the system's specialist record and the general recommendation from an earlier work for more explicit use in information management.",
"The Tawil patent, U.S. Pat. No. 5,225,976, issued in 1993, discloses an automated health benefit processing system.",
"This system minimizes health care costs by informing the purchasers of medical services about market conditions of those medical services.",
"A database includes, for each covered medical procedure in a specific geographic area, a list of capable providers and their charges.",
"A first processor identifies the insured then generates a treatment plan and the required medical procedures.",
"Next, the first processor retrieves information related to the medical procedures and appends the information to the treatment plan.",
"A second processor generates an actual treatment record including the actual charges.",
"A third processor compares the plan and the actual records to determine the amounts payable to the insured and the provider.",
"The Ertel patent, U.S. Pat. No. 5,307,262, issued in 1994, discloses a patient data quality review method and system.",
"The system performs data quality checks and generates documents to ensure the best description of a case.",
"The system provides file security and tracks the cases through the entire review process.",
"Patient data and system performance data are aggregated into a common database that interfaces with existing data systems.",
"Data profiles categorize data quality problems by type and source.",
"Problems are classified as to potential consequences.",
"The system stores data, processes it to determine misreporting, classifies the case and displays the case-specific patient data and aggregate patient data.",
"The Holloway, et al.",
"patent, U.S. Pat. No. 5,253,164, issued in 1993, discloses a system and method for detecting fraudulent medical claims via examination of service codes.",
"This system interprets medical claims and associated representation according to specific rules and against a predetermined CPT-4 code database.",
"A knowledge base interpreter applies the knowledge base using the rules specified.",
"The database can be updated as new methods of inappropriate coding are discovered.",
"The system recommends appropriate CPT codes or recommends pending the claims until additional information is received.",
"The recommendations are based on the decision rules that physician reviewers have already used on a manual basis.",
"The Cummings patent, U.S. Pat. No. 5,301,105, issued in 1994, discloses an all care health management system.",
"The patient-based system includes an integrated interconnection and interaction of essential health care participants to provide patients with complete support.",
"The system includes interactive participation with the patients employers and banks.",
"The system also integrates all aspects of the optimization of health-inducing diet and life style factors and makes customized recommendations for health-enhancing practices.",
"By pre-certifying patients and procedures, the system enhances health care efficiency and reduces overhead costs.",
"The Dome patent, U.S. Pat. No. 5,325,293, issued in 1994, discloses a system and method for correlating medical procedures and medical billing codes.",
"After an examination, the system automatically determines raw codes directly associated with all of the medical procedures performed or planned to be performed with a particular patient.",
"The system allows the physician to modify the procedures after performing the examination.",
"By manipulating the raw codes, the system generates intermediate and billing codes without altering the raw codes.",
"The Kessler, et al.",
"patent, U.S. Pat. No. 5,324,077, issued in 1994, discloses a negotiable medical data draft for tracking and evaluating medical treatment.",
"This system gathers medical data from ambulatory visits using a medical data draft completed by the provider to obtain payment for services, to permit quality review by medical insurers.",
"In exchange for immediate partial payment of services, providers are required to enter data summarizing the patient's visit on negotiable medical drafts.",
"The partial payments are incentives to providers for participating in the system.",
"The Torma, et al.",
"patent, U.S. Pat. No. 5,365,425, issued in 1994, discloses a method and system for measuring management effectiveness.",
"Quality, cost and access are integrated to provide a holistic description of the effectiveness of care.",
"The system compares general medical treatment databases and surveyed patient perceptions of care.",
"Adjustments based on severity of illness, case weight and military costs are made to the data to ensure that all medical facilities are considered fairly.",
"Health Chex's PEER-A-MED computer program is a physician practice profiling system that provides case-mix adjusted physician analysis based on a clinical severity concept.",
"The system employs a multivariate linear regression analysis to appropriately adjust for case-mix.",
"After adjusting for the complexity of the physician's caseload, the system compares the relative performance of a physician to the performance of the peer group as a whole.",
"The system also compares physician utilization performance for uncomplicated, commonly seen diagnosis.",
"Because the full spectrum of clinical care that is rendered to a patient is not represented in its databases, the system is primarily used as an economic performance measurement tool.",
"This system categorizes the claims into general codes including acute, chronic, mental health and pregnancy.",
"Comorbidity and CPT-4 codes adjust for acuity level.",
"The codes are subcategorized into twenty cluster groups based upon the level of severity.",
"The system buckets the codes for the year and contains no apparent episode building methodology.",
"While the PEER-A-MED system contains clinically heterogeneous groupings, the groupings are not episode-based and recurrent episodes cannot be accounted.",
"Ambulatory Care Groups (ACG) provides a patient-based system that uses the patient and the analysis unit.",
"Patients are assigned to an diagnosis group and an entire year's claims are bucketed into thirty-one diagnosis groups.",
"By pre-defining the diagnosis groups, this is a bucketing-type system and claim management by medical episode does not occur.",
"The system determines if a claim is in one of the buckets.",
"Because different diseases could be categorized into the same ACG, this system is not clinically homogeneous.",
"An additional problem with ACGs is that too many diagnosis groups are in each ACG.",
"Ambulatory Patient Groups (APGs) are a patient classification system designed to explain the amount and type of resources used in an ambulatory visit.",
"Patients in each APG have similar clinical characteristics and similar resource use and cost.",
"Patient characteristics should relate to a common organ system or etiology.",
"The resources used are constant and predictable across the patients within each APG.",
"This system is an encounter-based system because it looks at only one of the patient's encounters with the health care system.",
"This system mainly analyzes outpatient hospital visits and does not address inpatient services.",
"The GMIS system uses a bucketing procedure that profiles by clumps of diagnosis codes including 460 diagnostic episode clusters (DECs).",
"The database is client specific and contains a flexible number and type of analytic data files.",
"This system is episode-based, but it does not account for recurrent episodes, so a patient's complete data history within a one-year period is analyzed as one pseudo-episode.",
"Signs and symptoms do not cluster to the actual disease state, e.g. abdominal pain and appendicitis are grouped in different clusters.",
"This system does not use CPT-4 codes and does not shift the DEC to account for acuity changes during the treatment of a patient.",
"Value Health Sciences offers a value profiling system, under the trademark VALUE PROFILER, which utilizes a DB2 mainframe relational database with 1,800 groups.",
"The system uses ICD9 and CPT-4 codes, which are bucket codes.",
"Based on quality and cost-effectiveness of care, the system evaluates all claims data to produce case-mix-adjusted profiles of networks, specialties, providers and episodes of illness.",
"The pseudo-episode building methodology contains clinically pre-defined time periods during which claims for a patient are associated with a particular condition and designated provider.",
"The automated practice review system analyzes health care claims to identify and correct aberrant claims in a pre-payment mode (Value Coder) and to profile practice patterns in a post-payment mode (Value Profiler).",
"This system does not link signs and symptoms and the diagnoses are non-comprehensive because the profiling is based on the exclusion of services.",
"No apparent shifting of episodes occurs and the episodes can only exist for a preset time because the windows are not recurrent.",
"The medical claim profiling programs described in foregoing patents and non-patent literature demonstrate that, while conventional computer-implemented health care systems exist, they each suffer from the principal disadvantage of not identifying and grouping medical claims on an episodic basis or shifting episodic groupings based upon complications or co-morbidities.",
"The present computer-implemented health care system contains important improvements and advances upon conventional health care systems by identifying concurrent and recurrent episodes, flagging records, creating new groupings, shifting groupings for changed clinical conditions, selecting the most recent claims, resetting windows, making a determination if the provider is an independent lab and continuing to collect information until an absence of treatment is detected.",
"SUMMARY OF THE INVENTION Accordingly, it is a broad aspect of the present invention to provide a computer-implemented medical claims profiling system.",
"It is a further object of the present invention to provide a medical claims profiling system that allows an objective means for measuring and quantifying health care services.",
"It is a further object of the present invention to provide a medical claims profiling system that includes a patient classification system based upon episode treatment groups.",
"It is a further object of the present invention to provide a medical claims profiling system that groups claims to clinically homogeneous and statistically stable episode treatment groups.",
"It is a further object of the present invention to provide a medical claims profiling system that includes claims grouping utilizing service or segment-level claim data as input data.",
"It is a further object of the present invention to provide a medical claims profiling system that assigns each claim to an appropriate episode.",
"It is a further object of the present invention to provide a medical claims profiling system that identifies concurrent and recurrent episodes.",
"It is a further object of the present invention to provide a medical claims profiling system that shifts groupings for changed clinical conditions.",
"It is a further object of the present invention to provide a medical claims profiling system that employs a decisional tree to assign claims to the most relevant episode treatment group.",
"It is a further object of the present invention to provide a medical claims profiling system that resets windows of time based upon complications, co-morbidities or increased severity of clinical conditions.",
"It is a further object of the present invention to provide a health care system that continues to collect claim information and assign claim information to an episode treatment group until an absence of treatment is detected.",
"It is a further object of the present invention to provide a health care system that creates orphan records.",
"It is a further object of the present invention to provide a health care system that creates phantom records.",
"The foregoing objectives are met by the present system that allows an objective means for measuring and quantifying health care services based upon episode treatment groups (ETGs).",
"An episode treatment group (ETG) is a clinically homogenous and statistically stable group of similar illness etiology and therapeutic treatment.",
"ETG grouper method uses service or segment-level claim data as input data and assigns each service to the appropriate episode.",
"ETGs gather all in-patient, ambulatory and ancillary claims into mutually exclusive treatment episodes, regardless of treatment duration, then use clinical algorithms to identify both concurrent and recurrent episodes.",
"ETG grouper method continues to collect information until an absence of treatment is detected for a predetermined period of time commensurate with the episode.",
"For example, a bronchitis episode will have a sixty-day window, while a myocardial infarction may have a one-year window.",
"Subsequent records of the same nature within the window reset the window for an additional period of time until the patient is asymptomatic for the pre-determined time period.",
"ETGs can identify a change in the patient's condition and shift the patient's episode from the initially defined ETG to the ETG that includes the change in condition.",
"ETGs identify all providers treating a single illness episode, allowing the user to uncover specific treatment patterns.",
"After adjusting for case-mix, ETGs measure and compare the financial and clinical performance of individual providers or entire networks.",
"Medical claim data is input as data records by data entry into a computer storage device, such as a hard disk drive.",
"The inventive medical claims profiling system may reside in any of a number of computer system architectures, i.e., it may be run from a stand-alone computer or exist in a client-server system, for example a local area network (LAN) or wide area network (WAN).",
"Once relevant medical claim data is input, claims data is processed by loading the computer program into the computer system memory.",
"During set-up of the program onto the computer system, the computer program will have previously set pointers to the physical location of the data files and look-up tables written to the computer storage device.",
"Upon initialization of the inventive computer program, the user is prompted to enter an identifier for a first patient.",
"The program then checks for open episodes for the identified patient, sets flags to identify the open episodes and closes any episodes based upon a predetermined time duration from date of episode to current date.",
"After all open episodes for a patient are identified, the new claims data records are read to memory and validated for type of provider, CPT code and ICD-9 (dx) code, then identified as a management, surgery, facility, ancillary, drug or other record.",
"As used herein, “Management records”",
"are defined as claims that represent a service by a provider engaging in the direct evaluation, management or treatment or a patient.",
"Examples of management records include office visits and therapeutic services.",
"Management records serve as anchor records because they represent focal points in the patient treatment as well as for related ancillary services.",
"“Ancillary records”",
"are claims which represent services which are incidental to the direct evaluation, management and treatment of the patient.",
"Examples of ancillary records include X-ray and laboratory tests.",
"“Surgery records”",
"are specific surgical claims.",
"Surgery records also serve as anchor records.",
"“Facility records”",
"are claims for medical care facility usage.",
"Examples of facility records include hospital room charges or outpatient surgical room charges.",
"“Drug records”",
"are specific for pharmaceutical prescription claims.",
"“Other records”",
"are those medical claim records which are not management, surgery, ancillary, facility or drug records.",
"Invalid records are flagged and logged to an error output file for the user.",
"Valid records are then processed by an ETG Assignor Sub-routine and, based upon diagnosis code, is either matched to existing open episodes for the patient or serve to create new episodes.",
"Management and surgery records serve as “anchor records.”",
"An “anchor record”",
"is a record which originates a diagnosis or a definitive treatment for a given medical condition.",
"Management and surgery records serve as base reference records for facility, ancillary and drug claim records relating to the diagnosis or treatment which is the subject of the management or surgery record.",
"Only management and surgery records can serve to start a given episode.",
"If the record is a management record or a surgery record, the diagnosis code in the claim record is compared with prior related open episodes in an existing look-up table for a possible ETG match.",
"If more than one open episode exists, the program selects the most recent open episode.",
"A positive match signifies that the current episode is related to an existing open episode.",
"After the match is determined, the time window is reset for an additional period of time corresponding to the episode.",
"A loop shifts the originally assigned ETG based on the additional or subsequent diagnoses.",
"If any of the additional or subsequent diagnoses is a defined co-morbidity diagnosis, the patient's co-morbidity file updated.",
"If no match between the first diagnosis code and an open episode is found, a new episode is created.",
"Grouping prescription drug records requires two tables, a NDC (National Drug Code) by GDC (Generic Drug Code) table and a GDC by ETG table.",
"Because the NDC table has approximately 200,000 entries, it has been found impracticable to directly construct an NDC by ETG table.",
"For this reason the NDC by GDC table serves as a translation table to translate NDCs to GDCs and construct a smaller table based upon GDCs.",
"Reading, then from these tables, the NDC code in the claim data record is read and translated to a GDC code.",
"The program then identifies all valid ETGs for the GDC codes in the claim data record then matches those valid ETGs with active episodes.",
"These and other objects, features and advantages of the present invention will become more apparent to those skilled in the art from the following more detailed description of the non-limiting preferred embodiment of the invention taken with reference to the accompanying Figures.",
"BRIEF DESCRIPTION OF THE DRAWINGS Briefly summarized, a preferred embodiment of the invention is described in conjunction with the illustrative disclosure thereof in the accompanying drawings, in which: FIG. 1 is a diagrammatic representation of a computer system used with the computer-implemented method for analyzing medical claims data in accordance with the present invention.",
"FIG. 2 is a flow diagram illustrating the general functional steps of the computer implemented method for analyzing medical claims data in accordance with the present invention.",
"FIG. 3 is a flow diagram illustrating an Eligible Record Check routine which validates and sorts patient claim data records.",
"FIGS. 4A to 4 F are flow diagrams illustrating the Management Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.",
"FIGS. 5A-5D are flow diagrams illustrating a Surgery Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.",
"FIGS. 6A-6E are flow diagrams illustrating a Facility Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.",
"FIGS. 7A-B are flow diagrams illustrating an Ancillary Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.",
"FIGS. 8A-8C are flow diagrams illustrating a Drug Record Grouping Sub-routine of the ETG Assignor Routine in accordance with the computer-implemented method of the present invention.",
"FIG. 9 is a flow diagram illustrating the Episode Definer Routine in accordance with the computer-implemented method of the present invention.",
"FIG. 10 is diagrammatic timeline illustrating a hypothetical patient diagnosis and medical claims history during a one year period and grouping of claim records as management records and ancillary records with cluster groupings.",
"FIG. 11 is a diagrammatic representation of a I-9 Diagnosis Code (dx) X ETG table illustrating predetermined table values called by the Episode Definer Routine of the present invention.",
"FIG. 12 is a diagrammatic representation of an I-9 Diagnosis Code 9 (dx) X CPT Code table illustrating predetermined table values called by the Episode Definer Routine of the present invention.",
"FIG. 13 is a diagrammatic representation of a National Drug Code (NDC) to Generic Drug Code (GDC) conversion table illustrating predetermined Generic Drug Code values called by the Drug Record Grouping Sub-routine of the Episode Definer Routine of the present invention.",
"FIG. 14 is a diagrammatic representation of a Generic Drug Code (GDC) to Episode Treatment Group (ETG) table illustrating predetermined table values called by the Drug Record Grouping Sub-routine of the Episode Definer Routine of the present invention.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring particularly to the accompanying drawings, the basic structural elements of a health care management system of the present invention are shown.",
"Health care management system consists generally of a computer system 10 .",
"Computer system 10 is capable of running a computer program 12 that incorporates the inventive method is shown in FIG. 1 .",
"The computer system 10 includes a central processing unit (CPU) 14 connected to a keyboard 16 which allows the user to input commands and data into the CPU 14 .",
"It will be understood by those skilled in the art that CPU 14 includes a microprocessor, random access memory (RAM), video display controller boards and at least one storage means, such as a hard disk drive or CD-ROM.",
"The computer system 10 also contains a video display 18 which displays video images to a person using the computer system 10 .",
"The video display screen 18 is capable of displaying video output in the form of text or other video images.",
"Episode Treatment Groups (ETGs) are used to define the basic analytical unit in the computer-implemented method of the present invention.",
"ETGs are episode based and conceptually similar to Diagnostic Related Groups (DRGs), with a principal difference being that DRGs are inpatient only.",
"ETGs encompass both inpatient and outpatient treatment.",
"Using ETGs as the basic episodic definer permits the present invention to track concurrently and recurrently occurring illnesses and correctly identify and assign each service event to the appropriate episode.",
"Additionally, ETGs account for changes in a patient's condition during a course of treatment by shifting from the initially defined ETG to one which includes the changed condition once the changed condition is identified.",
"The inventive medical claims profiling system defines Episode Treatment Groups (ETGs).",
"The number of ETGs may vary, depending upon the definitional specificity the health care management organization desires.",
"Presently, the inventive system defines 558 ETGs, which are assigned ETG Numbers 1-900 distributed across the following medical areas: Infectious Diseases, Endocrinology, Hematology, Psychiatry, Chemical Dependency, Neurology, Ophthalmology, Cardiology, Otolaryngology, Pulmonology, Gastroenterology, Hepatology, Nephrology, Obstetrics, Gynecology, Dermatology, Orthopedics and Rheumatology, Neonatology, Preventative and Administrative and Signs and Isolated Signs, Symptoms and Non-Specific Diagnoses or Conditions.",
"Under the presently existing system, ETG 900 is reserved to “Isolated Signs, Symptoms and Non-Specific Diagnoses or Conditions,” and is an ETG designation used where the diagnosis code is incapable of being assigned to another ETG.",
"A listing of exemplary ETGs for typical episodes is found at Table 1, below.",
"Those skilled in the art will understand, however, that the number of ETGs may change, the ETG numbering system is variable, the ETG classifications may be defined with relatively broader or narrower degrees of specificity and the range of medical specialties may be greater or fewer, as required may be require by the management organization in their medical claims data analysis protocols.",
"An episode may be considered a low outlier or high outlier.",
"Low outliers are episodes with dollar values below the minimum amount which is specific to each ETG.",
"Examples of low outliers include patients which drop from a plan during mid-episode and patients who use out-of-network providers and do not submit claims.",
"High outliers are those episodes with high dollar values greater than the 75th percentile plus 2.5 times the interquartile range, based upon a predefined database.",
"The low and high outlier points are pre-determined and hard-coded into the inventive system and will vary across analysis periods.",
"If no ICD-9 (diagnosis code) on a given record matches the CPT-4 code, i.e., a diagnosis of bronchitis and a CPT of knee x-ray, an invalid code segment results.",
"The inventive system outputs invalid records and discontinues the processing of these records.",
"An invalid ICD-9 code is assigned to ETG 997, an invalid CPT-4 code is assigned to ETG 996 and an invalid provider type is assigned to ETG 995.",
"A sequential anchor count and a sequential episode count are incremented after each ETG assignment.",
"Active open and closed ETG files include ETG number, sequential episode number, most recent anchor from date of service and most recent sequential anchor record count.",
"An alternative embodiment creates a single record for each individual episode containing ETG number, patient age, patient sex, episode number, total charges, total payments, earlier anchor record, last anchor record, whether the episode was closed (“clean finish”), number of days between database start date and earliest anchor record, whether a number of days between database start date and earliest anchor record exceeds the ETG's days interval, patient identification, physician identification, management charges, management paid, surgery charges, surgery paid, ancillary charges and ancillary paid.",
"The inventive system uses clinical algorithms to identify both concurrent and recurrent episodes.",
"Subsequent episodes of the same nature within a window reset the window for an additional period of time until the patient is asymptomatic for a pre-determined time period.",
"If an ETG matches a prior ETG, a recurrent ETG is created and the window is reset.",
"The most recent claim is selected if more than one matched claim exists.",
"If the ETG does not match an active ETG, a new concurrent ETG is created.",
"Comorbidities, complications or a defining surgery could require an update of the patient's condition to an ETG requiring a more aggressive treatment profile.",
"ETG's changes in the patient's clinical condition and shift the patient's episode from the initially defined ETG to an ETG which includes the change in clinical condition.",
"If the claim is an ancillary record and it does not match an active ETG it is designated an “orphan”",
"ancillary record.",
"Termination of an episode is detected by an absence of treatment for a period of time commensurate with the episode.",
"If the claim is a prescription drug record, two pre-defined tables written to the computer data storage medium, are read.",
"The first of the tables is a National Drug Code (NDC) by Generic Drug Code (GDC) table.",
"The GDC code is equivalent to the Generic Drug Code table known in the art.",
"This table acts as a translator table to translate a large number of NDCs to a smaller set of GCNs.",
"A second pre-defined table is employed and is constructed as a GDC by ETG table.",
"The GDC by ETG table is used, in conjunction with the NDC by GDC translator table, to identify all valid ETGs for a particular NDC code in the claim record.",
"To determine specific treatment patterns and performance contributions, the computer-implemented method identifies all providers treating a single illness episode.",
"If a network of providers contains Primary Care Physicians (PCP), the ETGs clearly identify each treatment episode by PCP.",
"Financial and clinical performance of individual providers or entire networks may be monitored and analyzed.",
"To monitor health care cost management abilities of providers, components of a provider's treatment plan may be analyzed by uncovering casemix-adjusted differences in direct patient management, the use of surgery and the prescribing of ancillary services.",
"By identifying excessive utilization and cost areas, continuous quality improvement protocols are readily engineered based on internally or externally derived benchmarks.",
"After adjusting for location and using geographically derived normative charge information, ETG-based analysis compares the cost performance of providers or entire networks.",
"By using geographically derived utilization norms, the present invention forms the methodology base for measuring both prevalence and incidence rates among a given population by quantifying health care demand in one population and comparing it to external utilization norms.",
"This comparison helps to identify health care providers who practice outside established utilization or cost norms.",
"Turning now to FIG. 2, there is illustrated the general operation of the computer-implemented method of the present invention.",
"Those skilled in the art will understand that the present invention is first read from a removable, transportable recordable medium, such as a floppy disk, magnetic tape or a CD-ROM onto a recordable, read-write medium, such as a hard disk drive, resident in the CPU 14 .",
"Upon a user's entry of appropriate initialization commands entered via the keyboard 16 , or other input device, such as a mouse or trackball device, computer object code is read from the hard disk drive into the memory of the CPU 14 and the computer-implemented method is initiated.",
"The computer-implemented method prompts the user by displaying appropriate prompts on display 18 , for data input by the user.",
"Those familiar with medical claims information processing will understand that medical claims information is typically received by a management service organization on paper forms.",
"If this is the case, a user first manually sorts claim records by patient, then input patient data through interfacing with the CPU 14 through the keyboard 16 or other input device.",
"Prior to being submitted to the grouping algorithm, records must be sorted by patient by chronological date of service.",
"An Eligible Record Check routine 48 to verify the validity and completeness of the input data.",
"As each record is read by the software, it first checks the date of service on the record and compares it to the last service date of all active episodes to evaluate which episodes have expired in terms of an absence of treatment.",
"These episodes are closed at step 50 .",
"Next the record is identified as either a management 52 , surgery 54 , facility 56 , ancillary 58 or drug 60 record.",
"These types of records are categorized as follows: “Management records”",
"are defined as claims which represent a service by a provider engaging in the direct evaluation, management or treatment or a patient.",
"Examples of management records include office visits, surgeries and therapeutic services.",
"Management records serve as anchor records because they represent focal points in the patient treatment as well as for related ancillary services.",
"“Ancillary records”",
"are claims which represent services which are incidental to the direct evaluation, management and treatment of the patient.",
"Examples of ancillary records include X-ray and laboratory tests.",
"“Surgery records”",
"represent surgical procedures performed by physicians and other like medical allied personnel.",
"Like management records, surgery records also serve as anchor records.",
"“Facility records”",
"are claims for medical care facility usage.",
"Examples of facility records include hospital room charges or ambulatory surgery room charges.",
"“Drug records”",
"are specific for pharmaceutical prescription claims.",
"A “cluster”",
"is a grouping of one, and only one, anchor record, management or surgery, and possibly ancillary, facility and/or drug records.",
"A cluster represents a group of services in which the focal point, and therefore the responsible medical personnel, is the anchor record.",
"An episode is made up of one or more clusters.",
"After the management, surgery, facility, ancillary and drug records are identified at steps 52 , 54 , 56 , 58 and 60 , respectively, an ETG Assignor Sub-routine is executed at step 62 .",
"The ETG Assignor Sub-routine 62 assigns patient medical claims to ETGs based one or more cluster of services related to the same episode, and provides for ETG shifting upon encountering a diagnosis code or CPT code which alters the relationship between the diagnosis or treatment coded in the claim record and an existing ETG assignment.",
"For example, ETG's may be shifted to account for changes in clinical severity, for a more aggressive ETG treatment profile if a complication or comorbidity is encountered during the course of treatment for a given ETG or where a defining surgery is encountered during the course of treatment for a given ETG.",
"When the last claim data record for a given patient is processed by the ETG Assignor Routine 62 , the Episode Definer Routine is executed at step 64 .",
"Episode Definer Routine 64 identifies all open and closed ETG episodes for the patient and appropriately shifts any episodes to a different ETG if such ETG is defined by age and/or the presence or absence of a co-morbidity.",
"The patient records are then output to a file with each record containing the ETG number, a sequential episode number, and a sequential cluster number.",
"Upon input of an identifier for the next patient, the processing of medical claims for the next patient is initiated at step 66 by looping back to check for eligible records for the new patient at step 48 .",
"Operation of the Eligible Record Check routine 100 is illustrated in FIG. 3 .",
"The patient records input by the user are read from the recordable read-write data storage medium into the CPU 14 memory in step 102 .",
"From the patient records read to memory in step 102 , a record validation step 104 is carried out to check provider type, treatment code and diagnosis code against pre-determined CPT code and diagnosis code look up tables.",
"The diagnosis code is preferably the industry standard ICD-9 code and the treatment code is preferably the industry standard CPT-4 code.",
"All valid patient records are assigned as one of a) management record, b) ancillary record, c) surgery record, d) facility record, e) drug record or f other record, and coded as follows: m=management record;",
"a=ancillary record;",
"s=surgery record;",
"f=facility record;",
"d=drug record;",
"or o=other record.",
"A sort of valid records 106 and invalid records 108 from step 104 is made.",
"For valid records 106 in step 110 , patient age is then read to memory from the first patient record from step 106 .",
"All valid records are then sorted by record type in step 112 , i.e., record type m, a, s, f, d or o by a date of service from date (DOS-from).",
"A sort index of all record-type sorted records from step 116 is generated and written to the hard disk, and the ETG Assignor routine 120 is initialized.",
"For invalid records 108 identified at step 104 , the records are assigned ETG designations reserved for records having invalid provider data, invalid treatment code, or invalid diagnosis code, e.g., ETG 995, 996 and 997, respectively, at step 111 .",
"An error log file is output identifying the invalid records by reserved ETG and written to disk or displayed for the user and processing of the invalid records terminates at step 113 .",
"The computer-implemented method of the present invention then initializes an Episode Assignor Routine 200 , the operation of which is illustrated in FIGS. 4A-8C.",
"Episode Assignor Routine 200 consists generally of five Sub-routine modules for processing management records, surgery records, facility records, ancillary records and drug records and assigning claims to proper ETGs.",
"FIGS. 4A-4F illustrate initial identification of records as management, surgery, facility ancillary and drug records and the Management Record Grouping Sub-Routine.",
"FIGS. 5A-5E illustrate operation of the Surgery Record Grouping routine 400 for matching surgery claim records to proper ETGs.",
"FIGS. 6A-6E illustrate operation of the Facility Record Grouping routine 500 for matching facilities records to proper ETGs.",
"FIGS. 7A-7 illustrate operation of the Ancillary Record Grouping routine 600 for matching ancillary records to proper ETGs.",
"Finally, FIGS. 8A-8C illustrate operation of the Drug Records Grouping routine 700 for matching drug records to proper ETGs.",
"Management Records The Episode Assignor routine begins by executing a Management Records Grouping Sub-routine 200 , illustrated in FIGS. 4A-4F, first reads the input claim record for a given patient in step 202 .",
"The first processing of the input claim record entails categorizing the record as a management, surgery, facility, ancillary or drug record at step 204 .",
"A series of logical operands 208 , 210 , 212 and 214 , read the record and determine whether the record is a management record at step 204 , a surgery record at step 208 , a facility record at step 210 , an ancillary record at step 212 or a drug record at step 214 .",
"If an affirmative response is returned in response to logical operand 204 , grouping of the management record to an ETG is initialized and processing of the management record proceeds to step 215 .",
"If, however, a negative response is returned in response to the logical operand 206 , logical operand 208 is executed to determine whether the record is a surgery record.",
"If an affirmative response is returned from logical operand 208 , the Surgery Record Grouping routine 400 is initialized.",
"If, however, a negative response to logical operand 208 is returned, logical operand 210 is executed to determine whether the record is a facility record.",
"If an affirmative response is returned in response to logical operand 210 , the Facility Record Grouping Sub-routine 500 is executed.",
"If, however, a negative response is returned in response to the logical operand 210 , logical operand 212 is executed to determine whether the record is an ancillary record.",
"If an affirmative response is returned from logical operand 212 , the Ancillary Record Grouping Sub-routine 600 is executed.",
"If, however, a negative response to logical operand 212 is returned, logical operand 214 is executed to determine whether the record is a facility record.",
"At this point all records except drug records have been selected.",
"Thus, all the remaining records are drug records and the Drug Record Grouping Sub-routine 700 is executed.",
"Returning now to the initialization of the Management Record Grouping routine 200 , and in particular to step 215 .",
"Once the record has been categorized as a management record in step 206 , the DOS-to value is compared to active episodes for the patient to determine if any active episodes should be closed.",
"Closed episodes are moved to an archive created on the storage means, such as a hard disk or CD-ROM.",
"The management record is examined and the first diagnosis code on record is read, a diagnosis code (dx) by ETG table 201 is read from the storage means and all valid ETGs for the first diagnosis code on record are identified at step 216 .",
"The dx by ETG table 201 consists of a table matrix having diagnosis codes on a first table axis and ETG numbers on a second table axis.",
"At intersection cells of the dx by ETG table are provided table values which serve as operational flags for the inventive method.",
"In accordance with the preferred embodiment of the invention, dx by ETG table values are assigned as follows: P=primary, with only one P value existing per ETG;",
"S=shift;",
"I=incidental;",
"A=shift to ETG with C value;",
"and C=P, where P′ is a shiftable primary value.",
"An illustrative example of a section of a dx by ETG table is found at FIG. 11 .",
"ETG validation in step 216 occurs where for a given diagnosis code on record, the code has either a P, S, I, A or C dx-ETG table value.",
"The ETGs identified as valid for the first diagnosis code on record in step 216 , are then matched with active open ETGs in step 217 by comparing the valid ETGs with the open ETGs identified in step 215 .",
"A logical operand is then executed at step 218 to determine whether a match exists between the valid ETG from the management record and any open ETGs.",
"A negative response at step 218 causes execution of another logical operand at step 220 to determine whether for the first diagnosis code is the P value in the dx-ETG table equal to the ETG for non-specific diagnosis, i.e., ETG 900.",
"If an affirmative response is returned at step 216 , ETG identifiers for the second to the fourth diagnosis codes in the management record are established from the dx-ETG table and the ETG identifier value is matched to active specific ETGs in step 222 and execution of the program continues as represented by designator AA 236 bridging to FIG. 5 B. If, however, a negative response is returned from logical operand 220 , a value of one is added to the management record or anchor count and to the episode count and the ETG with a P value on the dx-ETG table is selected and a new episode is initialized.",
"Further processing of the new episode by the program continues as represented by designator F 236 bridging to FIG. 5 C. If an affirmative response is returned at logical operand step 218 , the matched active ETG with the most recent DOS-to are selected at step 230 .",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"A value of one is then added to the management record or anchor record counter at step 232 and further processing continues as represented by designator G 238 bridging to FIG. 5 C. Turning now to FIG. 4B, which is a continuation from designator AA 236 of FIG. 4A, identifier ETGs for the second to fourth diagnoses in the management record are matched to active ETGs in logical operand 237 .",
"If an affirmative response is returned in response to logical operand 237 , the matched active ETG with the most recent DOS-to is selected in step 240 .",
"If there is a tie between two or more ETGs with the most recent DOS-to value, the most recent DOS-from ETG is selected.",
"If, however, there is a tie between two or more active ETGs with the most recent DOS-from value, then the first encountered ETG is selected in step 240 .",
"A value of one is then added to the sequential anchor record counter in step 241 and operation of the computer-implemented method continues as indicated by designator G 243 bridging to FIG. 5 C. From logical step 237 , if a negative response is returned, the ETG with the second diagnosis value of P is selected at step 242 , then a logical query is made to determine whether the selected ETG is a non-specific ETG, i.e., ETG 900 at step 244 .",
"A negative response to logical query 244 causes a value of one to be added to the sequential anchor count and to the sequential episode count at step 254 .",
"If an affirmative response to logical query 244 is returned, logical queries 246 and 248 are sequentially executed to select ETGs with the third and fourth diagnosis values of P from the dx-ETG table written on the storage means, respectively, and logical query 244 is executed to determine whether the selected ETG is the non-specific ETG, i.e., ETG 900.",
"If a negative response is returned to logical query 244 for the ETG selected in step 248 , a value of one is added to the sequential anchor count and to the sequential episode count in step 254 .",
"If an affirmative response is returned from logical query 244 , a value of one is added to the sequential anchor count and the sequential episode count at step 250 .",
"From step 250 , the non-specific ETG, i.e., ETG 900 is selected and a new episode is started in the active ETG file.",
"The updated sequential episode number, the updated sequential anchor count, the DOS-from and the DOS-to from the record are written to the new episode in the active ETG file in step 252 .",
"From step 254 , the ETG with a dx-ETG table value of P is selected and a new episode is started in the active ETG file.",
"The updated sequential episode number, the updated sequential anchor count, the DOS-from and the DOS-to from the record are written to the new episode in the active ETG file in step 256 .",
"A comorbidity file written on the storage means is then updated with all the dx codes in the management record in step 258 .",
"From each of steps 252 and steps 258 a check is made to determine whether the processed management record is the last record for the patient at logical step 260 .",
"An affirmative response returned to logical step 260 prompts the program operation to the Episode Definer Sub-routine 264 , bridging to FIG. 9 with identifier GG, while a negative response to logical step 260 returns program operation to the beginning of the ETG Assignor routine 200 and the next patient record is read at step 262 .",
"Turning now to FIG. 4C, the bridge reference G 238 is continued from FIG. 4 A. For those records having a match with an open ETG, a query is made at step 270 of the dx-ETG table 201 to determine the table value of the dx code for the selected ETG.",
"Again, valid table values are one of P, S, I, A, or C. If the table value returned from step 270 is A, the selected ETG in the active file is changed at step 272 to the ETG number having an equivalent table value of C for the diagnosis on record.",
"If the table value returned from step 270 is S, the selected ETG in the active file is shifted at step 274 to an ETG value having a table value of P for the diagnosis code on record.",
"If the table value is one of P, I or C, the ETG remains the same and the selected active ETG's most recent DOS-to is updated by writing the record date to the ETG DOS-to field, and the sequential anchor count in the selected active ETG is updated to reflect writing of the record to the ETG at step 276 .",
"At step 278 , the record is then written with a sequential episode number and the sequential anchor count of the selected ETG from the selected active ETG.",
"In this manner, the record is identified with the ETG and the specific episode.",
"The patient's co-morbidity file is flagged with the output read from bridge designator F at step 234 .",
"A patient's comorbidity file is a predefined list of diagnoses which have been identified as comorbidities.",
"If during the course of grouping a patient's records, a management record is encountered which is a comorbidity diagnosis, the ETG for that diagnosis is flagged or “turned on”",
"in the comorbidity file.",
"Then, during the execution of the Episode Definer Routine, all the patient's episodes with an ETG which can shift based on the presence of a comorbidity and which are “turned on”",
"are appropriately shifted to the ETG “with comorbidity.”",
"A loop beginning at step 282 is then executed to determine whether the ETG assigned by the first diagnosis code should be shifted to another ETG based upon the second, third and fourth diagnoses on record.",
"At step 282 , the second diagnosis is read from the patient's claim record and all valid ETGs for the second diagnosis are read from the dx-ETG table 201 .",
"A logical operand 284 is executed to determine whether one of the valid ETGs for the second diagnosis matches the primary diagnosis ETG.",
"If a negative response is returned to logical operand 284 , a loop back at step 285 is executed to step 282 for the next sequential diagnosis code on record, i.e., the third and forth diagnosis codes on record.",
"If an affirmative response is returned to the logical operand 284 , the a logical operand 286 queries the table value of the matched ETG to determine if a value of A is returned from the dx-ETG table.",
"If a negative response is returned, the loop back step 285 is initialized.",
"If an affirmative response is returned, the first dx ETG is flagged for change to a second dx ETG having an equivalent table value of C for the second diagnosis code on record at step 288 and all valid ETGs for the current diagnosis code on record are identified at step 290 from the dx-ETG table.",
"The identified C-value ETG is then matched with any open active ETGs at step 292 .",
"Program operation then continues at bridge H 292 to FIG. 4 D. At FIG. 4D the continued operation of the Management Grouping Sub-routine from bridge H 292 of FIG. 4 C. Logical operand 296 queries the open active ETGs to determine whether a valid match with the identified C-value ETG exists.",
"If a negative response is returned to logical operand 296 , a value of 1 is added to the sequential episode count at step 297 and a new episode having a P value ETG is started in the patient's master active ETG file at step 299 .",
"The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom management record.",
"A phantom record is an anchor record, management or surgery, with more than one diagnosis, which is assigned to one episode and its corresponding ETG based on one diagnosis, but can start a new episode(s) or update the most recent date of another active episode(s) based on other diagnoses on the record.",
"If an affirmative response is returned from logical operand 296 , the matched active ETG with the most recent DOS-to value is selected at step 298 .",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 300 .",
"For either the new episode created at step 299 or the updated ETG from step 300 , the patient's co-morbidity file is then updated with the second diagnosis code on-record at step 302 .",
"Processing then continues to identify all valid ETGs for a third diagnosis code on record at step 304 and the identified valid ETGs from step 304 are compared to the active ETGs in the patient's master active ETG file in step 306 .",
"Bridge I 308 continues to FIG. 4E, and a logical operand 310 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 304 with any active ETG from the patients master active ETG file.",
"If a negative response is returned to logical operand 310 , a value of 1 is added to the sequential episode count at step 311 and a new episode having a P value ETG is started in the patient's master active ETG file at step 313 .",
"The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom management record.",
"If an affirmative response is returned from logical operand 310 , the matched active ETG with the most recent DOS-to value is selected at step 312 .",
"Again a decisional hierarchy is executed.",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 314 .",
"For either the new episode created at step 311 or the updated ETG from step 314 , the patient's co-morbidity file is then updated with the third diagnosis code on-record at step 316 .",
"Processing then continues to identify all valid ETGs for a fourth diagnosis code on record at step 318 and the identified valid ETGs from step 3318 are compared to the active ETGs in the patient's master active ETG file in step 320 .",
"Bridge reference I 322 , bridges to FIG. 4 F. Turning to FIG. 4F, a logical operand 324 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 320 with any active ETG from the patients master active ETG file.",
"If a negative response is returned to logical operand 324 , a value of 1 is added to the sequential episode count at step 325 and a new episode having a P value ETG is started in the patient's master active ETG file at step 337 .",
"The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom management record.",
"If an affirmative response is returned from logical operand 324 , the matched active ETG with the most recent DOS-to value is selected at step 326 .",
"Again a decisional hierarchy is executed.",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 328 .",
"For either the new episode created at step 337 or the updated ETG from step 324 , the patient's co-morbidity file is then updated with the fourth diagnosis code on-record at step 330 .",
"A check is then made to determine whether the processed record is the last record for the patient by execution of logical operand 332 and reading the input claim records from the storage means.",
"If logical operand 332 returns an affirmative value, the ETG Definer Sub-routine is called at step 334 , as represented by bridge reference GG.",
"If, however, a negative response is returned to logical operand 332 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means.",
"Surgery Records Grouping of Surgery Records to ETGs is governed by the Surgery Record Grouping Sub-routine 400 , the operation of which is illustrated in FIGS. 5A-5D.",
"For those patient claim records identified as Surgery Records at step 208 , the DOS-from value on-record is compared with the DOS-to value read from the patient master active ETG file at step 402 .",
"This identifies and flags those active ETGs which are to be closed, the flagged ETGs are then moved to the patient master closed ETG file.",
"The first diagnosis code on-record is then read and compared to the dx-ETG table 201 to identify all possible valid ETGs for the first diagnosis code on-record in step 404 .",
"Surgery records are coded with treatment codes (CPT codes).",
"Each surgery record has a single CPT code value.",
"The CPT code on-record is then read, and compared to a CPT by ETG table 401 previously written to the storage means.",
"The CPT-ETG table will have pre-determined table values.",
"For example, in accordance with the preferred embodiment of the invention, the CPT-ETG table 401 has table values of R, W and X, where R is a value shiftable to W and X is a validator value.",
"All valid ETGs for the on-record CPT code are identified by this comparison at step 406 .",
"A logical operand 408 is then executed to determine whether there is a match of valid ETGs returned from the dx-ETG table 201 and the CPT-ETG table 401 .",
"If an affirmative response is returned to logical operand 408 , a second logical operand 410 is executed to determine whether a match of valid specific ETGs exists.",
"Again, if an affirmative response is returned from second logical operand 410 , the valid specific ETGs matched in step 410 are then compared at step 414 with the open active ETGs for the patient read from the patient's master active ETG file at step 412 .",
"If an affirmative response is returned from step 414 , the matched ETG with the most recent DOS-to is selected at step 416 and a value of 1 is added to the sequential anchor count in the selected ETG at step 418 .",
"In step 416 , if a tie is found based upon most recent DOS-to values, then a decisional hierarchy is followed to select the most recent DOS-from value for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"If a negative response is returned to any of logical operands 408 , 410 or 414 , second, third and fourth dx codes on-record are read and all possible valid ETGs are read in step 411 from the dx-ETG table 201 .",
"Further processing of the valid ETGs output from step 411 is continued at FIG. 5B identified by bridge reference P, 413 .",
"Turning to FIG. 5B, a logical operand 415 compares the valid ETGs for the second, third and fourth dx codes with the valid ETGs for the CPT code on-record in step 411 .",
"If a negative response is returned from logical operand 415 , the patient claim record is assigned to an ETG reserved for match errors between dx code and CPT code, e.g., ETG 998, and further processing of the match error ETG bridges at reference R, 431 , to FIG. 5 D. If an affirmative response is returned from logical operand 415 , the matched ETGs are compared with active ETGs read from the patient master active ETG file at step 417 and logical operand 419 is executed at step 419 to determine whether any valid matches between matched ETGs and active ETGs.",
"If a negative response is returned to logical operand 419 , a value of 1 is added to the sequential anchor count and to the sequential episode count at step 425 and a new episode is started at step 437 with the first dx code on-record having a P value for a specific ETG in the dx-ETG table 201 .",
"If no specific ETG has a P value, a non-specific ETG having a P value for the dx code on record is used to start the new episode.",
"The new episode is started by writing the sequential episode number, the sequential anchor count, the DOS-from and the DOS-to values on the record.",
"If an affirmative response is returned from logical operand 419 , the matched specific ETG with the most recent DOS-to is selected at step 421 .",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"A value of 1 is added to the sequential anchor count at step 423 .",
"Processing the new episode started at step 427 or of the selected matched specific ETG at step 421 continues to bridge Q, 420 , continued at FIG. 5 C. Turning to FIG. 5C, bridged from reference Q, 420 , logical operand 422 is executed which reads the CPT-ETG table 401 and determines the table value of the selected ETG from step 421 and step 427 based on the CPT value on-record.",
"If a table value of R is returned from the read of the CPT-ETG table 401 at step 422 , the matched ETG in the master active ETG file is shifted at step 424 to the ETG with an equivalent value of W for the CPT code on-record.",
"If a table value of X or W is returned from step 422 or from step 242 , the dx-ETG table 201 is read at step 426 and the dx code for the selected matched ETG from the CPT-ETG table 401 or the shifted ETG from step 424 is read.",
"From the dx-ETG table 201 , if a value of S is returned, the matched ETG in the patient master active ETG file is shifted at step 428 to the ETG with a table value of P for the dx code on-record.",
"If a table value of A is returned, the matched ETG in the patient master active ETG file is changed in step 430 to an equivalent value of C for the dx code on-record.",
"If a table value of P, I or C is returned either from logical operand 426 , or from the ETG change step 428 or the ETG shift step 430 , the DOS-to and the sequential anchor count of the ETG in the patient master active ETG file are updated in step 432 .",
"The patient claim record is then assigned and written with the sequential episode number and the sequential anchor count of the selected ETG at step 434 .",
"The patient co-morbidity file is then updated with all diagnosis codes on-record at step 436 .",
"FIG. 5D bridges from FIG. 5C with bridge reference BB, 438 .",
"In FIG. 5D, the diagnosis codes on-record which were not used in the ETG selection described above, are then read from the patient claim record to identify all possible valid ETGs in the dx-ETG table 201 .",
"The identified possible valid ETGs are then matched against the patient master active ETG file in step 442 and logical operand 444 is executed to validate the matches.",
"If an affirmative response is returned to logical operand 444 , for each matched dx code on-record, the matched active ETG with the most recent DOS-to is selected at step 446 .",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The selected ETG's most recent DOS-to value is updated to the date of the patient medical claim, and the sequential anchor count in the active ETG is updated in step 448 .",
"If a negative response is returned to logical operand 444 , a value of 1 is added to sequential episode count at step 456 and a new episode having a P value ETG is started in the patient's master active ETG file at step 458 .",
"The new episode is written with a sequential episode number, DOS-from and DOS-to values and forms a phantom surgery record.",
"If an affirmative response is returned to logical operand 444 , the matched active ETG for each diagnosis code is selected at step 446 on the basis of the most recent DOS-to value.",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The DOS-to field of the selected ETG from step 446 is updated in step 448 to the date of service on-record and the sequential anchor count in the active ETG file is updated.",
"From either step 458 or from step 448 , the patient co-morbidity file is updated to reference the selected ETG and a check is made to determine whether the patient claim record processed in step 429 , which assigned an invalid dx-CPT code match to the record, or from step 450 , which updated the co-morbidity file, is the last record for the patient at logical operand 462 .",
"If an affirmative response is returned to logical operand 462 , record processing proceeds to the Episode Definer Sub-routine at step 464 , bridged by reference GG, to FIG. 9 .",
"If, however, a negative response is returned to logical operand 462 , a loop back 468 to the beginning of the ETG Assigner routine 200 is executed and the next patient claim record is read.",
"Facility Records The Facility Record Grouping Sub-routine 500 assigns facility records to ETGs on the basis of diagnosis codes on-record.",
"The patient claim record is read and the first diagnosis code on-record is read to the dx-ETG table 201 to identify all valid ETGs for the first dx code at step 502 .",
"The identified valid ETGs are then compared to the open active ETGs in the patient master active ETG file in step 504 .",
"Logical operand 506 executes to determine whether any valid matches exist between identified ETGs for the dx code and the active ETGs for the patient.",
"If a negative response is returned to step 506 , a value of 1 is added to the sequential episode count at step 507 and a new episode is started in step 509 in the patient active ETG file with the ETG corresponding to the dx-ETG table value of P. If logical operand 507 returns an affirmative response, a query of the matched ETG value is made at step 508 to determine whether the matched ETG has a table value of P, C, A or S. If a negative response is returned to step 508 , the matched active ETG with the most recent DOS-from value is selected at step 511 .",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"If an affirmative response is returned at step 508 , the table value of the matched ETG table value is identified at step 510 .",
"If the table value for the matched ETG in the dx-ETG table 201 is S, the matched ETG is shifted at step 514 to the ETG having a table value of P for the dx code.",
"If the table value for the matched ETG returns a value of A, the matched ETG in the patient master active ETG file is changed at step 512 to an ETG having an equivalent table value of C for the dx code.",
"If a table value of either P or C is returned at step 510 , the most recent DOS-to is updated at step 516 in the ETG to the on-record claim date.",
"Further processing of the claim record from steps 509 , 511 and 516 bridges at reference 1 , 520 , to FIG. 6 B. Turning to FIG. 6B, bridged from reference 1 , 520 , in FIG. 6A, the patient's co-morbidity file is updated with the first dx code at step 522 .",
"A loop beginning at step 524 is then executed to determine whether the ETG assigned by the first diagnosis code should be shifted to another ETG based upon the second, third and fourth diagnoses on record.",
"At step 524 , the second diagnosis is read from the patient's claim record and all valid ETGs for the second diagnosis are read from the dx-ETG table 201 .",
"A logical operand 526 is executed to determine whether one of the valid ETGs for the second diagnosis matches the primary diagnosis ETG.",
"If a negative response is returned to logical operand 526 , a loop back at step 527 is executed to step 524 for the next sequential diagnosis code on record, i.e., the third and forth diagnosis codes on record.",
"If an affirmative response is returned to the logical operand 524 , the logical operand 528 queries the table value of the matched ETG to determine if a value of A is returned from the dx-ETG table.",
"If a negative response is returned, the loop back step 527 is initialized.",
"If an affirmative response is returned, the first dx ETG is flagged for change to a second dx ETG having an equivalent table value of C for the second diagnosis code on record at step 530 .",
"All valid ETGs for the second diagnosis code on record are identified at step 532 from the dx-ETG table.",
"The identified ETGs are then matched with any open active ETGs at step 532 .",
"Program operation then continues at bridge 2 , 536 to FIG. 6 C. At FIG. 6C the continued operation of the Facility Record Grouping Sub-routine 500 from bridge 2 of FIG. 6 b is illustrated.",
"Logical operand 538 queries the open active ETGs to determine whether a valid match with the identified ETGs exists.",
"If a negative response is returned to logical operand 538 , the patient co-morbidity file is updated with the second diagnosis code at step 544 .",
"If an affirmative response is returned from logical operand 538 , the matched active ETG with the most recent DOS-to value is selected at step 540 .",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The selected ETG's most recent DOS-to and sequential anchor count are updated in the patient's master active ETG file in step 542 .",
"Processing then continues to identify all valid ETGs for a third diagnosis code on record at step 546 and the identified valid ETGs from step 546 are compared to the active ETGs in the patient's master active ETG file in step 548 .",
"Bridge 3 , 550 , continues to FIG. 6D, and a logical operand 552 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 548 with any active ETG from the patients master active ETG file.",
"If a negative response is returned to logical operand 538 , the patient's comorbidity file is updated with the third diagnosis code at 558 .",
"If an affirmative response is returned from logical operand 552 , the matched active ETG with the most recent DOS-to value is selected at step 554 .",
"Again a decisional hierarchy is executed.",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The patient's co-morbidity file is then updated with the third diagnosis code on-record at step 558 .",
"Processing then continues to identify all valid ETGs for a fourth diagnosis code on record at step 560 and the identified valid ETGs from step 3318 are compared to the active ETGs in the patient's master active ETG file in step 562 .",
"Bridge reference 4 , 564 , bridges to FIG. 6 D. Turning to FIG. 6D, a logical operand 566 is executed to query the patient's master active ETG file to determine whether a match exists between the valid ETGs identified in step 562 with any active ETG from the patients master active ETG file.",
"If a negative response is returned to logical operand 566 , the patient's comorbidity file is updated with the fourth diagnosis code.",
"If an affirmative response is returned from logical operand 566 , the matched active ETG with the most recent DOS-to value is selected at step 568 .",
"In the event of a tie, a decisional hierarchy is executed.",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected and matched.",
"The selected ETG's most recent DOS-to are updated in the patient's master active ETG file in step 570 and the patient's co-morbidity file is then updated with the fourth diagnosis code on-record at step 572 .",
"A check is then made to determine whether the processed record is the last record for the patient by execution of logical operand 574 and reading the input claim records from the storage means.",
"If logical operand 574 returns an affirmative value, the ETG Definer Sub-routine is called at step 576 , as represented by bridge reference GG.",
"If, however, a negative response is returned to logical operand 574 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means at step 578 .",
"Ancillary Records Operation of the Ancillary Record Grouping Sub-routine 600 is illustrated in FIGS. 7A-7B.",
"Like surgery records, ancillary records are grouped to ETGs on the basis of both dx codes and CPT code on record.",
"First all valid ETGs for the treatment or CPT code on-record are identified in step 602 from the CPT-ETG table 401 .",
"Then all valid ETGs for the first dx code on record are identified in step 604 from the dx-ETG table 201 .",
"The ETGs from the CPT-ETG table 401 are then compared at step 606 to the ETGs from the dx-ETG table 201 and a logical operand 608 determines whether there is an ETG match.",
"An affirmative response returned from logical operand 608 continues record processing at bridge D, 610 , which continues on FIG. 7B.",
"A negative response returned from logical operand 608 prompts a look up on the dx-ETG table to determine all valid ETGs for the second diagnosis code on record in step 611 .",
"Step 613 again compares the valid ETGs for the CPT code on record and with the valid ETGs for the second dx code on record and a logical operand 614 is executed to match the second dx code ETG with the CPT code ETG.",
"Again, an affirmative response returned from logical operand 614 continues record processing at bridge D, 610 , which continues on FIG. 7 B. If a negative response is returned to logical operand 614 , a look up on the dx-ETG table occurs to determine all valid ETGs for the third diagnosis code on record in step 615 .",
"Step 616 again compares the valid ETGs for the CPT code on record and with the valid ETGs for the third dx code on-record, which bridges E, 619 , to FIG. 7B for identification of all valid ETGs for the fourth dx code on-record at step 625 .",
"Step 627 then compares the valid ETGs for the CPT code on record and with the valid ETGs for the fourth dx code on record and a logical operand 629 is executed to match the fourth dx code ETG with the CPT code ETG.",
"An affirmative response returned from logical operand 629 continues to step 616 which compares the matched ETGs with the ETGs in the patient master active ETG file and a query is made at logical operand 618 to determine whether any valid matches exist.",
"If a negative response is returned to logical operand 629 , the record is output to the ETG reserved for a CPT code-dx code mismatch at step 631 and a check is made at step 635 to determine whether the record is the last record for the patient.",
"If a match is found between the matched ETGs from the dx code-CPT code comparison in step 616 .",
"The matched active ETG with the most recent DOS-to value is selected.",
"In the event of a tie, a decisional hierarchy is executed.",
"If a tie is found based upon most recent DOS-to values, then the most recent DOS-from value is selected for matching with active ETGs.",
"If a tie is found at most recent DOS-from values is found, the first encountered ETG is selected.",
"The sequential episode number of the selected ETG is assigned to the record and the most recent sequential anchor count of the episode from the active ETG file is assigned to the record at step 622 .",
"If the response to logical operand 618 is negative, the record is assigned to an orphan record ETG at step 633 and maintained in the claims records until subsequent record processing either matches the record to an ETG or the orphan record DOS-from exceeds a one-year time period, at which time the record is output to an error log file.",
"A check is then made to determine whether this record is the last record for the patient at step 635 .",
"If logical operand 635 returns an affirmative value, the ETG Definer Sub-routine is called at step 642 , as represented by bridge reference GG.",
"If, however, a negative response is returned to logical operand 635 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means at step 644 .",
"Prescription Drug Records FIGS. 8A-8C illustrate the operation of the Drug Record Grouping Sub-routine 700 .",
"Drug Record Grouping Sub-routine 700 references two predetermined tables previously written to the storage means.",
"The first of the tables is a National Drug Code (NDC) by Generic Drug Code (GDC) table 800 .",
"This table acts as a translator table to translate a large number of NDCs to a smaller set of GDCs.",
"A second pre-defined table is employed and is constructed as a GDC by ETG table 900 .",
"The GDC by ETG table is used, in conjunction with the NDC by GDC translator table, to identify all valid ETGs for a particular NDC code in the claim record.",
"Once identified as a drug record in the initial operation of the Episode Assignor Routine 200 , the drug record is read from storage to memory in step 702 .",
"The NDC code on-record is converted to a GDC code by reading from the NDC-GDC table 800 in step 704 .",
"Using the GDC number so identified, all possible valid ETGs for the GDC code are identified in step 706 .",
"The possible valid ETGs for the GDC code are then compared to the patient master active ETG file in step 708 .",
"Following bridge LL, 710 , to FIG. 8B, a logical operand is executed in step 712 based upon the comparison executed in step 708 , to determine whether a match occurs having a table value of P, A, C or S. If a negative response is returned to logical operand 712 , a check is made to determine whether a match having table value I in the GDC-ETG table 900 exists in step 713 .",
"If another negative response is returned to logical operand 713 , the record is flagged an orphan drug record and assigned to an orphan drug record ETG in step 715 .",
"If an affirmative response is returned to logical operand 713 , the ETG with the highest second value is selected in step 718 (e.g. I 1 , I 2 , I 3 and so on).",
"If more than one ETG having the highest second value exists, the ETG having the most recent DOS-from value is selected.",
"If a tie is again encountered, the first encountered ETG is selected.",
"A sequential episode number and the most recent sequential anchor count of the episode from the patient master active ETG file is assigned to the drug record for the selected ETG in step 720 .",
"If an affirmative response is returned to logical operand 712 , the ETG having the highest second value, in order of P, S, A, C is selected in step 714 (e.g. P 1 , then P 2 .",
"then S 1 , then S 2 .",
"and so on).",
"The record is then assigned a sequential episode number of the selected ETG and the most recent sequential anchor count of the episode from the patient master active ETG file in step 716 .",
"Further processing of the drug record continues from steps 716 , 715 and 720 through bridge MM, 724 and is described with reference to FIG. 8C.",
"A check is made in step 726 to determine whether the drug record is the last drug record for the patient on the record date.",
"If a negative response is returned, a loop back to the top of the Drug Record Grouping Sub-routine 700 is executed.",
"If an affirmative response is returned at step 726 , a check is made to determine whether the drug record is the last record for the patient in step 728 .",
"If logical operand 728 returns an affirmative value, the ETG Definer Sub-routine is called at step 732 , as represented by bridge reference GG.",
"If, however, a negative response is returned to logical operand 728 , program execution returns to the step 204 of the Episode Assignor routine 200 and the next patient claim record is read from the storage means at step 730 .",
"The Episode Definer Sub-routine is illustrated with reference to FIG. 9 .",
"Episode Definer Routine 118 is employed to assign all non-specific claims records, i.e., those initially assigned to ETG 900, to specific more appropriate ETGs.",
"Episode Definer routine 750 .",
"Once all episodes have been grouped to ETGs, all ETG episodes in both active and closed ETGs are then identified in step 752 by patient age and presence or absence of a comorbidity.",
"The ETG number for each episode is then shifted and re-written to an ETG appropriate for the patient age and/or presence or absence of a comorbidity in step 754 .",
"All patient records are then output in step 756 to the display, to a file or to a printer, along with their shifted ETG number, sequential episode number of the record and in patient master active and closed ETG file for the patient.",
"The Episode Definer routine 750 then writes a single record at step 758 for each episode containing key analytical information, for example: the ETG number, patient age, patient sex, the sequential episode number, the total sum charges, the total sum paid, the earliest anchor record DOS-from value, the last anchor record DOS-to value, patient identification, physician identification, management charges, management charges paid, surgery charges, surgery charges paid, ancillary charges, and ancillary charges paid.",
"After the single record for each episode is written in step 758 for the patient, processing for the next patient begins by initialization of the next patient master active and closed ETG file, the next patient co-morbidity file, and the patient age file in step 760 and the Eligible Record Check Routine is re-initiated for processing claims records for the next patient at step 762 .",
"EXAMPLE FIG. 10 provides an example of Management and Ancillary record clustering over a hypothetical time line for a single patient over a one year period from January, 1995 to December, 1995.",
"FIG. 10 depicts time frames of occurrences for claims classified as management records, i.e., office visit 84 , hospital or emergency room visit 85 , and surgery and surgical follow-up 86 and for claims records classified as ancillary records, i.e., laboratory tests 87 , X-ray and laboratory tests 88 and x-ray 89 .",
"Two time lines are provided.",
"A first timeline 71 includes the diagnosis and the time duration of the diagnosed clinical condition.",
"A second timeline 72 includes the claim events which gave rise to the medical claims.",
"Where claim events occur more than once, an alphabetic designator is added to the reference numeral to denote chronological order of the event.",
"For example, the first office visit is denoted 84 a , the second office visit is denoted 84 b , the third denoted 84 c , etc.",
"Vertical broken lines denote the beginning and end of each Episode Treatment Group 90 , and facilitate correlation of the episode event, e.g., office visit, with the resulting diagnosis, e.g., bronchitis.",
"A first office visit 84 a resulted in a diagnosis of bronchitis 76 .",
"Office visit 84 a started an episode 90 a for this patient based upon the bronchitis diagnosis 76 .",
"A second office visit 84 b occurred concurrently with the bronchitis episode 90 a , but resulted in a diagnosis of eye infection 77 .",
"Because the eye infection 77 is unrelated to the open bronchitis episode ETG 90a, a new eye infection episode ETG 90 b is started.",
"An X-ray and lab test 88 was taken during the time frame of each of the bronchitis episode 90 a and the eye infection 90 b .",
"Based upon the CPT-ETG table, discussed above, the X-ray and lab test 88 is assigned to the eye infection episode 90 b .",
"A third office visit 84 c and x-ray 89 a occured and related to the bronchitis episode 90 a rather than the eye infection episode 90 b. A fourth office visit 84 d occured and resulted in a diagnosis of major infection 78 unrelated to the bronchitis diagnosis 76 .",
"Because the major infection 78 is unrelated to the bronchitis, the fourth office visit 84 d opened a new ETG 90 c .",
"Two subsequent lab tests 87 a and 87 b were both assigned to the only open episode, i.e., ETG 90 c .",
"A fifth office visit 84 e resulted in a diagnosis of benign breast neoplasm 79 , which is unrelated to the major infection ETG 90 c .",
"A fifth office visit 84 e opened a new ETG 90 d because the benign breast neoplasm is unrelated to either the bronchitis episode ETG 90 a , the eye infection episode ETG 90 b , or the major infection episode 90 c .",
"Sixth office visit 84 f was assigned then to the only open episode, i.e., ETG 90 d .",
"Similarly, the surgery and follow-up records 86 a and 86 b related to the benign neoplasm ETG 90 d and are grouped to that ETG.",
"Some months later, the patient has a seventh office visit 84 g which resulted in a diagnosis of bronchitis 80 .",
"However, because the time period between the prior bronchitis episode 76 and the current bronchitis episode 80 exceeds a pre-determined period of time in which there was an absence of treatment for bronchitis, the bronchitis episode 90 a is closed and the bronchitis episode 90 e is opened.",
"A hospital record 85 occurs as a result of an eye trauma and eye trauma 81 is the resulting diagnosis.",
"Because the eye trauma 85 is unrelated to the bronchitis 80 , a new eye trauma ETG 90 f is started which is open concurrently with the bronchitis ETG 90 e .",
"An eighth office visity 84 h occurs during the time when both ETG 90 e and ETG 90 f are open.",
"Eighth office visity 84 h is, therefore, grouped to the ETG most relevant to the office visity 84 h , i.e., ETG 90 e .",
"A subsequent x-ray record 89 b occurs and is related to the eye trauma diagnosis and is, therefore, grouped to ETG 90 f .",
"Because and absence of treatment has occured for the bronchitis ETG 90 e , that ETG 90 e is closed.",
"Finally, while the eye trauma ETG 90 f is open, the patient has a routine office visit 84 h which is unrelated to the open ETG 90 f for the eye trauma diagnosis 91 .",
"Because it is unrelated to the open ETG 90 f , the routine office visity 84 i starts and groups to a new episode 90 g which contains only one management record 84 i .",
"An x-ray record 89 c occurs after and is unrelated to the routine office visity 84 i .",
"The only open episode is the eye trauma episode 90 f and the x-ray record 89 c is, therefore, grouped to the eye trauma episode 90 f .",
"At the end of the year, all open episodes, i.e., the eye trauma ETG 90 f are closed.",
"It will be apparent to those skilled in the art, that the foregoing detailed description of the preferred embodiment of the present invention is representative of a type of health care system within the scope and spirit of the present invention.",
"Further, those skilled in the art will recognize that various changes and modifications may be made without departing from the true spirit and scope of the present invention.",
"Those skilled in the art will recognize that the invention is not limited to the specifics as shown here, but is claimed in any form or modification falling within the scope of the appended claims.",
"For that reason, the scope of the present invention is set forth in the following claims.",
"TABLE 1 ETG DESCRIPTION 1 AIDS with major infectious complication 2 AIDS with minor infectious complication 3 AIDS with inflammatory complication 4 AIDS with neoplastic complication, with surgery 5 AIDS with neoplastic complication, w/o surgery 6 HIV sero-positive without AIDS 7 Major infectious disease except HIV, with comorbidity 8 Septicemia, w/o comorbidity 9 Major infectious disease except HIV and septicemia, w/o comorbidity 10 Minor infectious disease 11 Infectious disease signs &",
"symptoms 20 Diseases of the thyroid gland, with surgery 21 Hyper-functioning thyroid gland 22 Hypo-functioning thyroid gland 23 Non-toxic goiter 24 Malignant neoplasm of the thyroid gland 25 Benign neoplasm of the thyroid gland 26 Other diseases of the thyroid gland 27 Insulin dependent diabetes, with comorbidity 28 Insulin dependent diabetes, w/o comorbidity 29 Non-insulin dependent diabetes, with comorbidity 30 Non-insulin dependent diabetes, w/o comorbidity 31 Malignant neoplasm of the pancreatic gland 32 Benign endocrine disorders of the pancreas 33 Malignant neoplasm of the pituitary gland 34 Benign neoplasm of the pituitary gland 35 Hyper-functioning adrenal gland 36 Hypo-functioning adrenal gland 37 Malignant neoplasm of the adrenal gland 38 Benign neoplasm of the adrenal gland 39 Hyper-functioning parathyroid gland 40 Hypo-functioning parathyroid gland 41 Malignant neoplasm of the parathyroid gland 42 Benign neoplasm of the parathyroid gland 43 Female sex gland disorders 44 Male sex gland disorders 45 Nutritional deficiency 46 Gout 47 Metabolic deficiency except gout 48 Other diseases of the endocrine glands or metabolic disorders, with surgery 49 Other diseases of the endocrine glands or metabolic disorders, w/o surgery 50 Endocrine disease signs &",
"symptoms 70 Leukemia with bone marrow transplant 71 Leukemia with splenectomy 72 Leukemia w/o splenectomy 73 Neoplastic disease of blood and lymphatic system except Leukemia 74 Non-neoplastic blood disease with splenectomy 75 Non-neoplastic blood disease, major 76 Non-neoplastic blood disease, minor 77 Hematology signs &",
"symptoms 90 Senile or pre-senile mental condition 91 Organic drug or metabolic disorders 92 Autism and childhood psychosis 93 Inorganic psychoses except infantile autism 94 Neuropsychological &",
"behavioral disorders 95 Personality disorder 96 Mental disease signs &",
"symptoms 110 Cocaine or amphetamine dependence with complications age less than 16 111 Cocaine or amphetamine dependence with complications age 16+ 112 Cocaine or amphetamine dependence w/o complications age less than 16 113 Cocaine or amphetamine dependence w/o complications age 16+ 114 Alcohol dependence with complications, age less than 16 115 Alcohol dependence with complications, age 16+ 116 Alcohol dependence w/o complications, age less than 16 117 Alcohol dependence w/o complications, age 16+ 118 Opioid and/or barbiturate dependence, age less than 16 119 Opioid and/or barbiturate dependence, age 16+ 120 Other drug dependence, age less than 16 121 Other drug dependence, age 16+ 140 Viral meningitis 141 Bacterial and fungal meningitis 142 Viral encephalitis 143 Non-viral encephalitis 144 Parasitic encephalitis 145 Toxic encephalitis 146 Brain abscess, with surgery 147 Brain abscess, w/o surgery 148 Spinal abscess 149 Inflammation of the central nervous system, with surgery 150 Inflammation of the central nervous system, w/o surgery 151 Epilepsy, with surgery 152 Epilepsy, w/o surgery 153 Malignant neoplasm of the central nervous system, with surgery 154 Malignant neoplasm of the central nervous system, w/o surgery 155 Benign neoplasm of the central nervous system, with surgery 156 Benign neoplasm of the central nervous system, w/o surgery 157 Cerebral vascular accident, hemorrhagic, with surgery 158 Cerebral vascular accident, hemorrhagic, w/o surgery 159 Cerebral vascular accident, non-hemorrhagic, with surgery 160 Cerebral vascular accident, non-hemorrhagic, w/o surgery 161 Major brain trauma, with surgery 162 Major brain trauma, w/o surgery 163 Minor brain trauma 164 Spinal trauma, with surgery 165 Spinal trauma, w/o surgery 166 Hereditary and degenerative diseases of the central nervous system, with surgery 167 Hereditary and degenerative diseases of the central nervous system, w/o surgery 168 Migraine headache, non-intractable 169 Migraine headache, intractable 170 Congenital and other disorders of the central nervous system, with surgery 171 Congenital and other disorders of the central nervous system, w/o surgery 172 Inflammation of the cranial nerves, with surgery 173 Inflammation of the cranial nerves, w/o surgery 174 Carpal tunnel syndrome, with surgery 175 Carpal tunnel syndrome, w/o surgery 176 Inflammation of the non-cranial nerves, except carpal tunnel, with surgery 177 Inflammation of the non-cranial nerves, except carpal tunnel, w/o surgery 178 Peripheral nerve neoplasm, with surgery 179 Peripheral nerve neoplasm, w/o surgery 180 Traumatic disorder of the cranial nerves, with surgery 181 Traumatic disorder of the cranial nerves, w/o surgery 182 Traumatic disorder of the non-cranial nerves, with surgery 183 Traumatic disorder of the non-cranial nerves, w/o surgery 184 Congenital disorders of the peripheral nerves 185 Neurological disease signs &",
"symptoms 200 Internal eye infection with surgery 201 Internal eye infection w/o surgery 202 External eye infection, with surgery 203 External eye infection, except conjunctivitis, w/o surgery 204 Conjunctivitis 205 Inflammatory eye disease, with surgery 206 Inflammatory eye disease, w/o surgery 207 Malignant neoplasm of the eye, internal, with surgery 208 Malignant neoplasm of the eye, internal, w/o surgery 209 Malignant neoplasm of the eye, external 210 Benign neoplasm of the eye, internal 211 Benign neoplasm of the eye, external 212 Glaucoma, closed angle with surgery 213 Glaucoma, closed angle w/o surgery 214 Glaucoma, open angle, with surgery 215 Glaucoma, open angle, w/o surgery 216 Cataract, with surgery 217 Cataract, w/o surgery 218 Trauma of the eye, with surgery 219 Trauma of the eye, w/o surgery 220 Congenital anomaly of the eye, with surgery 221 Congenital anomaly of the eye, w/o surgery 222 Diabetic retinopathy, with surgery 223 Diabetic retinopathy, w/o surgery with comorbidity 224 Diabetic retinopathy, w/o surgery w/o comorbidity 225 Non-diabetic vascular retinopathy, with surgery 226 Non-diabetic vascular retinopathy, w/o surgery 227 Other vascular disorders of the eye except retinopathies, with surgery 228 Other vascular disorders of the eye except retinopathies, w/o surgery 229 Macular degeneration, with surgery 230 Macular degeneration, w/o surgery 231 Non-macular degeneration, with surgery 232 Non-macular degeneration, w/o surgery 233 Major visual disturbances, with surgery 234 Major visual disturbances, w/o surgery 235 Minor visual disturbances, with surgery 236 Minor visual disturbances, w/o surgery 237 Other diseases and disorders of the eye and adnexa 250 Heart transplant 251 AMI, with coronary artery bypass graft 252 AMI or acquired defect, with valvular procedure 253 AMI, with angioplasty 254 AMI, with arrhythmia, with pacemaker implant 255 AMI, with cardiac catheterization 256 AMI, anterior wall with complication 257 AMI, anterior wall w/o complication 258 AMI, inferior wall with complication 259 AMI, inferior wall w/o complication 260 Ischemic heart disease, w/o AMI, with coronary artery bypass graft 261 Ischemic heart disease, w/o AMI, with valvular procedure 262 Ischemic heart disease, w/o AMI, with angioplasty 263 Ischemic heart disease, w/o AMI, with arrhythmia, with pacemaker implant 264 Ischemic heart disease, w/o AMI, with cardiac catheterization 265 Ischemic heart disease, w/o AMI 266 Pulmonary heart disease, w/o AMI 267 Aortic aneurysm, with surgery 268 Aortic aneurysm, w/o surgery 269 Cardiac infection, with surgery 270 Cardiac infection, w/o surgery 271 Valvular disorder, with complication 272 Valvular disorder, w/o complication 273 Major conduction disorder, with pacemaker/defibrillator implant 274 Major conduction disorder, w/o pacemaker/defibrillator implant 275 Minor conduction disorder 276 Malignant hypertension with comorbidity 277 Malignant hypertension w/o comorbidity 278 Benign hypertension with comorbidity 279 Benign hypertension w/o comorbidity 280 Cardiac congenital disorder, with surgery 281 Cardiac congenital disorder, w/o surgery 282 Major cardiac trauma, with surgery 283 Major cardiac trauma, w/o surgery 284 Minor cardiac trauma 285 Other cardiac diseases 286 Arterial inflammation, with surgery 287 Major arterial inflammation, w/o surgery 288 Minor arterial inflammation, w/o surgery 289 Major non-inflammatory arterial disease with surgery 290 Arterial embolism/thrombosis, w/o surgery 291 Major non-inflammatory arterial disease, except embolism/- thrombosis, w/o surgery 292 Atherosclerosis, with surgery 293 Atherosclerosis, w/o surgery 294 Arterial aneurysm, except aorta, with surgery 295 Arterial aneurysm, except aorta, w/o surgery 296 Other minor non-inflammatory arterial disease, with surgery 297 Other minor non-inflammatory arterial disease, w/o surgery 298 Arterial trauma, with surgery 299 Arterial trauma, w/o surgery 300 Vein inflammation, with surgery 301 Embolism and thrombosis of the veins 302 Disorder of the lymphatic channels 303 Phlebitis and thrombophlebitis of the veins 304 Varicose veins of the lower extremity 305 Other minor inflammatory disease of the veins 306 Venous trauma, with surgery 307 Venous trauma, w/o surgery 308 Other diseases of the veins 309 Cardiovascular disease signs &",
"symptoms 320 Infection of the oral cavity 321 Inflammation of the oral cavity, with surgery 322 Inflammation of the oral cavity, w/o surgery 323 Trauma of the oral cavity, with surgery 324 Trauma of the oral cavity, w/o surgery 325 Other diseases of the oral cavity, with surgery 326 Other diseases of the oral cavity, w/o surgery 327 Otitis media, with major surgery 328 Otitis media, with minor surgery 329 Otitis media, w/o surgery 330 Tonsillitis, adenoiditis or pharyngitis, with surgery 331 Tonsillitis, adenoiditis or pharyngitis, w/o surgery 332 Sinusitis and Rhinitis, with surgery 333 Sinusitis and Rhinitis, w/o surgery 334 Other ENT infection, with surgery 335 Other ENT infection, w/o surgery 336 Major ENT inflammatory conditions with surgery 337 Major ENT inflammatory conditions w/o surgery 338 Minor ENT inflammatory conditions with surgery 339 Minor ENT inflammatory conditions w/o surgery 340 ENT malignant neoplasm, with surgery 341 ENT malignant neoplasm, w/o surgery 342 ENT benign neoplasm, with surgery 343 ENT benign neoplasm, w/o surgery 344 ENT congenital anomalies, with surgery 345 ENT congenital anomalies, w/o surgery 346 Hearing disorders, with surgery 347 Hearing disorders, w/o surgery 348 ENT trauma, with surgery 349 ENT trauma, w/o surgery 350 Other ENT disorders, with surgery 351 Other ENT disorders, w/o surgery 352 Otolaryngology disease signs &",
"symptoms 371 Viral pneumonia, with comorbidity 372 Viral pneumonia, w/o comorbidity 373 Bacterial lung infections, with comorbidity 374 Bacterial lung infections, w/o comorbidity 375 Fungal and other pneumonia, with comorbidity 376 Fungal and other pneumonia, w/o comorbidity 377 Pulmonary TB with comorbidity 378 Pulmonary TB w/o comorbidity 379 Disseminated TB with comorbidity 380 Disseminated TB w/o comorbidity 381 Acute bronchitis, with comorbidity, age less than 5 382 Acute bronchitis, with comorbidity, age 5+ 383 Acute bronchitis, w/o comorbidity, age less than 5 384 Acute bronchitis, w/o comorbidity, age 5+ 385 Minor infectious pulmonary disease other than acute bronchitis 386 Asthma with comorbidity, age less than 18 387 Asthma with comorbidity, age 18+ 388 Asthma w/o comorbidity, age less than 18 389 Asthma w/o comorbidity, age 18+ 390 Chronic bronchitis, with complication with comorbidity 391 Chronic bronchitis with complication w/o comorbidity 392 Chronic bronchitis, w/o complication with comorbidity 393 Chronic bronchitis w/o complication w/o comorbidity 394 Emphysema, with comorbidity 395 Emphysema w/o comorbidity 396 Occupational and environmental pulmonary diseases, with comorbidity 397 Occupational and environmental pulmonary diseases, w/o comorbidity 398 Other inflammatory lung disease, with surgery 399 Other inflammatory lung disease, w/o surgery 400 Malignant pulmonary neoplasm, with surgery 401 Malignant pulmonary neoplasm, w/o surgery 402 Benign pulmonary neoplasm, with surgery 403 Benign pulmonary neoplasm, w/o surgery 404 Chest trauma, with surgery 405 Chest trauma, open, w/o surgery 406 Chest trauma, closed, w/o surgery 407 Pulmonary congenital anomalies, with surgery 408 Pulmonary congenital anomalies, w/o surgery 409 Other pulmonary disorders 410 Pulmonology disease signs &",
"symptoms 430 Infection of the stomach and esophagus with comorbidity 431 Infection of the stomach and esophagus w/o comorbidity 432 Inflammation of the esophagus, with surgery 433 Inflammation of the esophagus, w/o surgery 434 Gastritis and/or duodenitis, complicated 435 Gastritis and/or duodenitis, simple 436 Ulcer, complicated with surgery 437 Ulcer, complicated w/o surgery 438 Ulcer, simple 439 Malignant neoplasm of the stomach and esophagus, with surgery 440 Malignant neoplasm of the stomach and esophagus, w/o surgery 441 Benign neoplasm of the stomach and esophagus, with surgery 442 Benign neoplasm of the stomach and esophagus, w/o surgery 443 Trauma or anomaly of the stomach or esophagus, with surgery 444 Trauma of the stomach or esophagus, w/o surgery 445 Anomaly of the stomach or esophagus, w/o surgery 446 Appendicitis, with rupture 447 Appendicitis, w/o rupture 448 Diverticulitis, with surgery 449 Diverticulitis, w/o surgery 450 Other infectious diseases of the intestines and abdomen 451 Inflammation of the intestines and abdomen with surgery 452 Inflammation of the intestines and abdomen, w/o surgery 453 Malignant neoplasm of the intestines and abdomen, with surgery 454 Malignant neoplasm of the intestines and abdomen, w/o surgery 455 Benign neoplasm of the intestines and abdomen, with surgery 456 Benign neoplasm of the intestines and abdomen, w/o surgery 457 Trauma of the intestines and abdomen, with surgery 458 Trauma of the intestines and abdomen, w/o surgery 459 Congenital anomalies of the intestines and abdomen, with surgery 460 Congenital anomalies of the intestines and abdomen, w/o surgery 461 Vascular disease of the intestines and abdomen 462 Bowel obstruction with surgery 463 Bowel obstruction w/o surgery 464 Irritable bowel syndrome 465 Hernias, except hiatal, with surgery 466 Hernias, except hiatal, w/o surgery 467 Hiatal hernia, with surgery 468 Hiatal hernia, w/o surgery 469 Other diseases of the intestines and abdomen 470 Infection of the rectum or anus, with surgery 471 Infection of the rectum or anus, w/o surgery 472 Hemorrhoids, complicated, with surgery 473 Hemorrhoids, complicated, w/o surgery 474 Hemorrhoids, simple 475 Inflammation of the rectum or anus, with surgery 476 Inflammation of the rectum or anus, w/o surgery 477 Malignant neoplasm of the rectum or anus, with surgery 478 Malignant neoplasm of the rectum or anus, w/o surgery 479 Benign neoplasm of the rectum or anus, with surgery 480 Benign neoplasm of the rectum or anus.",
"w/o surgery 481 Trauma of the rectum or anus, open, with surgery 482 Trauma of the rectum or anus, open, w/o surgery 483 Trauma of the rectum or anus, closed 484 Other diseases and disorders of the rectum and anus, with surgery 485 Other diseases and disorders of the rectum and anus, w/o surgery 486 Gastroenterology disease signs &",
"symptoms 510 Liver Transplant 511 Infectious hepatitis, high severity with comorbidity 512 Infectious hepatitis, high severity w/o comorbidity 513 Infectious hepatitis, low severity with comorbidity 514 Infectious hepatitis, low severity w/o comorbidity 515 Non-infectious hepatitis, with complications 516 Non-infectious hepatitis, w/o complications 517 Cirrhosis, with surgery 518 Cirrhosis, w/o surgery 519 Acute pancreatitis 520 Chronic pancreatitis 521 Cholelithiasis, complicated 522 Cholelithiasis, simple, with surgery 523 Cholelithiasis, simple, w/o surgery 524 Malignant neoplasm of the hepato-biliary system, with surgery 525 Malignant neoplasm of the hepato-biliary system, w/o surgery 526 Benign neoplasm of the hepato-biliary system, with surgery 527 Benign neoplasm of the hepato-biliary system, w/o surgery 528 Trauma of the hepato-biliary system, complicated, with surgery 529 Trauma of the hepato-biliary system, complicated, w/o surgery 530 Trauma of the hepato-biliary system, simple 531 Other diseases of the hepato-biliary system, with surgery 532 Other diseases of the hepato-biliary system, w/o surgery 533 Hepatology disease signs &",
"symptoms 550 Kidney Transplant 551 Acute renal failure, with comorbidity 552 Acute renal failure, w/o comorbidity 553 Chronic renal failure, with ESRD 554 Chronic renal failure, w/o ESRD 555 Acute renal inflammation, with comorbidity 556 Acute renal inflammation, w/o comorbidity 557 Chronic renal inflammation, with surgery 558 Chronic renal inflammation, w/o surgery 559 Nephrotic syndrome, minimal change 560 Nephrotic syndrome 561 Other renal conditions 562 Nephrology disease signs &",
"symptoms 570 Infection of the genitourinary system with surgery 571 Infection of the genitourinary system w/o surgery 572 Sexually transmitted infection of the lower genitourinary system 573 Infection of the lower genitourinary system, not sexually transmitted 574 Kidney stones, with surgery with comorbidity 575 Kidney stones, with surgery w/o comorbidity 576 Kidney stones, w/o surgery with comorbidity 577 Kidney stones, w/o surgery w/o comorbidity 578 Inflammation of the genitourinary tract except kidney stones, with surgery 579 Inflammation of the genitourinary tract except kidney stones, w/o surgery 580 Malignant neoplasm of the prostate, with surgery 581 Malignant neoplasm of the prostate, w/o surgery 582 Benign neoplasm of the prostate, with surgery 583 Benign neoplasm of the prostate, w/o surgery 584 Malignant neoplasm of the genitourinary tract, except prostate, with surgery 585 Malignant neoplasm of the genitourinary tract, except prostate, w/o surgery 586 Benign neoplasm of the genitourinary tract, except prostate with surgery 587 Benign neoplasm of the genitourinary tract, except prostate, w/o surgery 588 Trauma to the genitourinary tract, with surgery 589 Trauma to the genitourinary tract, w/o surgery 590 Urinary incontinence, with surgery 591 Urinary incontinence, w/o surgery 592 Other diseases of the genitourinary tract, with surgery 593 Other diseases of the genitourinary tract, w/o surgery 594 Urological disease signs &",
"symptoms 610 Normal pregnancy, normal labor &",
"delivery, with cesarean section 611 Normal pregnancy, normal labor &",
"delivery, w/o cesarean section 612 Complicated pregnancy, with cesarean section 613 Complicated pregnancy, w/o cesarean section 614 Hemorrhage during pregnancy, with cesarean section 615 Hemorrhage during pregnancy, w/o cesarean section 616 Other condition during pregnancy, with cesarean section 617 Other condition during pregnancy, w/o cesarean section 618 Fetal problems during pregnancy, with cesarean section 619 Fetal problems during pregnancy, w/o cesarean section 620 Ectopic pregnancy, with surgery 621 Ectopic pregnancy, w/o surgery 622 Spontaneous abortion 623 Non-spontaneous abortion 624 Obstetric signs &",
"symptoms 630 Infection of the ovary and/or fallopian tube, with surgery 631 Infection of the ovary and/or fallopian tube, w/o surgery, with comorbidity 632 Infection of the ovary and/or fallopian tube, w/o surgery, w/o comorbidity 633 Infection of the uterus, with surgery 634 Infection of the uterus, w/o surgery, with comorbidity 635 Infection of the uterus, w/o surgery, w/o comorbidity 636 Infection of the cervix, with surgery 637 Infection of the cervix, w/o surgery 638 Vaginal infection, with surgery 639 Monilial infection of the vagina (yeast) 640 Infection of the vagina except monilial 641 Inflammation of the female genital system, with surgery 642 Endometriosis, w/o surgery 643 Inflammatory condition of the female genital tract except endometriosis, w/o surgery 644 Malignant neoplasm of the female genital tract, with surgery 645 Malignant neoplasm of the female genital tract, w/o surgery 646 Benign neoplasm of the female genital tract, with surgery 647 Benign neoplasm of the female genital tract, w/o surgery 648 Conditions associated with menstruation, with surgery 649 Conditions associated with menstruation, w/o surgery 650 Conditions associated with female infertility, with surgery 651 Conditions associated with female infertility, w/o surgery 652 Other diseases of the female genital tract, with surgery 653 Other diseases of the female genital tract, w/o surgery 654 Malignant neoplasm of the breast, with surgery 655 Malignant neoplasm of the breast, w/o surgery 656 Benign neoplasm of the breast, with surgery 657 Benign neoplasm of the breast, w/o surgery 658 Other disorders of the breast, with surgery 659 Other disorders of the breast, w/o surgery 660 Gynecological signs &",
"symptoms 670 Major bacterial infection of the skin, with surgery 671 Major bacterial infection of the skin, w/o surgery 672 Minor bacterial infection of the skin 673 Viral skin infection 674 Fungal skin infection, with surgery 675 Fungal skin infection, w/o surgery 676 Parasitic skin infection 677 Major inflammation of skin &",
"subcutaneous tissue 678 Minor inflammation of skin &",
"subcutaneous tissue 679 Malignant neoplasm of the skin, major, with surgery 680 Malignant neoplasm of the skin, major, w/o surgery 681 Malignant neoplasm of the skin, minor 682 Benign neoplasm of the skin 683 Major burns, with surgery 684 Major burns, w/o surgery 685 Major skin trauma, except bums, with surgery 686 Major skin trauma, except burns, w/o surgery 687 Minor burn 688 Minor trauma of the skin except burn, with surgery 689 Open wound of the skin, w/o surgery 690 Minor trauma of the skin except burn and open wound, w/o surgery 691 Other skin disorders 692 Dermatological signs &",
"symptoms 710 Infection of the large joints with comorbidity 711 Infection of the large joints w/o comorbidity 712 Infection of the small joints with comorbidity 713 Infection of the small joints w/o comorbidity 714 Degenerative orthopedic diseases with hip or spine surgery 715 Degenerative orthopedic diseases with large joint surgery 716 Degenerative orthopedic diseases with hand or foot surgery 717 Juvenile rheumatoid arthritis with complication with comorbidity 718 Juvenile rheumatoid arthritis with complication w/o comorbidity 719 Juvenile rheumatoid arthritis w/o complication with comorbidity 720 Juvenile rheumatoid arthritis w/o complication w/o comorbidity 721 Adult rheumatoid arthritis with complication with comorbidity 722 Adult rheumatoid arthritis with complication w/o comorbidity 723 Adult rheumatoid arthritis w/o complication with comorbidity 724 Adult rheumatoid arthritis w/o complication w/o comorbidity 725 Lupus, with complication 726 Lupus, w/o complication 727 Autoimmune rheumatologic disease except lupus 728 Inflammation of the joints other than rheumatoid arthritis, with comorbidity 729 Inflammation of the joints other than rheumatoid arthritis, w/o comorbidity 730 Degenerative joint disease, generalized 731 Degenerative joint disease, localized with comorbidity 732 Degenerative joint disease, localized w/o comorbidity 733 Infections of bone, with surgery 734 Infections of bone, w/o surgery 735 Maxillofacial fracture or dislocation, with surgery 736 Maxillofacial fracture or dislocation, w/o surgery 737 Pelvis fracture or dislocation, with surgery 738 Pelvis fracture or dislocation, w/o surgery 739 Hip and/or femur fracture or dislocation, with surgery 740 Hip and/or femur fracture or dislocation, open, w/o surgery 741 Hip and/or femur fracture or dislocation, closed, w/o surgery 742 Upper extremity fracture or dislocation, with surgery 743 Upper extremity fracture or dislocation, open, w/o surgery 744 Upper extremity fracture or dislocation, closed, w/o surgery 745 Lower extremity fracture or dislocation, with surgery 746 Lower extremity fracture or dislocation, open, w/o surgery 747 Lower extremity fracture or dislocation, closed, w/o surgery 748 Trunk fracture or dislocation, with surgery 749 Trunk fracture or dislocation, open, w/o surgery 750 Trunk fracture or dislocation, closed, w/o surgery 751 Malignant neoplasm of the bone and connective tissue, head and neck 752 Malignant neoplasm of the bone and connective tissue other than head and neck 753 Benign neoplasm of the bone and connective tissue, head and neck 754 Benign neoplasm of the bone and connective tissue other than head and neck 755 Internal derangement of joints, with surgery 756 Internal derangement of joints, w/o surgery 757 Major orthopedic trauma other than fracture or dislocation, with surgery 758 Major orthopedic trauma other than fracture or dislocation, w/o surgery 759 Major neck and back disorders, with surgery 760 Major neck and back disorders, w/o surgery 761 Bursitis and tendinitis, with surgery 762 Bursitis and tendinitis, w/o surgery 763 Minor orthopedic disorder except bursitis and tendinitis, with surgery 764 Minor neck and back disorder, except bursitis and tendinitis, w/o surgery 765 Minor orthopedic disorder other than neck and back, except bursitis and tendinitis, w/o surgery 766 Orthopedic congenital and acquired deformities, with surgery 767 Orthopedic congenital and acquired deformities, w/o surgery 768 Orthopedic and rheumatological signs &",
"symptoms 780 Uncomplicated neonatal management 781 Chromosomal anomalies 782 Metabolic related disorders originating the antenatal period 783 Chemical dependency related disorders originating in the antenatal period 784 Mechanical related disorders originating in the antenatal period 785 Other disorders originating in the antenatal period 786 Other major neonatal disorders, perinatal origin 787 Other minor neonatal disorders, perinatal origin 788 Neonatal signs &",
"symptoms 796 Exposure to infectious diseases 791 Routine inoculation 792 Non-routine inoculation 793 Prophylactic procedures other than inoculation and exposure to infectious disease 794 Routine exam 795 Contraceptive management, with surgery 796 Contraceptive management, w/o surgery 797 Conditional exam 798 Major specific procedures not classified elsewhere 799 Minor specific procedures not classified elsewhere 800 Administrative services 801 Other preventative and administrative services 810 Late effects and late complications 811 Environmental trauma 812 Poisonings and toxic effects of drugs 900 Isolated signs, symptoms and non-specific diagnoses or conditions 990 Drug record, no drug module 991 Orphan drug record 992 Non-Rx NDC code 993 Invalid NDC code 994 Invalid provider type, e.g., dentist 995 Record outside date range 996 Invalid CPT-4 code 997 Invalid Dx code 998 Inappropriate Dx-CPT-4 matched record 999 Orphan record"
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to power generation devices, and in particular to a flywheel generator system and method of generating electricity which conserves electric energy by the use of a series of C-shaped or other shape looped coils positioned around a flywheel with magnets extending from the outer edge of the flywheel passing through the coils to generate electricity and with no magnetic material is the coils there is no resistance created thereby providing more efficient electricity generation.
[0006] 2. Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98
[0007] As is known in the prior art, electric generator methods of energy production are based on the principal of electromagnetic induction. The stator of the generator has magnetic material inside of the coil, and when the rotor moves the magnets close to the coil and the magnets are attracted by metal inside of the coil, the metal becomes a magnet itself by magnetic induction, and the impulse of the magnetic field produces electric current in the coil.
[0008] The problem with prior art electric generators is that a rotor with permanent or electric magnets is attracted by magnetic material inside of the coils of the stator to make the rotor spin inside the stator with high magnetic resistance. The more load to the generator the higher the resistance, and more mechanical power must be applied to the rotor of the generator in the order to produce electric energy.
[0009] U.S. Pat. No. 5,341,060, issued Aug. 23, 1994 to Kawamura, claims an engine having a flywheel which has a high peripheral speed even when the engine rotates at a low speed. The flywheel has a plurality of permanent magnets mounted on an outer circumference thereof and having alternately different magnetic poles. A stator is disposed in confronting relation to radially outer ends of the permanent magnets. Electric energy induced by the stator upon rotation of the flywheel is supplied to a rotary electric machine combined with a turbocharger to assist the turbocharger in supplying air under pressure to the engine when the engine rotates at low speed.
[0010] U.S. Pat. No. 3,629,632, issued Dec. 21, 1971 to Loupe, describes a generator for use with a small rotary engine incorporating permanent magnets in its flywheel, the generator being mounted exteriorly of the flywheel and within the flywheel housing, if any is used. The magnets move relative to a stator having a “double-E” configuration with two poles, each of which carry a pair of windings. The windings on each pole are connected in electrical opposition through diodes to supply the desired electrical current. The stator structure is laminated and has preferred physical dimensions.
[0011] U.S. Pat. No. 5,214,333, issued May 25, 1993 to Kawamura, discloses an engine having a flywheel which has a high peripheral speed even when the engine rotates at a low speed. The flywheel has a plurality of permanent magnets mounted on an outer circumference thereof and having alternately different magnetic poles. A stator is disposed in confronting relation to radially outer ends of the permanent magnets. Electric energy induced by the stator upon rotation of the flywheel is supplied to a rotary electric machine combined with a turbocharger to assist the turbocharger in supplying air under pressure to the engine when the engine rotates at low speed.
[0012] U.S. Pat. No. 6,791,225, issued Sep. 14, 2004 to Campbell et al, indicates a flywheel magneto generator having a rotor assembly and a stator assembly. The rotor assembly includes a non-ferromagnetic flywheel and a plurality of magnetic poles that are positioned in spaced relationship around the circumference of the flywheel. The stator assembly includes an E-shaped core with a single magnet mounted on the center leg and coils associated with at least the outer legs. The poles and core may be formed of a bonded iron material. The poles may be joined to the flywheel by press fitting or integral molding, among other methods.
[0013] U.S. Pat. No. 7,132,775, issued Nov. 7, 2006 to Oohashi et al, is for a dynamoelectric stator and a method for the manufacture thereof enabling electrical insulation properties to be improved by forming slot-housed portions with a racetrack-shaped cross section to suppress damage to an electrically-insulating coating arising during mounting of a stator winding to a stator core. The construction is such that the slot-housed portions of the stator winding are formed with the racetrack-shaped cross section, and are housed inside slots so as to line up in single columns in a radial direction with a longitudinal direction of the cross section of the slot-housed portions aligned in a circumferential direction. Thus, because short sides of the slot-housed portions facing inner circumferential side surfaces of the slots form convex curved surfaces, the occurrence of damage to the electrically-insulating coating resulting from rubbing between the short sides of the slot-housed portions and the inner circumferential side surfaces of the slots during insertion of the slot-housed portions into the slots is suppressed, thereby improving electrical insulation properties.
[0014] U.S. Pat. No. 4,460,834, issued Jul. 17, 1984 to Gottfried, provides an uninterruptible power supply to an external load comprising a flywheel generator, a first motor, a standby generator, and a transfer controller. The flywheel generator is adapted to supply energy to the external load. The first motor is drivingly connected to the flywheel generator. The first motor is adapted to be connected to a source of power external to the power system. The standby generator is electrically connected to the first motor. A standby motor is drivingly connected to the standby generator. The transfer controller is adapted to switchably interconnect the first motor to the source of power and to interconnect the standby generator to the first motor. The flywheel generator comprises a flywheel having a vertical axis, a shaft connected to the flywheel, and a synchronous A.C. generator arranged about the shaft. The standby motor is a diesel engine having an electric starter. A voltage regulator is electrically connected about the output of the flywheel generator.
[0015] U.S. Pat. No. 7,126,233, issued Oct. 24, 2006 to Thomas et al, shows a method and apparatus for generating power in a rotating environment without access to the axis of rotation. A non-center engagement generator is implemented within the rotating reference frame of a vehicle wheel. Further, a method and apparatus detect a potential rollover state and prevent occurrence of a rollover state or eliminate a rollover state once attained.
[0016] U.S. Pat. No. 6,891,295, issued May 10, 2005 to Maritomi et al, puts forth a flywheel magneto generator which comprises a rotor having a magnet attached to an outer circumferential side of a flywheel and a stator constructed by winding a generating coil around a core having a magnetic pole portion opposed to a magnetic pole of the rotor, wherein a through hole is formed in a peripheral wall portion of the flywheel, a yoke plate is provided so as to block one end of the through hole which is opened on an inner circumferential side of a peripheral wall portion of the flywheel, the magnet to which a magnet cover is attached is supported on the yoke plate, and one magnetic pole face of the magnet is opposed to the yoke plate.
[0017] What is needed is a more efficient system for generating electricity wherein the coils do not create magnetic resistance.
BRIEF SUMMARY OF THE INVENTION
[0018] An object of the present invention is to provide a flywheel generator system and method of generating electricity which conserves electric energy by the use of a series of C-shaped or other shape looped coils positioned around a flywheel with magnets extending from the outer edge of the flywheel passing through the coils to generate electricity and with no magnetic material is the coils there is no resistance created thereby providing more efficient electricity generation.
[0019] In brief, a series of elongated oval wire windings bent into open C-shaped or other loop shape coils are positioned around a flywheel. Magnets, mating the loop opening shape, extend from the outer edge of the flywheel on a thin disc to pass through the coils to generate electricity with the spin of the flywheel. With no magnetic material is the coils there is no resistance created thereby providing more efficient electricity generation.
[0020] An advantage of the C-coil (C-shaped coil or semicircular coil) of the present invention is that it doesn't have any magnetic material inside the coil and has a special type of coil winding to allow magnets to pass through the winding of the C-coil itself, and because there is no magnetic material at all, so there is no magnetic resistance at all, so that the magnets to go through the C-coils freely, and electro magnetic induction from the magnets makes the windings of each of the C-coils to produce electric current.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] These and other details of the present invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention, and in which drawings:
[0022] FIG. 1 is a diagrammatic view of the flywheel electric generator system of the present invention using loop shaped coils of the present invention showing rechargeable batteries powering the electric motor;
[0023] FIG. 2 is a diagrammatic side elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;
[0024] FIG. 3 is a diagrammatic front elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;
[0025] FIG. 4 is a diagrammatic top elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;
[0026] FIG. 5 is a diagrammatic back elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;
[0027] FIG. 6 is a diagrammatic view of the flywheel electric generator system of the present invention using loop shaped coils of the present invention showing the flywheel and loop coils housed in a vacuum chamber;
[0028] FIG. 7 is a diagrammatic perspective view showing one of the coils of FIG. 1 having a circular loop opening showing the wires wound into the loop;
[0029] FIG. 8 is a diagrammatic perspective view showing one of the coils of FIG. 1 having a rectangular loop opening showing the wires wound into the loop.
DETAILED DESCRIPTION OF THE INVENTION
[0030] In FIGS. 1-8 , a flywheel electric generator system 20 uses loop shaped coils 4 encircling a spinning flywheel 1 so that a series of mating shaped permanent magnets 5 attached to a disc 6 extending from the outer perimeter of the flywheel 1 with the shaped magnets 5 passing through the mating shaped coil openings 17 and 1 7 A to generate electricity in the coils.
[0031] In FIGS. 1 and 6 . the flywheel 1 for the flywheel electric generator system 20 comprises a flywheel 1 of substantial mass and thickness pivoting about a center axis 2 . A thin annular disc 6 extends outwardly from an outer perimeter of the flywheel 1 . The annular disc 6 has a thickness substantially less than the flywheel. A series of magnets 5 attached to an outer perimeter of the annular disc 6 . The magnets 5 each having a mating identical peripheral shape. A source of rotational power causes the flywheel 1 to spin.
[0032] In FIGS. 2-5 , 7 and 8 , a series of coil loops 4 are attached to a structure separate from the flywheel 1 , positioned in a circular array around the outside of the flywheel 1 out of contact with the flywheel. Each of the coil loops 4 comprises an elongated oval coil winding bent into an open loop configuration with the coil ends 18 A and 18 B of the elongated oval coil windings spaced apart in close proximity to form a coil end space 16 and 16 A facing the flywheel 1 to receive the annular disc 6 spinning within the coil end space 16 and 16 A without contacting the coil ends. The open loop configuration of the coil loop 4 forms an interior loop opening 17 and 17 A mating the outer peripheral shape of each of the magnets 5 , the interior loop opening 17 and 17 A being slightly larger than the peripheral shape of each of the magnets 5 so that the magnets spin around as the attached flywheel 1 spins, with the magnets 5 each passing through all of the coil loops 4 with each rotation of the flywheel without contacting the coil loops. Each of the moving magnets 5 generates a flow of electricity is each of the coil loops 4 . The flow of electricity generated in the coils 4 is transmitted from the coil loops 4 to devices for using and storing the flow of electricity.
[0033] In FIGS. 7 and 8 , each of the coil loops 4 and 4 A comprises an electrically conductive wire 15 wound around two spaced posts in a multiplicity of windings to form a built up cable in the shape of a closed elongated oval loop with two parallel spaced sides 19 and two semicircular ends 18 A and 18 B which is bent into an open loop coil configuration having the two semicircular ends 18 A and 18 B positioned in close proximity to leave the coil end space 16 and 16 A between the two semicircular ends 18 A and 18 B with the two parallel sides 19 forming two parallel loops around the interior opening 17 and 17 A.
[0034] In FIGS. 1-7 , each of the coil loops 4 has a circular (or oval) interior opening 17 to form a C-shaped coil loop used with magnets 5 each having a circular (or oval) peripheral shape.
[0035] In FIG. 8 , each of the coil loops 4 has a rectangular interior opening 17 A for a square shaped coil loop used with magnets 5 each having a rectangular peripheral shape.
[0036] The coil loops 4 may have any of a variety of shapes of interior opening 17 and 17 A for any of a variety of shaped coil loops 4 used with magnets 5 each having any of a variety of mating peripheral shapes.
[0037] In FIGS. 1 and 6 , the system 20 preferably comprises an electric motor 7 as a rotational force supply communicating with the flywheel 1 for maintaining the rotation of the flywheel 1 at a desired optimum level for efficiency. A means for detecting the flywheel speed of revolution 12 , such as an RPM counter, controls a means for activating the electric motor 7 , such as a time controller 8 , to speed up the flywheel 1 to a desired rotational speed and deactivating the electric motor 7 upon detecting the desired rotational speed so that the flywheel 1 continues to spin by inertia for maximum output of electricity. The combination of speed of revolution of the flywheel 1 , mass of the flywheel, and diameter of flywheel determine the desired rotational speed of the flywheel.
[0038] The flywheel 1 may be connected to a rotor of the electric motor 7 for turning the flywheel. Alternately, the flywheel 1 may be connected to the electric motor 7 through a transmission interface system 13 for spinning the flywheel.
[0039] To generate electric power in the coils by spinning the flywheel, the flywheel 1 may be connected to at least one of the following rotational power sources 9 taken from the list of rotational power sources comprising an electric motor, an electric motor powered from rechargeable batteries 9 preferably with a charge control 10 and wiring 11 connected to a time controller 8 to the electric motor 7 (shown in FIG. 1 ), an electric motor powered from rechargeable batteries powered by at least one solar panel, an electric motor powered from rechargeable batteries powered by at least one wind generator, an air motor, an air turbine, a wind turbine, an engine, a rotational force source from pressurized air, a rotational force source from pressurized vapor, a rotational force source from pressurized vapor of a liquid gas or other sources of rotational power.
[0040] A vacuum chamber 14 , as shown in FIG. 6 , may be used for containing the flywheel 1 and the series of coil loops 4 inside of the vacuum chamber to lower air resistance for greater efficiency in generating electricity.
[0041] The center axis 2 of the flywheel may comprise or connect with at least one of the following rotation devices taken from the list of rotation devices comprising bearings 3 , low friction bearings, magnetic bearings, and electromagnetic bearings for minimizing rotational friction for optimum performance of the flywheel.
[0042] A great advantage of using a shaped loop wire coil is that it doesn't have any magnetic material inside and has a special type of coil winding with the elongated wire winding loop bent into a shaped loop which allows magnets to go through the winding of shaped loop coil itself. Because there is no magnetic material at all in the shaped loop coil, therefore there is no magnetic resistance at all, which allows the magnets to go through shaped loop coil freely, while at the same time electro magnetic induction from the magnets makes the winding of the shaped loop coil produce electric current. The shaped loop coil can have any type of shape of winding. What is most important is that it has a narrow opening in the windings facing the flywheel 1 to allow the disc 6 or other element holding the magnets 5 to fit through the narrow opening and maintain the magnets within the loop opening without touching the loop itself while the magnets 5 spin through all of the loops 4 with the spin of the flywheel 1 .
[0043] In use, the flywheel 1 and flywheel axis 2 can be connected to the rotor of the electric motor 7 directly or it can be connected through a transmission (Interface System) 13 or it can be connected to any other Rotational Force Supply 9 such as (air motor, air or wind turbine any type of engines and other). The electric motor 7 powered from rechargeable batteries 9 or powered from any other Rotational Force Source 9 , such as pressurized air, vapor of liquid nitrogen or other liquid gases and other sources depending on the type of Rotational Force Supply. Rechargeable batteries 9 can be charged from solar panels, wind generators or any other source of energy. The flywheel 1 and loop shaped coils 4 can be located inside of a vacuum chamber 14 , to lower air resistance.
[0044] The electric motor 7 speeds up the flywheel 1 to a desired speed measured by an RPM (Revolutions Per Minute) counter and a time controller 8 and then the flywheel 1 is disconnected from the power from electric motor 7 , and the flywheel 1 continues to spin by inertia force. When the flywheel 1 goes down below a set RPM, the time controller 8 which is connected with the RPM counter 12 turns on the electric motor 7 for several seconds to speed up the flywheel 1 for optimum set RPM. This cycle is constantly repeated to keep the flywheel spinning in diapason of maximum and minimum RPM. The duration of spinning of flywheel 1 is dependant on the speed, mass and diameter of the flywheel. When the flywheel 1 is spinning, the magnets 5 attached to the flywheel 1 or to a separated mounting located on the same axis 2 , going through coils 4 to produce electric current.
[0045] The electric energy from the shaped loop coil flywheel electric generator system of the present invention can be used for different types of applications. It can be used as source of energy for houses, buildings, commercial buildings, factory and other production facilities. It can be used in power plants for towns and cities. It can also be used as a source of energy for land vehicles, marine vehicles, marine platforms and other types of vehicles.
[0046] Also the shaped loop coil flywheel generator of the present invention can be used as a source of energy in space for space stations or space vehicles. Because there is vacuum and no air resistance in space, the present invention can produce energy with high efficiency. And it can be used in many other applications by scaling up or scaling down the size of the device.
[0047] It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed. | A series of elongated oval wire windings bent into open C-shaped or other loop shape coils are positioned around a flywheel. Magnets, mating the loop opening shape, extend from the outer edge of the flywheel on a thin disc to pass through the coils to generate electricity with the spin of the flywheel. With no magnetic material is the coils there is no magnetic resistance created thereby providing more efficient electricity generation. | Analyze the document's illustrations and descriptions to summarize the main idea's core structure and function. | [
"CROSS-REFERENCE TO RELATED APPLICATIONS [0001] Not Applicable.",
"STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not Applicable.",
"THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT [0003] Not Applicable.",
"BACKGROUND OF THE INVENTION [0004] 1.",
"Field of the Invention [0005] The present invention relates generally to power generation devices, and in particular to a flywheel generator system and method of generating electricity which conserves electric energy by the use of a series of C-shaped or other shape looped coils positioned around a flywheel with magnets extending from the outer edge of the flywheel passing through the coils to generate electricity and with no magnetic material is the coils there is no resistance created thereby providing more efficient electricity generation.",
"[0006] 2.",
"Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98 [0007] As is known in the prior art, electric generator methods of energy production are based on the principal of electromagnetic induction.",
"The stator of the generator has magnetic material inside of the coil, and when the rotor moves the magnets close to the coil and the magnets are attracted by metal inside of the coil, the metal becomes a magnet itself by magnetic induction, and the impulse of the magnetic field produces electric current in the coil.",
"[0008] The problem with prior art electric generators is that a rotor with permanent or electric magnets is attracted by magnetic material inside of the coils of the stator to make the rotor spin inside the stator with high magnetic resistance.",
"The more load to the generator the higher the resistance, and more mechanical power must be applied to the rotor of the generator in the order to produce electric energy.",
"[0009] U.S. Pat. No. 5,341,060, issued Aug. 23, 1994 to Kawamura, claims an engine having a flywheel which has a high peripheral speed even when the engine rotates at a low speed.",
"The flywheel has a plurality of permanent magnets mounted on an outer circumference thereof and having alternately different magnetic poles.",
"A stator is disposed in confronting relation to radially outer ends of the permanent magnets.",
"Electric energy induced by the stator upon rotation of the flywheel is supplied to a rotary electric machine combined with a turbocharger to assist the turbocharger in supplying air under pressure to the engine when the engine rotates at low speed.",
"[0010] U.S. Pat. No. 3,629,632, issued Dec. 21, 1971 to Loupe, describes a generator for use with a small rotary engine incorporating permanent magnets in its flywheel, the generator being mounted exteriorly of the flywheel and within the flywheel housing, if any is used.",
"The magnets move relative to a stator having a “double-E”",
"configuration with two poles, each of which carry a pair of windings.",
"The windings on each pole are connected in electrical opposition through diodes to supply the desired electrical current.",
"The stator structure is laminated and has preferred physical dimensions.",
"[0011] U.S. Pat. No. 5,214,333, issued May 25, 1993 to Kawamura, discloses an engine having a flywheel which has a high peripheral speed even when the engine rotates at a low speed.",
"The flywheel has a plurality of permanent magnets mounted on an outer circumference thereof and having alternately different magnetic poles.",
"A stator is disposed in confronting relation to radially outer ends of the permanent magnets.",
"Electric energy induced by the stator upon rotation of the flywheel is supplied to a rotary electric machine combined with a turbocharger to assist the turbocharger in supplying air under pressure to the engine when the engine rotates at low speed.",
"[0012] U.S. Pat. No. 6,791,225, issued Sep. 14, 2004 to Campbell et al, indicates a flywheel magneto generator having a rotor assembly and a stator assembly.",
"The rotor assembly includes a non-ferromagnetic flywheel and a plurality of magnetic poles that are positioned in spaced relationship around the circumference of the flywheel.",
"The stator assembly includes an E-shaped core with a single magnet mounted on the center leg and coils associated with at least the outer legs.",
"The poles and core may be formed of a bonded iron material.",
"The poles may be joined to the flywheel by press fitting or integral molding, among other methods.",
"[0013] U.S. Pat. No. 7,132,775, issued Nov. 7, 2006 to Oohashi et al, is for a dynamoelectric stator and a method for the manufacture thereof enabling electrical insulation properties to be improved by forming slot-housed portions with a racetrack-shaped cross section to suppress damage to an electrically-insulating coating arising during mounting of a stator winding to a stator core.",
"The construction is such that the slot-housed portions of the stator winding are formed with the racetrack-shaped cross section, and are housed inside slots so as to line up in single columns in a radial direction with a longitudinal direction of the cross section of the slot-housed portions aligned in a circumferential direction.",
"Thus, because short sides of the slot-housed portions facing inner circumferential side surfaces of the slots form convex curved surfaces, the occurrence of damage to the electrically-insulating coating resulting from rubbing between the short sides of the slot-housed portions and the inner circumferential side surfaces of the slots during insertion of the slot-housed portions into the slots is suppressed, thereby improving electrical insulation properties.",
"[0014] U.S. Pat. No. 4,460,834, issued Jul. 17, 1984 to Gottfried, provides an uninterruptible power supply to an external load comprising a flywheel generator, a first motor, a standby generator, and a transfer controller.",
"The flywheel generator is adapted to supply energy to the external load.",
"The first motor is drivingly connected to the flywheel generator.",
"The first motor is adapted to be connected to a source of power external to the power system.",
"The standby generator is electrically connected to the first motor.",
"A standby motor is drivingly connected to the standby generator.",
"The transfer controller is adapted to switchably interconnect the first motor to the source of power and to interconnect the standby generator to the first motor.",
"The flywheel generator comprises a flywheel having a vertical axis, a shaft connected to the flywheel, and a synchronous A.C. generator arranged about the shaft.",
"The standby motor is a diesel engine having an electric starter.",
"A voltage regulator is electrically connected about the output of the flywheel generator.",
"[0015] U.S. Pat. No. 7,126,233, issued Oct. 24, 2006 to Thomas et al, shows a method and apparatus for generating power in a rotating environment without access to the axis of rotation.",
"A non-center engagement generator is implemented within the rotating reference frame of a vehicle wheel.",
"Further, a method and apparatus detect a potential rollover state and prevent occurrence of a rollover state or eliminate a rollover state once attained.",
"[0016] U.S. Pat. No. 6,891,295, issued May 10, 2005 to Maritomi et al, puts forth a flywheel magneto generator which comprises a rotor having a magnet attached to an outer circumferential side of a flywheel and a stator constructed by winding a generating coil around a core having a magnetic pole portion opposed to a magnetic pole of the rotor, wherein a through hole is formed in a peripheral wall portion of the flywheel, a yoke plate is provided so as to block one end of the through hole which is opened on an inner circumferential side of a peripheral wall portion of the flywheel, the magnet to which a magnet cover is attached is supported on the yoke plate, and one magnetic pole face of the magnet is opposed to the yoke plate.",
"[0017] What is needed is a more efficient system for generating electricity wherein the coils do not create magnetic resistance.",
"BRIEF SUMMARY OF THE INVENTION [0018] An object of the present invention is to provide a flywheel generator system and method of generating electricity which conserves electric energy by the use of a series of C-shaped or other shape looped coils positioned around a flywheel with magnets extending from the outer edge of the flywheel passing through the coils to generate electricity and with no magnetic material is the coils there is no resistance created thereby providing more efficient electricity generation.",
"[0019] In brief, a series of elongated oval wire windings bent into open C-shaped or other loop shape coils are positioned around a flywheel.",
"Magnets, mating the loop opening shape, extend from the outer edge of the flywheel on a thin disc to pass through the coils to generate electricity with the spin of the flywheel.",
"With no magnetic material is the coils there is no resistance created thereby providing more efficient electricity generation.",
"[0020] An advantage of the C-coil (C-shaped coil or semicircular coil) of the present invention is that it doesn't have any magnetic material inside the coil and has a special type of coil winding to allow magnets to pass through the winding of the C-coil itself, and because there is no magnetic material at all, so there is no magnetic resistance at all, so that the magnets to go through the C-coils freely, and electro magnetic induction from the magnets makes the windings of each of the C-coils to produce electric current.",
"BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0021] These and other details of the present invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention, and in which drawings: [0022] FIG. 1 is a diagrammatic view of the flywheel electric generator system of the present invention using loop shaped coils of the present invention showing rechargeable batteries powering the electric motor;",
"[0023] FIG. 2 is a diagrammatic side elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;",
"[0024] FIG. 3 is a diagrammatic front elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;",
"[0025] FIG. 4 is a diagrammatic top elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;",
"[0026] FIG. 5 is a diagrammatic back elevational view showing one of the magnets passing through one of the coils of FIG. 1 ;",
"[0027] FIG. 6 is a diagrammatic view of the flywheel electric generator system of the present invention using loop shaped coils of the present invention showing the flywheel and loop coils housed in a vacuum chamber;",
"[0028] FIG. 7 is a diagrammatic perspective view showing one of the coils of FIG. 1 having a circular loop opening showing the wires wound into the loop;",
"[0029] FIG. 8 is a diagrammatic perspective view showing one of the coils of FIG. 1 having a rectangular loop opening showing the wires wound into the loop.",
"DETAILED DESCRIPTION OF THE INVENTION [0030] In FIGS. 1-8 , a flywheel electric generator system 20 uses loop shaped coils 4 encircling a spinning flywheel 1 so that a series of mating shaped permanent magnets 5 attached to a disc 6 extending from the outer perimeter of the flywheel 1 with the shaped magnets 5 passing through the mating shaped coil openings 17 and 1 7 A to generate electricity in the coils.",
"[0031] In FIGS. 1 and 6 .",
"the flywheel 1 for the flywheel electric generator system 20 comprises a flywheel 1 of substantial mass and thickness pivoting about a center axis 2 .",
"A thin annular disc 6 extends outwardly from an outer perimeter of the flywheel 1 .",
"The annular disc 6 has a thickness substantially less than the flywheel.",
"A series of magnets 5 attached to an outer perimeter of the annular disc 6 .",
"The magnets 5 each having a mating identical peripheral shape.",
"A source of rotational power causes the flywheel 1 to spin.",
"[0032] In FIGS. 2-5 , 7 and 8 , a series of coil loops 4 are attached to a structure separate from the flywheel 1 , positioned in a circular array around the outside of the flywheel 1 out of contact with the flywheel.",
"Each of the coil loops 4 comprises an elongated oval coil winding bent into an open loop configuration with the coil ends 18 A and 18 B of the elongated oval coil windings spaced apart in close proximity to form a coil end space 16 and 16 A facing the flywheel 1 to receive the annular disc 6 spinning within the coil end space 16 and 16 A without contacting the coil ends.",
"The open loop configuration of the coil loop 4 forms an interior loop opening 17 and 17 A mating the outer peripheral shape of each of the magnets 5 , the interior loop opening 17 and 17 A being slightly larger than the peripheral shape of each of the magnets 5 so that the magnets spin around as the attached flywheel 1 spins, with the magnets 5 each passing through all of the coil loops 4 with each rotation of the flywheel without contacting the coil loops.",
"Each of the moving magnets 5 generates a flow of electricity is each of the coil loops 4 .",
"The flow of electricity generated in the coils 4 is transmitted from the coil loops 4 to devices for using and storing the flow of electricity.",
"[0033] In FIGS. 7 and 8 , each of the coil loops 4 and 4 A comprises an electrically conductive wire 15 wound around two spaced posts in a multiplicity of windings to form a built up cable in the shape of a closed elongated oval loop with two parallel spaced sides 19 and two semicircular ends 18 A and 18 B which is bent into an open loop coil configuration having the two semicircular ends 18 A and 18 B positioned in close proximity to leave the coil end space 16 and 16 A between the two semicircular ends 18 A and 18 B with the two parallel sides 19 forming two parallel loops around the interior opening 17 and 17 A. [0034] In FIGS. 1-7 , each of the coil loops 4 has a circular (or oval) interior opening 17 to form a C-shaped coil loop used with magnets 5 each having a circular (or oval) peripheral shape.",
"[0035] In FIG. 8 , each of the coil loops 4 has a rectangular interior opening 17 A for a square shaped coil loop used with magnets 5 each having a rectangular peripheral shape.",
"[0036] The coil loops 4 may have any of a variety of shapes of interior opening 17 and 17 A for any of a variety of shaped coil loops 4 used with magnets 5 each having any of a variety of mating peripheral shapes.",
"[0037] In FIGS. 1 and 6 , the system 20 preferably comprises an electric motor 7 as a rotational force supply communicating with the flywheel 1 for maintaining the rotation of the flywheel 1 at a desired optimum level for efficiency.",
"A means for detecting the flywheel speed of revolution 12 , such as an RPM counter, controls a means for activating the electric motor 7 , such as a time controller 8 , to speed up the flywheel 1 to a desired rotational speed and deactivating the electric motor 7 upon detecting the desired rotational speed so that the flywheel 1 continues to spin by inertia for maximum output of electricity.",
"The combination of speed of revolution of the flywheel 1 , mass of the flywheel, and diameter of flywheel determine the desired rotational speed of the flywheel.",
"[0038] The flywheel 1 may be connected to a rotor of the electric motor 7 for turning the flywheel.",
"Alternately, the flywheel 1 may be connected to the electric motor 7 through a transmission interface system 13 for spinning the flywheel.",
"[0039] To generate electric power in the coils by spinning the flywheel, the flywheel 1 may be connected to at least one of the following rotational power sources 9 taken from the list of rotational power sources comprising an electric motor, an electric motor powered from rechargeable batteries 9 preferably with a charge control 10 and wiring 11 connected to a time controller 8 to the electric motor 7 (shown in FIG. 1 ), an electric motor powered from rechargeable batteries powered by at least one solar panel, an electric motor powered from rechargeable batteries powered by at least one wind generator, an air motor, an air turbine, a wind turbine, an engine, a rotational force source from pressurized air, a rotational force source from pressurized vapor, a rotational force source from pressurized vapor of a liquid gas or other sources of rotational power.",
"[0040] A vacuum chamber 14 , as shown in FIG. 6 , may be used for containing the flywheel 1 and the series of coil loops 4 inside of the vacuum chamber to lower air resistance for greater efficiency in generating electricity.",
"[0041] The center axis 2 of the flywheel may comprise or connect with at least one of the following rotation devices taken from the list of rotation devices comprising bearings 3 , low friction bearings, magnetic bearings, and electromagnetic bearings for minimizing rotational friction for optimum performance of the flywheel.",
"[0042] A great advantage of using a shaped loop wire coil is that it doesn't have any magnetic material inside and has a special type of coil winding with the elongated wire winding loop bent into a shaped loop which allows magnets to go through the winding of shaped loop coil itself.",
"Because there is no magnetic material at all in the shaped loop coil, therefore there is no magnetic resistance at all, which allows the magnets to go through shaped loop coil freely, while at the same time electro magnetic induction from the magnets makes the winding of the shaped loop coil produce electric current.",
"The shaped loop coil can have any type of shape of winding.",
"What is most important is that it has a narrow opening in the windings facing the flywheel 1 to allow the disc 6 or other element holding the magnets 5 to fit through the narrow opening and maintain the magnets within the loop opening without touching the loop itself while the magnets 5 spin through all of the loops 4 with the spin of the flywheel 1 .",
"[0043] In use, the flywheel 1 and flywheel axis 2 can be connected to the rotor of the electric motor 7 directly or it can be connected through a transmission (Interface System) 13 or it can be connected to any other Rotational Force Supply 9 such as (air motor, air or wind turbine any type of engines and other).",
"The electric motor 7 powered from rechargeable batteries 9 or powered from any other Rotational Force Source 9 , such as pressurized air, vapor of liquid nitrogen or other liquid gases and other sources depending on the type of Rotational Force Supply.",
"Rechargeable batteries 9 can be charged from solar panels, wind generators or any other source of energy.",
"The flywheel 1 and loop shaped coils 4 can be located inside of a vacuum chamber 14 , to lower air resistance.",
"[0044] The electric motor 7 speeds up the flywheel 1 to a desired speed measured by an RPM (Revolutions Per Minute) counter and a time controller 8 and then the flywheel 1 is disconnected from the power from electric motor 7 , and the flywheel 1 continues to spin by inertia force.",
"When the flywheel 1 goes down below a set RPM, the time controller 8 which is connected with the RPM counter 12 turns on the electric motor 7 for several seconds to speed up the flywheel 1 for optimum set RPM.",
"This cycle is constantly repeated to keep the flywheel spinning in diapason of maximum and minimum RPM.",
"The duration of spinning of flywheel 1 is dependant on the speed, mass and diameter of the flywheel.",
"When the flywheel 1 is spinning, the magnets 5 attached to the flywheel 1 or to a separated mounting located on the same axis 2 , going through coils 4 to produce electric current.",
"[0045] The electric energy from the shaped loop coil flywheel electric generator system of the present invention can be used for different types of applications.",
"It can be used as source of energy for houses, buildings, commercial buildings, factory and other production facilities.",
"It can be used in power plants for towns and cities.",
"It can also be used as a source of energy for land vehicles, marine vehicles, marine platforms and other types of vehicles.",
"[0046] Also the shaped loop coil flywheel generator of the present invention can be used as a source of energy in space for space stations or space vehicles.",
"Because there is vacuum and no air resistance in space, the present invention can produce energy with high efficiency.",
"And it can be used in many other applications by scaling up or scaling down the size of the device.",
"[0047] It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an image scanning system, and more particularly to improvements in the control of the signal integration time of image sensing means in an image scanning system using signal integration type image sensing means.
2. Description of the Prior Art
In recent years, a one-dimensional or two-dimensional signal integration type image sensing means such as a charge-coupled device (CCD) has become used in various fields. Such an image sensing means produces an output linearly proportional to the intensity of incident light and therefore its dynamic range is narrow. To cause the image sensing means to respond to a variation in the intensity of a wide range of incident light, a method has been proposed in which an upper limit reference level determined by the saturation level of the output of the sensing means and a lower limit reference level determined with noise such as dark current taken into account are preset, the output level of the sensing means relative to these reference levels is determined by level determination means and the signal integration time of the sensing means is stepwise changed by integration time control means so that the output level of the sensing means is within a predetermined range of levels, thereby enlarging the dynamic range.
Heretofore, design has been made such that the controllable longest integration time or the controllable shortest integration time or the medium integration time is preselected as an initial integration time set by the integration time control means. However, if this has been done, for example, in a system wherein the controllable shortest integration time is set as the initial integration time, where the intensity of the light incident on the sensing means is low, a considerable time has been required until an output of appropriate level is obtained from the sensing means by successively changing the integration time to prolong it by the cooperation of level determination means and integration time control means. Conversely, in a system wherein the controllable longest integration time is set as the initial integration time, a similar demerit has occurred where the intensity of the incident light is high. On the other hand, in a system wherein a medium suitable integration time is set as the initial integration time, such inconvenience is alleviated to some extent, but where a variation in intensity of light over a very wide range is the object, such system is still insufficient and a similar demerit has occurred when the intensity of the incident light has been very high or very low.
SUMMARY OF THE INVENTION
The present invention has been made in view of such inconveniences peculiar to the prior art and has as its primary object the provision of a novel integration time control method which, as a method of controlling the signal integration time of signal integration type image sensing means in an image scanning system using such sensing means, can clear off the inconveniences peculiar to the prior art regarding the control of the signal integration time of the sensing means.
It is another object of the present invention to provide improvements in an image scanning system using signal integration type image sensing means and adapted to stepwise control the signal integration time of the sensing means (i.e., the amount of the electrical signal to be produced and stored for each image scanning) on the basis of the output level thereof, whereby the time required for the setting of an integration time corresponding to the intensity of incident light can be greatly shortened and accordingly, for a certain intensity of incident light, an output of appropriate level can be obtained from the sensing means in a very short time.
To achieve such objects, according to the present invention, there is provided a radiation sensing system or an image scanning system having the following characteristic construction. The system includes: signal integration type radiation sensing means producing an electrical output capable of indicating the distribution pattern of incident radiation; means for measuring radiation substantially equivalent to the radiation incident on the sensing means and producing an electrical output capable of indicating the intensity thereof; and means for controlling the signal integration time of the sensing means on the basis of the output of the measuring means and the output of the sensing means.
In a preferred embodiment of the present invention, the integration time control means is designed to determine the initial integration time on the basis of the output of the measuring means, and thereafter stepwise control the integration time on the basis of the output of the sensing means with the initial integration time as the starting point.
Also, in one embodiment, the integration time control means is designed to use the peak level of the output of the sensing means as the basis of the determination as disclosed, for example, in U.S. Pat. Nos. 4,305,657 entitled "Range Finding Device", 4,283,137 entitled "Image Scanning System" and 4,329,033 entitled "Distance Detecting Device and Focus Control System Utilizing the Same" all of which were assigned to the same assignee of the subject application, in controlling the integration time among a plurality of preset different integration times on the basis of the output of the sensing means, but may also use the average level of the output as the basis of the determination or, as disclosed, for example, in U.S. Pat. No. 4,004,852, may use as the basis of the determination data obtained by quantizing the output of the sensing means.
Thus, according to the present invention, the intended purposes are completely achieved and there is provided a radiation sensing system or an image scanning system which is very excellent in responsiveness, that is, which can obtain the output of proper level pf the sensing means in a short time.
Other objects and features of the present invention will become apparent from the following detailed description of an embodiment thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a model view for illustrating a method of controlling the signal integration time of signal integration type image sensing means which is the base of the present invention.
FIG. 2 is a model view showing an embodiment in which the image scanning system according to the present invention is applied to the focus detecting device of a single lens reflex camera.
FIG. 3 is a circuit diagram showing the construction of the electric circuitry of the camera shown in FIG. 2, displayed in halves in FIG. 3A and FIG. 3B.
FIG. 4 is a timing chart showing the relation between the output of a 3-bit up-down counter shown in FIG. 3 and the signal integration time.
FIG. 5 is a timing chart showing various control signals produced by a timing control circuit shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is first had to FIG. 1 to describe the method of controlling the signal integration time of image sensing means which is the basis of the present invention. In FIG. 1, V MAX and V MIN are upper and lower limit reference levels between which the sensing means operates linearly. This figure shows the manner in which the accumulating time is changed between t 1 and t 8 so that the output level of the sensing means lies between the upper limit and lower limit reference levels.
Reference is now had to FIG. 2 and so on to describe an embodiment in which the image scanning system according to the present invention is applied to the focus detecting device of a single lens reflex camera. In FIG. 2, LS designates a picture-taking lens, FP denotes a film, QM designates a quick return mirror having a light-transmitting portion LP in the center thereof, and SM denotes an auxiliary mirror for downwardly reflecting the transmitted light from the light-transmitting portion LP of the mirror QM. The light beam reflected by the auxiliary mirror SM enters a prism PM, where it is divided into three light beams which respectively enter the three image scanning sections SD 1 , SD 2 and SD 3 of the image sensing means SD. These three image scanning sections SD 3 , SD 1 and SD 2 are adapted to receive the incident lights respectively at a position optically equivalent to the surface the film FP, a position slightly forward of the equivalent position and a position slightly rearward of the equivalent position due to the action of the prism PM. Each of the image scanning sections SD 1 , SD 2 and SD 3 has a one-dimensional array of a plurality of signal integration type light-receiving elements as will later be described. FS designates a focusing screen, CL denotes a condenser lens, PN designates a penta prism, EL denotes an eyepiece lens, and ML designates a metering condenser lens which condenses light on a metering photoelectric conversion element PE. MT designates a display meter. As conceptionally shown in broken line in FIG. 2, the initial setting of the signal integration time of the image sensing means SD may be effected by the output of the metering photoelectric conversion element PE.
Referring to FIG. 3, SD 3 is the middle image scanning section of the image sensing means SD disposed so as to receive light at a position optically equivalent to the surface of the film FP and, in the present embodiment, the signal integration time of the image sensing means SD is controlled on the basis of the output of the image scanning section SD 3 . S 1 -S n designate light receiving elements (arranged one-dimensionally) included in the image scanning section SD 3 , and D 1 and D 2 denote dummy elements masked, for example, by a mask MS(which can be formed by evaporation of Al) for dark current detection. FA 1 , FA 2 , . . . , FA m (m=n+2) designate integration clear gates responsive to the high of an integration clear signal ICG to clear the charges stored in the light-receiving elements S 1 -S n and dummy elements D 1 , D 2 . FB 1 , FB 2 , . . . , FB m denote charge shift gates responsive to the high of a shift pulse SH to shift to charge transfer analog shift registers CA 1 -CA 2m the charges stored in the light-receiving elements S 1 -S n corresponding to the integrated amount of the light incident thereon and the charges corresponding to the dark currents stored in the dummy elements D 1 and D 2 . The analog shift registers CA 1 -CA 2m are of the two-phase driven type operated by clock pulses .0. 1 and .0. 2 , and the transferred charges thereof are put out as voltage information at the last stage through a charge-voltage converting circuit comprising resistors R 1 , R 2 , R 3 and FET FC 1 , FC 2 .
AG 1 designates an analog gate for taking out only the signals obtained by the dummy elements D 1 and D 2 , of the output of the image scanning section SD 3 , and a holding capacitor C 1 , a resistor R 4 and a buffer amplifier BP subsequent to the analog gate AG 1 together constitute a dark current signal holding circuit. The resistor R 4 is a resistor for forming a low-pass filter together with the capacitor C 1 , and is not always necessary. Resistors R 5 , R 6 , R 7 , R 8 and an operational amplifier OP 1 together constitute a differential amplifier circuit as a dark current compensating differential circuit, and this circuit puts out a dark-current-compensated true scanning output VF by subtracting the dark current signal components obtained by the dummy elements D 1 and D 2 which are held by the dark current signal holding circuit from the scanning output including the dark current components obtained by the light-receiving elements S 1 -S n .
AG 2 designates an analog gate for taking out only the signals corresponding to the light-receiving elements S 1 -S n , of the output of the differential amplifier circuit. PD denotes a peak detecting circuit (which may also detect the average value) for detecting, for example, the peak value (hereinafter referred to as VP) of the signal obtained through the analog gate AG 2 . PH designates a peak holding circuit for holding the peak value VP detected by the peak detecting circuit. R 9 , R 10 and R 11 denote voltage dividing resistors for obtaining the voltages V MAX and V MIN corresponding to the upper limit and lower limit reference levels described in connection with FIG. 1. CP 1 designates a comparator which compares the held value VP of the peak holding circuit PH with the upper limit reference voltage V MAX and puts out a high level signal when VP>V MAX and puts out a low level signal when VP≦V MAX . CP 2 denotes a comparator which compares the held value VP with the lower limit reference voltage V MIN and puts out a high level signal when VP<V MIN and puts out a low level signal when VP≧V MIN . IV 1 designates an inverter for inverting the output of the comparator CP 1 . The output of the inverter IV 1 is imparted to an up-down counter UDC(which is a binary up-down counter of 3-bit construction) as a signal for controlling the counting mode of this up-down counter UDC. The up-down counter UDC is set so as to assume an up count mode by the high of the output of the inverter IV 1 and to assume a down count mode by the low of the output of the inverter IV 1 . OR 1 denotes an OR gate for taking the logical sum of the output of the comparator CP 1 and the output of the comparator CP 2 . EX denotes an exclusive OR gate for taking the exclusive-or of the 3-bit outputs Q 1 , Q 2 , Q 3 of the up-down counter UDC and the output of the inverter IV 1 . AN 1 designates an AND gate for taking the logical multiple of the output of the OR gate OR 1 , the output of the exclusive OR gate EX and the counting pulse CP from a timing control circuit TCC to be described. The output of the AND gate AN 1 is imparted to the up-down counter UDC as the count clock of this up-down counter UDC. The exclusive OR gate EX is for preventing the resetting of the up-down counter UDC when the integration time has been set to the shortest time t 1 or the longest time t 8 and further the shift information toward the short time or the long time side has been put out from the comparator CP 1 or CP 2 and for fixing the integration time to the currently set shortest or longest integration time. The relations between the 3-bit outputs Q 1 -Q 3 of the up-down counter UDC and the eight stages of integration time t 1 -t 8 designated thereby are as shown in FIG. 4.
TCC designates a timing control circuit for generating various control pulses and control signals in accordance with the timing chart shown in FIG. 5. CP is the counting pulse of the up-down counter UDC generated once each time the signals of the image scanning sections SD 1 -SD 3 are read out (that is, the integration time controlling pulse). A.0. 1 is a gate controlling signal for the analog gate AG 1 for taking out through the analog gate AG 1 the signals of the portions necessary for detection of dark current during each read-out, namely, the signals corresponding to the dummy elements D 1 and D 2 . A.0. 2 is a gate controlling signal for the analog gate AG 2 for taking out through the analog gate AG 1 the signals corresponding to the light-receiving elements S 1 -S n , of the output of the differential amplifier circuit OP 1 , during each read-out. .0. R is a peak resetting control signal for resetting the peak detecting circuit PD, for example, immediately after each read-out is initiated. .0. H is a peak holding control signal for causing the peak detection value VP before the peak detecting circuit PD is reset to be held by the peak holding circuit PH each time each read-out is terminated. SH is a gate controlling pulse (shift pulse) for the charge shift gates FB 1 -FB m in the image scanning section SD 3 . ICG is a gate controlling signal (integration clear signal) for the integration clear gates FA 1 -FA m . .0. 1 and .0. 2 are transfer clock pulses for the charge transfer analog shift registers CA 1 -CA 2m (that is, the analog shift registers CA 1 -CA 2m are of the two-phase driven type, and the shift pulse SH is synchronous with .0. 1 ). RS is a reset pulse for the charge-voltage converting circuit FET FC 1 . The above-described signals 2CG, SH, .0. 1 , .0. 2 and RS are also supplied to the other image scanning sections SD 1 and SD 2 .
The timing control circuit TCC has the function of controlling the signal integration time (charge accumulating time) of the image scanning sections SD 1 -SD 3 on the basis of the time information designated by the outputs Q 1 -Q 3 of the up-down counter UDC, and specifically realizes the control of the integration time by controlling the period of time from the falling of the integration clear signal ICG to its low level indicated by t in FIG. 5 till the rising of the shift pulse SH between the eight stages t 1 -t 8 in accordance with the conditions of the outputs Q 1-Q 3 of the up-down counter UDC. Thus, the actual integration time of the image scanning sections SD 1 -SD 3 is "the image t+ the duration Δt of the high level of the shift pulse SH". Incidentally, the image scanning sections SD 1 -SD 3 is of the two-phase driven type as previously described, but the signal of each element thereof is put out in synchronism with .0. 1 and the outputting thereof is initiated in synchronism with the shift pulse SH.
Now, in accordance with the improvement of the present invention, a construction for initial setting of the integration time as will hereinafter be described is added to the above-described construction of the image scanning system. In FIG. 3, a metering photoelectric conversion element PE is connected between the input terminals of a high input impedance operational amplifier MP 1 . LD 1 designates a logarithmic compression element for logarithmically compressing the photocurrent produced in the photoelectric conversion element PE correspondingly to the brightness of the object to be photographed, and CS 1 denotes a constant current source which, together with a resistor R 20 , supplies a bias voltage to the non-inverting input terminal of the operational amplifier MP 1 . R 21 -R 23 designate operational resistors, OP 5 denotes an operational amplifier, CP 5 designates a comparator, and Mg 1 denotes an aperture controlling magnet. VR 1 designates a variable resistor in which information "Sv - Tv", i.e., the film speed information Sv minus the shutter time information Tv, and in the operational amplifier OP 5 , this information and the object luminance information which is the output of the operational amplifier MP 1 are computed and aperture information is put out to the output of the operational amplifier OP 5 . The aperture information is displayed by an aperture information displaying ammeter MT and ah aperture corresponding to the luminance of the object to be photographed is automatically set through a variable resistor VR 2 operatively associated with an aperture adjusting member, the comparator CP 5 and the magnet Mg 1 . Vc applied to the non-inverting inputs H) of the operational amplifier OP 5 and the comparator CP 5 is a bias level setting reference voltage.
On the other hand, VR 3 designates a variable resistor operatively associated with a shutter time setting member. The variable resistor VR 3 , together with a capacitor C 5 , constitutes a timer circuit. SW 10 denotes a count switch adapted to be opened substantially simultaneously with the start of movement of the first curtain of the shutter ST (FIG. 2). When the voltage across the capacitor C 5 reaches a predetermined value, a Schmidt trigger circuit ST is inverted to deenergize a magnet Mg 2 for controlling the second curtain of the shutter ST, thus terminating the exposure. SW 1 denotes a main switch, and E designates a power source. ADC denotes an A/D converter for converting the output of the operational amplifier MP 1 , for example, into a 3-bit digital data. OS designates a one-shot circuit. AN 2 denotes an AND gate for taking the logical multiply of the output pulse of the one-shot circuit OS and the A/D conversion termination pulse from the terminal ED of the A/D converter ADC. The output of the AND gate AN 2 is imparted to the preset enable terminal PE of the up-down counter UDC.
Now, in the above-described construction, when the main switch SW 1 of the camera is closed at time T 1 (see FIG. 5), the exposure amount control circuit of the camera starts operating and the one-shot circuit OS generates a pulse which assumes high level during the time from time T 1 till time T 3 . Also, the A/D converter ADC starts the A/D conversion of the output of the operational amplifier MP 1 which is the information corresponding to the luminance of the object to be photographed. When the A/D converter ADC terminates the A/D conversion of the object luminance information at time T 2 , an A/D conversion termination pulse is generated from the terminal ED thereof and accordingly, by the output of the AND gate AN 2 , the preset enable terminal PE of the integration time setting up-down counter UDC assumes high level, whereby the output of the A/D converter ADC is preset to the up-down counter UDC. For example, if the conditions of the output terminals Q 1 , Q 2 and Q 3 of the A/D converter ADC are high level, low level and high level, respectively, the output terminals Q 1 , Q 2 and Q 3 of the up-down counter UDC also assume similar conditions and accordingly, the first integration time becomes t 6 (see FIG. 4).
On the other hand, upon closing of the main switch SW 1 , the timing control circuit TCC starts to put out transferring clock pulses .0. 1 , .0. 2 and reset pulse RS to the image scanning sections SD 1 -SD 3 at time t 1 and renders the integration clear signal ICG high and opens the integration clearing gates FA 1 -FA m , thereby inhibiting the accumulation of the produced charges in the dummy elements D 1 , D 2 and the light-receiving elements S 1 -S n .
Thereafter, at time T 3 , the output of the one-shot circuit OS is inverted to low level, whereupon in response to this signal, the integration clear signal ICG is rendered low as shown in FIG. 5 and the integration clearing gates FA 1 -FA m are closed, whereby the accumulation of the produced charges in the elements D 1 , D 2 and S 1 -S n is initiated while, at the same time, the accumulating time designated by the outputs Q 1 -Q 3 of the up-down counter UDC (in this case, the accumulating time is t 6 ) begins to be counted and, when this time counting is terminated, the shift pulse SH is put out. Accordingly, at this point of time, the charge shifting gates FB 1 -FB m are opened, whereby the charges accumulated in the elements D 1 , D 2 and SD 1 -SD n while said time counting is being effected are introduced through the charge shifting gates FB 1 -FB m into the corresponding bits of the charge transferring analog shift resisters CA 1 -CA.sub. 2m, whereafter the charges are transferred through the analog shift resisters CA 1 -CA 2m to the charge-voltage converting circuit, where the charges are converted into a voltage and put out as voltage information. The timing control circuit TCC, after having put out the shift pulse SH, again renders the integration clear signal ICG high and opens the integration clearing gates FA 1 -FA m , thereby inhibiting the accumulation of the produced charges in the elements D 1 , D 2 and S 1 -S n . Now, when the outputting of scanning signals from the image scanning sections SD 1 -SD 3 is thus initiated, the timing control circuit TCC renders the gate controlling signal A.0. 1 to the analog gate AG 1 high at a timing whereat the signal corresponding to the dummy elements D 1 and D 2 is put out as shown in FIG. 5, and opens the analog gate AG 1 and thus, the signal corresponding to the dummy elements D 1 and D 2 is held as the dark current signal of the image scanning section SD 3 by the capacitor C 1 , and the dark current signal thus held is imparted to one input of the differential amplifier circuit through the buffer amplifier BP. Thus, the differential amplifier circuit then receives at the other input thereof the signal corresponding to the light-receiving elements S 1 -S n , whereby it puts out said signal minus the dark current signal component, namely, the dark-current-compensated scanning signal VF. On the other hand, at this time, the timing control circuit renders the gate controlling signal A.0. 2 to the analog gate AG 2 high during the period of time in which the signal corresponding to the light-receiving elements S 1 -S n is put out from the image scanning section SD 3 as shown in FIG. 5, thereby opening the analog gate AG 2 and accordingly, of the output of the differential amplifier circuit, the output corresponding to the light-receiving elements S 1 -S n is imparted to the peak detecting circuit PD. The peak detecting circuit PD is already reset by the reset signal .0. R from the timing control circuit TCC as shown in FIG. 5 during the period of time in which, for example, the signal corresponding to the dummy elements D 1 and D 2 , and is imparted the output of the differential amplifier circuit corresponding to the light-receiving elements S 1 -S n through the analog gate AG 2 , whereby it detects the peak value thereof. When the outputting of the signal corresponding to the light-receiving elements S 1 -S n from the image scanning section SD 3 is terminated, the timing control circuit TCC renders the gate controlling signal A.0. 2 low as shown in FIG. 5 and closes the analog gate AG 2 to thereby terminate the peak value detection by the peak detecting circuit PD, whereafter it imparts a hold signal .0. H to the peak holding circuit PH to cause the same to hold the peak detection output VP of the peak detecting circuit PD at this point of time. When the peak value VP is held by the peak holding circuit PH, the comparators CP 1 and CP 2 compare the held peak value VP with the upper limit and lower limit reference voltages V MAX and V MIN , and put out the result of the comparison as a high or low logic signal. Generally, good control of the integration time of the image sensing device disposed within the camera can be accomplished by the output of the metering photoelectric conversion element in the camera, but where the metering portion of the metering photoelectric conversion element is not the same as the light-receiving portion of the image sensing device, a scanning output of appropriate level may sometimes not be obtained from the image sensing device for the integration time controlled by the output of the metering photoelectric conversion element.
The present invention solves these problems and provides a method for obtaining a scanning output of appropriate level in a very short time. According to the present invention, the initial integration time is set in an integration time setting circuit by the output of an exposure amount controlling photoelectric conversion element disposed within the camera, and whether the level of a scanning signal put out under such initial integration time is within the range of a predetermined signal level is discriminated and when only (and when) the level of the scanning signal is not within the range of the predetermined signal level, a new setting of the integration time is effected through the integration time setting circuit so that the level of the scanning signal is within the range of the predetermined signal level, whereby a scanning output of appropriate level is obtained in a very short time.
Now, assuming, for example, that the peak hold value VP in VP<V MIN , the output of the comparator CP 1 is low and the output of the comparator CP 2 is high and accordingly, the output of the inverter IV 1 is high, whereby the up-down counter UDC is set to the up count mode while, at the same time, the output of the OR gate OR 1 becomes high and at this time, the output of the exclusive OR gate EX also becomes high. Accordingly, after the holding of the peak detection output VP of the peak detecting circuit PD by the peak holding circuit PH is completed, a count pulse CP is put out to the up-down counter UDC from the timing control circuit TCC as shown in FIG. 5, whereupon the count pulse CP is imparted to the count input of the up-down counter UDC through the AND gate AN 1 and the up-down counter UDC effects one count up and accordingly, as shown in FIG. 4, the outputs Q 1 -Q 3 thereof become high, high and low, respectively, whereby as shown in FIG. 4, the designated integration time of the solid state image sensing element SP is changed from the shortest time t 6 to the next time t 7 . Thus, during the next cycle of scanning, the timing control circuit TCC controls the period of time t from the falling of the integration clear signal ICG to its low level till the rising of the shift pulse SH in accordance with the time t, whereby the integration time of the image scanning sections SD 1 -SD 3 is prolonged from t 6 to t 7 and the level of the scanning output VF obtained through the differential amplifier circuit is caused to rise from this. This integration time changing operation is repeated until the condition that V MIN ≦VP≦V MAX is obtained and, when the condition that V MIN ≦VP≦V MAX is finally obtained, the outputs of the comparators CP 1 and CP 2 both become low, whereby the output of the OR gate OR 1 becomes low and the supply of the count pulse CP from the timing control circuit TCC to the up-down counter UDC is inhibited by the AND gate AN 1 and thus, at this point of time, the change of the integration time is stopped and the integration time is maintained at this proper time. Of course, if the condition that VP<V MIN again arises during the time the scanning is repeated under this proper integration time, the integration time will be changed to a longer time by the above-described operation. If, conversely, the condition that VP>V MAX arises, the output of the comparator CP 1 will become high and the output of the comparator CP 2 will become low and the output of the inverter IV 1 will become low, whereby the up-down counter UDC will be set to the down count mode and will effect one count down by the count pulse CP from the timing control circuit TCC, whereby the integration time will be changed to a shorter time. Thus, through such operation, the integration time of the image scanning sections SD 1 -SD 3 is always controlled to a proper time, namely, such a time that the proper image signal level of V MIN ≦VP≦V MAX is obtained.
On the basis of the scanning outputs VF', VF" and VF thus obtained from the image scanning sections SD 1 -SD 3 , detection of the focus is carried out in a focus detecting circuit PCK and, when the picture-taking lens is automatically or manually set to the in-focus position, the output of the terminal ED of the focus detecting circuit PCK assumes high level and shutter release becomes possible. The focus detecting circuit PCK thus using the scanning signals from the three image scanning sections SD 1 -SD 3 to effect detection of the focus is fully disclosed in U.S. patent application Ser. No. 310,483 entitled "Focus Detecting System" filed on Oct. 9, 1981, assigned to the assignee hereof, abandoned in favor of continuation application U.S. Ser. No. 572,972, filed Jan. 23, 1984, abandoned in favor of continuation application U.S. Ser. No. 627,488, filed July 5, 1984, and U.S. patent applications Ser. No. 313,579, entitled "Focus Detecting System", which was filed Oct. 21, 1981 and issued as U.S. Pat. No. 4,459,002 on July 10, 1984, U.S. Ser. No. 313,582 "Camera System", filed Oct. 21, 1981, abandoned in favor of continuation application U.S. Ser. No. 631,008, U.S. Ser. No. 313,583 "Focus Detecting System", which was filed Oct. 21, 1981 and issued as U.S. Pat. No. 4,411,504 on Oct. 25, 1983, U.S. Ser. No. 313,584 "Focus Detecting System", which was filed Oct. 21, 1981, abandoned in favor of continuation application U.S. Ser. No. 577,329, which was filed Feb. 8, 1984 and issued as U.S. Pat. No. 4,475,800 on Oct. 9, 1984, and U.S. Ser. No. 313,599 "Signal Processing System", which was filed Oct. 21, 1981 and issued as U.S. Pat. No. 4,437,743 on Mar. 10, 1984, all of which are assigned to the assignee of the present application.
When a shutter release button (not shown) is depressed in this condition, the switch SW 2 is closed and a transistor TR 1 is turned on by an inverter IV 2 and an AND gate AN 3 , so that the charge stored in a capacitor C 6 is discharged through a resistor 24 and a magnet Mg3 is energized to start the release of the shutter ST.
According to the present invention, a scanning output of appropriate level can be obtained in a very short time and therefore, where the image scanning system of the present invention is applied, for example, to the focus detecting portion of an automatic focus camera, there can be obtained a great advantage that focusing is accomplished in a short time to enable photography. | Disclosed is an image scanning system including signal integration type image sensor, measuring device for measuring a light substantially equivalent to a light incident on the sensor, and a controller for controlling the signal integration time of the sensor on the basis of the output of the sensor and the output of the measuring device, the controller determining an initial signal integration time on the basis of the output of the measuring device and thereafter stepwise controlling the signal integration time on the basis of the output of the sensor with the initial integration time as the starting point. | Summarize the information, clearly outlining the challenges and proposed solutions. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to an image scanning system, and more particularly to improvements in the control of the signal integration time of image sensing means in an image scanning system using signal integration type image sensing means.",
"Description of the Prior Art In recent years, a one-dimensional or two-dimensional signal integration type image sensing means such as a charge-coupled device (CCD) has become used in various fields.",
"Such an image sensing means produces an output linearly proportional to the intensity of incident light and therefore its dynamic range is narrow.",
"To cause the image sensing means to respond to a variation in the intensity of a wide range of incident light, a method has been proposed in which an upper limit reference level determined by the saturation level of the output of the sensing means and a lower limit reference level determined with noise such as dark current taken into account are preset, the output level of the sensing means relative to these reference levels is determined by level determination means and the signal integration time of the sensing means is stepwise changed by integration time control means so that the output level of the sensing means is within a predetermined range of levels, thereby enlarging the dynamic range.",
"Heretofore, design has been made such that the controllable longest integration time or the controllable shortest integration time or the medium integration time is preselected as an initial integration time set by the integration time control means.",
"However, if this has been done, for example, in a system wherein the controllable shortest integration time is set as the initial integration time, where the intensity of the light incident on the sensing means is low, a considerable time has been required until an output of appropriate level is obtained from the sensing means by successively changing the integration time to prolong it by the cooperation of level determination means and integration time control means.",
"Conversely, in a system wherein the controllable longest integration time is set as the initial integration time, a similar demerit has occurred where the intensity of the incident light is high.",
"On the other hand, in a system wherein a medium suitable integration time is set as the initial integration time, such inconvenience is alleviated to some extent, but where a variation in intensity of light over a very wide range is the object, such system is still insufficient and a similar demerit has occurred when the intensity of the incident light has been very high or very low.",
"SUMMARY OF THE INVENTION The present invention has been made in view of such inconveniences peculiar to the prior art and has as its primary object the provision of a novel integration time control method which, as a method of controlling the signal integration time of signal integration type image sensing means in an image scanning system using such sensing means, can clear off the inconveniences peculiar to the prior art regarding the control of the signal integration time of the sensing means.",
"It is another object of the present invention to provide improvements in an image scanning system using signal integration type image sensing means and adapted to stepwise control the signal integration time of the sensing means (i.e., the amount of the electrical signal to be produced and stored for each image scanning) on the basis of the output level thereof, whereby the time required for the setting of an integration time corresponding to the intensity of incident light can be greatly shortened and accordingly, for a certain intensity of incident light, an output of appropriate level can be obtained from the sensing means in a very short time.",
"To achieve such objects, according to the present invention, there is provided a radiation sensing system or an image scanning system having the following characteristic construction.",
"The system includes: signal integration type radiation sensing means producing an electrical output capable of indicating the distribution pattern of incident radiation;",
"means for measuring radiation substantially equivalent to the radiation incident on the sensing means and producing an electrical output capable of indicating the intensity thereof;",
"and means for controlling the signal integration time of the sensing means on the basis of the output of the measuring means and the output of the sensing means.",
"In a preferred embodiment of the present invention, the integration time control means is designed to determine the initial integration time on the basis of the output of the measuring means, and thereafter stepwise control the integration time on the basis of the output of the sensing means with the initial integration time as the starting point.",
"Also, in one embodiment, the integration time control means is designed to use the peak level of the output of the sensing means as the basis of the determination as disclosed, for example, in U.S. Pat. Nos. 4,305,657 entitled "Range Finding Device", 4,283,137 entitled "Image Scanning System"",
"and 4,329,033 entitled "Distance Detecting Device and Focus Control System Utilizing the Same"",
"all of which were assigned to the same assignee of the subject application, in controlling the integration time among a plurality of preset different integration times on the basis of the output of the sensing means, but may also use the average level of the output as the basis of the determination or, as disclosed, for example, in U.S. Pat. No. 4,004,852, may use as the basis of the determination data obtained by quantizing the output of the sensing means.",
"Thus, according to the present invention, the intended purposes are completely achieved and there is provided a radiation sensing system or an image scanning system which is very excellent in responsiveness, that is, which can obtain the output of proper level pf the sensing means in a short time.",
"Other objects and features of the present invention will become apparent from the following detailed description of an embodiment thereof taken in conjunction with the accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a model view for illustrating a method of controlling the signal integration time of signal integration type image sensing means which is the base of the present invention.",
"FIG. 2 is a model view showing an embodiment in which the image scanning system according to the present invention is applied to the focus detecting device of a single lens reflex camera.",
"FIG. 3 is a circuit diagram showing the construction of the electric circuitry of the camera shown in FIG. 2, displayed in halves in FIG. 3A and FIG. 3B.",
"FIG. 4 is a timing chart showing the relation between the output of a 3-bit up-down counter shown in FIG. 3 and the signal integration time.",
"FIG. 5 is a timing chart showing various control signals produced by a timing control circuit shown in FIG. 3. DESCRIPTION OF THE PREFERRED EMBODIMENT Reference is first had to FIG. 1 to describe the method of controlling the signal integration time of image sensing means which is the basis of the present invention.",
"In FIG. 1, V MAX and V MIN are upper and lower limit reference levels between which the sensing means operates linearly.",
"This figure shows the manner in which the accumulating time is changed between t 1 and t 8 so that the output level of the sensing means lies between the upper limit and lower limit reference levels.",
"Reference is now had to FIG. 2 and so on to describe an embodiment in which the image scanning system according to the present invention is applied to the focus detecting device of a single lens reflex camera.",
"In FIG. 2, LS designates a picture-taking lens, FP denotes a film, QM designates a quick return mirror having a light-transmitting portion LP in the center thereof, and SM denotes an auxiliary mirror for downwardly reflecting the transmitted light from the light-transmitting portion LP of the mirror QM.",
"The light beam reflected by the auxiliary mirror SM enters a prism PM, where it is divided into three light beams which respectively enter the three image scanning sections SD 1 , SD 2 and SD 3 of the image sensing means SD.",
"These three image scanning sections SD 3 , SD 1 and SD 2 are adapted to receive the incident lights respectively at a position optically equivalent to the surface the film FP, a position slightly forward of the equivalent position and a position slightly rearward of the equivalent position due to the action of the prism PM.",
"Each of the image scanning sections SD 1 , SD 2 and SD 3 has a one-dimensional array of a plurality of signal integration type light-receiving elements as will later be described.",
"FS designates a focusing screen, CL denotes a condenser lens, PN designates a penta prism, EL denotes an eyepiece lens, and ML designates a metering condenser lens which condenses light on a metering photoelectric conversion element PE.",
"MT designates a display meter.",
"As conceptionally shown in broken line in FIG. 2, the initial setting of the signal integration time of the image sensing means SD may be effected by the output of the metering photoelectric conversion element PE.",
"Referring to FIG. 3, SD 3 is the middle image scanning section of the image sensing means SD disposed so as to receive light at a position optically equivalent to the surface of the film FP and, in the present embodiment, the signal integration time of the image sensing means SD is controlled on the basis of the output of the image scanning section SD 3 .",
"S 1 -S n designate light receiving elements (arranged one-dimensionally) included in the image scanning section SD 3 , and D 1 and D 2 denote dummy elements masked, for example, by a mask MS(which can be formed by evaporation of Al) for dark current detection.",
"FA 1 , FA 2 , .",
", FA m (m=n+2) designate integration clear gates responsive to the high of an integration clear signal ICG to clear the charges stored in the light-receiving elements S 1 -S n and dummy elements D 1 , D 2 .",
"FB 1 , FB 2 , .",
", FB m denote charge shift gates responsive to the high of a shift pulse SH to shift to charge transfer analog shift registers CA 1 -CA 2m the charges stored in the light-receiving elements S 1 -S n corresponding to the integrated amount of the light incident thereon and the charges corresponding to the dark currents stored in the dummy elements D 1 and D 2 .",
"The analog shift registers CA 1 -CA 2m are of the two-phase driven type operated by clock pulses [.",
"].0.",
"1 and [.",
"].0.",
"2 , and the transferred charges thereof are put out as voltage information at the last stage through a charge-voltage converting circuit comprising resistors R 1 , R 2 , R 3 and FET FC 1 , FC 2 .",
"AG 1 designates an analog gate for taking out only the signals obtained by the dummy elements D 1 and D 2 , of the output of the image scanning section SD 3 , and a holding capacitor C 1 , a resistor R 4 and a buffer amplifier BP subsequent to the analog gate AG 1 together constitute a dark current signal holding circuit.",
"The resistor R 4 is a resistor for forming a low-pass filter together with the capacitor C 1 , and is not always necessary.",
"Resistors R 5 , R 6 , R 7 , R 8 and an operational amplifier OP 1 together constitute a differential amplifier circuit as a dark current compensating differential circuit, and this circuit puts out a dark-current-compensated true scanning output VF by subtracting the dark current signal components obtained by the dummy elements D 1 and D 2 which are held by the dark current signal holding circuit from the scanning output including the dark current components obtained by the light-receiving elements S 1 -S n .",
"AG 2 designates an analog gate for taking out only the signals corresponding to the light-receiving elements S 1 -S n , of the output of the differential amplifier circuit.",
"PD denotes a peak detecting circuit (which may also detect the average value) for detecting, for example, the peak value (hereinafter referred to as VP) of the signal obtained through the analog gate AG 2 .",
"PH designates a peak holding circuit for holding the peak value VP detected by the peak detecting circuit.",
"R 9 , R 10 and R 11 denote voltage dividing resistors for obtaining the voltages V MAX and V MIN corresponding to the upper limit and lower limit reference levels described in connection with FIG. 1. CP 1 designates a comparator which compares the held value VP of the peak holding circuit PH with the upper limit reference voltage V MAX and puts out a high level signal when VP>V MAX and puts out a low level signal when VP≦V MAX .",
"CP 2 denotes a comparator which compares the held value VP with the lower limit reference voltage V MIN and puts out a high level signal when VP<V MIN and puts out a low level signal when VP≧V MIN .",
"IV 1 designates an inverter for inverting the output of the comparator CP 1 .",
"The output of the inverter IV 1 is imparted to an up-down counter UDC(which is a binary up-down counter of 3-bit construction) as a signal for controlling the counting mode of this up-down counter UDC.",
"The up-down counter UDC is set so as to assume an up count mode by the high of the output of the inverter IV 1 and to assume a down count mode by the low of the output of the inverter IV 1 .",
"OR 1 denotes an OR gate for taking the logical sum of the output of the comparator CP 1 and the output of the comparator CP 2 .",
"EX denotes an exclusive OR gate for taking the exclusive-or of the 3-bit outputs Q 1 , Q 2 , Q 3 of the up-down counter UDC and the output of the inverter IV 1 .",
"AN 1 designates an AND gate for taking the logical multiple of the output of the OR gate OR 1 , the output of the exclusive OR gate EX and the counting pulse CP from a timing control circuit TCC to be described.",
"The output of the AND gate AN 1 is imparted to the up-down counter UDC as the count clock of this up-down counter UDC.",
"The exclusive OR gate EX is for preventing the resetting of the up-down counter UDC when the integration time has been set to the shortest time t 1 or the longest time t 8 and further the shift information toward the short time or the long time side has been put out from the comparator CP 1 or CP 2 and for fixing the integration time to the currently set shortest or longest integration time.",
"The relations between the 3-bit outputs Q 1 -Q 3 of the up-down counter UDC and the eight stages of integration time t 1 -t 8 designated thereby are as shown in FIG. 4. TCC designates a timing control circuit for generating various control pulses and control signals in accordance with the timing chart shown in FIG. 5. CP is the counting pulse of the up-down counter UDC generated once each time the signals of the image scanning sections SD 1 -SD 3 are read out (that is, the integration time controlling pulse).",
"A[.",
"].0.",
"1 is a gate controlling signal for the analog gate AG 1 for taking out through the analog gate AG 1 the signals of the portions necessary for detection of dark current during each read-out, namely, the signals corresponding to the dummy elements D 1 and D 2 .",
"A[.",
"].0.",
"2 is a gate controlling signal for the analog gate AG 2 for taking out through the analog gate AG 1 the signals corresponding to the light-receiving elements S 1 -S n , of the output of the differential amplifier circuit OP 1 , during each read-out.",
"].0.",
"R is a peak resetting control signal for resetting the peak detecting circuit PD, for example, immediately after each read-out is initiated.",
"].0.",
"H is a peak holding control signal for causing the peak detection value VP before the peak detecting circuit PD is reset to be held by the peak holding circuit PH each time each read-out is terminated.",
"SH is a gate controlling pulse (shift pulse) for the charge shift gates FB 1 -FB m in the image scanning section SD 3 .",
"ICG is a gate controlling signal (integration clear signal) for the integration clear gates FA 1 -FA m .",
"].0.",
"1 and [.",
"].0.",
"2 are transfer clock pulses for the charge transfer analog shift registers CA 1 -CA 2m (that is, the analog shift registers CA 1 -CA 2m are of the two-phase driven type, and the shift pulse SH is synchronous with [.",
"].0.",
"1 ).",
"RS is a reset pulse for the charge-voltage converting circuit FET FC 1 .",
"The above-described signals 2CG, SH, [.",
"].0.",
"1 , [.",
"].0.",
"2 and RS are also supplied to the other image scanning sections SD 1 and SD 2 .",
"The timing control circuit TCC has the function of controlling the signal integration time (charge accumulating time) of the image scanning sections SD 1 -SD 3 on the basis of the time information designated by the outputs Q 1 -Q 3 of the up-down counter UDC, and specifically realizes the control of the integration time by controlling the period of time from the falling of the integration clear signal ICG to its low level indicated by t in FIG. 5 till the rising of the shift pulse SH between the eight stages t 1 -t 8 in accordance with the conditions of the outputs Q 1-Q 3 of the up-down counter UDC.",
"Thus, the actual integration time of the image scanning sections SD 1 -SD 3 is "the image t+ the duration Δt of the high level of the shift pulse SH".",
"Incidentally, the image scanning sections SD 1 -SD 3 is of the two-phase driven type as previously described, but the signal of each element thereof is put out in synchronism with [.",
"].0.",
"1 and the outputting thereof is initiated in synchronism with the shift pulse SH.",
"Now, in accordance with the improvement of the present invention, a construction for initial setting of the integration time as will hereinafter be described is added to the above-described construction of the image scanning system.",
"In FIG. 3, a metering photoelectric conversion element PE is connected between the input terminals of a high input impedance operational amplifier MP 1 .",
"LD 1 designates a logarithmic compression element for logarithmically compressing the photocurrent produced in the photoelectric conversion element PE correspondingly to the brightness of the object to be photographed, and CS 1 denotes a constant current source which, together with a resistor R 20 , supplies a bias voltage to the non-inverting input terminal of the operational amplifier MP 1 .",
"R 21 -R 23 designate operational resistors, OP 5 denotes an operational amplifier, CP 5 designates a comparator, and Mg 1 denotes an aperture controlling magnet.",
"VR 1 designates a variable resistor in which information "Sv - Tv", i.e., the film speed information Sv minus the shutter time information Tv, and in the operational amplifier OP 5 , this information and the object luminance information which is the output of the operational amplifier MP 1 are computed and aperture information is put out to the output of the operational amplifier OP 5 .",
"The aperture information is displayed by an aperture information displaying ammeter MT and ah aperture corresponding to the luminance of the object to be photographed is automatically set through a variable resistor VR 2 operatively associated with an aperture adjusting member, the comparator CP 5 and the magnet Mg 1 .",
"Vc applied to the non-inverting inputs H) of the operational amplifier OP 5 and the comparator CP 5 is a bias level setting reference voltage.",
"On the other hand, VR 3 designates a variable resistor operatively associated with a shutter time setting member.",
"The variable resistor VR 3 , together with a capacitor C 5 , constitutes a timer circuit.",
"SW 10 denotes a count switch adapted to be opened substantially simultaneously with the start of movement of the first curtain of the shutter ST (FIG.",
"2).",
"When the voltage across the capacitor C 5 reaches a predetermined value, a Schmidt trigger circuit ST is inverted to deenergize a magnet Mg 2 for controlling the second curtain of the shutter ST, thus terminating the exposure.",
"SW 1 denotes a main switch, and E designates a power source.",
"ADC denotes an A/D converter for converting the output of the operational amplifier MP 1 , for example, into a 3-bit digital data.",
"OS designates a one-shot circuit.",
"AN 2 denotes an AND gate for taking the logical multiply of the output pulse of the one-shot circuit OS and the A/D conversion termination pulse from the terminal ED of the A/D converter ADC.",
"The output of the AND gate AN 2 is imparted to the preset enable terminal PE of the up-down counter UDC.",
"Now, in the above-described construction, when the main switch SW 1 of the camera is closed at time T 1 (see FIG. 5), the exposure amount control circuit of the camera starts operating and the one-shot circuit OS generates a pulse which assumes high level during the time from time T 1 till time T 3 .",
"Also, the A/D converter ADC starts the A/D conversion of the output of the operational amplifier MP 1 which is the information corresponding to the luminance of the object to be photographed.",
"When the A/D converter ADC terminates the A/D conversion of the object luminance information at time T 2 , an A/D conversion termination pulse is generated from the terminal ED thereof and accordingly, by the output of the AND gate AN 2 , the preset enable terminal PE of the integration time setting up-down counter UDC assumes high level, whereby the output of the A/D converter ADC is preset to the up-down counter UDC.",
"For example, if the conditions of the output terminals Q 1 , Q 2 and Q 3 of the A/D converter ADC are high level, low level and high level, respectively, the output terminals Q 1 , Q 2 and Q 3 of the up-down counter UDC also assume similar conditions and accordingly, the first integration time becomes t 6 (see FIG. 4).",
"On the other hand, upon closing of the main switch SW 1 , the timing control circuit TCC starts to put out transferring clock pulses [.",
"].0.",
"1 , [.",
"].0.",
"2 and reset pulse RS to the image scanning sections SD 1 -SD 3 at time t 1 and renders the integration clear signal ICG high and opens the integration clearing gates FA 1 -FA m , thereby inhibiting the accumulation of the produced charges in the dummy elements D 1 , D 2 and the light-receiving elements S 1 -S n .",
"Thereafter, at time T 3 , the output of the one-shot circuit OS is inverted to low level, whereupon in response to this signal, the integration clear signal ICG is rendered low as shown in FIG. 5 and the integration clearing gates FA 1 -FA m are closed, whereby the accumulation of the produced charges in the elements D 1 , D 2 and S 1 -S n is initiated while, at the same time, the accumulating time designated by the outputs Q 1 -Q 3 of the up-down counter UDC (in this case, the accumulating time is t 6 ) begins to be counted and, when this time counting is terminated, the shift pulse SH is put out.",
"Accordingly, at this point of time, the charge shifting gates FB 1 -FB m are opened, whereby the charges accumulated in the elements D 1 , D 2 and SD 1 -SD n while said time counting is being effected are introduced through the charge shifting gates FB 1 -FB m into the corresponding bits of the charge transferring analog shift resisters CA 1 -CA.",
"sub.",
"2m, whereafter the charges are transferred through the analog shift resisters CA 1 -CA 2m to the charge-voltage converting circuit, where the charges are converted into a voltage and put out as voltage information.",
"The timing control circuit TCC, after having put out the shift pulse SH, again renders the integration clear signal ICG high and opens the integration clearing gates FA 1 -FA m , thereby inhibiting the accumulation of the produced charges in the elements D 1 , D 2 and S 1 -S n .",
"Now, when the outputting of scanning signals from the image scanning sections SD 1 -SD 3 is thus initiated, the timing control circuit TCC renders the gate controlling signal A[.",
"].0.",
"1 to the analog gate AG 1 high at a timing whereat the signal corresponding to the dummy elements D 1 and D 2 is put out as shown in FIG. 5, and opens the analog gate AG 1 and thus, the signal corresponding to the dummy elements D 1 and D 2 is held as the dark current signal of the image scanning section SD 3 by the capacitor C 1 , and the dark current signal thus held is imparted to one input of the differential amplifier circuit through the buffer amplifier BP.",
"Thus, the differential amplifier circuit then receives at the other input thereof the signal corresponding to the light-receiving elements S 1 -S n , whereby it puts out said signal minus the dark current signal component, namely, the dark-current-compensated scanning signal VF.",
"On the other hand, at this time, the timing control circuit renders the gate controlling signal A[.",
"].0.",
"2 to the analog gate AG 2 high during the period of time in which the signal corresponding to the light-receiving elements S 1 -S n is put out from the image scanning section SD 3 as shown in FIG. 5, thereby opening the analog gate AG 2 and accordingly, of the output of the differential amplifier circuit, the output corresponding to the light-receiving elements S 1 -S n is imparted to the peak detecting circuit PD.",
"The peak detecting circuit PD is already reset by the reset signal [.",
"].0.",
"R from the timing control circuit TCC as shown in FIG. 5 during the period of time in which, for example, the signal corresponding to the dummy elements D 1 and D 2 , and is imparted the output of the differential amplifier circuit corresponding to the light-receiving elements S 1 -S n through the analog gate AG 2 , whereby it detects the peak value thereof.",
"When the outputting of the signal corresponding to the light-receiving elements S 1 -S n from the image scanning section SD 3 is terminated, the timing control circuit TCC renders the gate controlling signal A[.",
"].0.",
"2 low as shown in FIG. 5 and closes the analog gate AG 2 to thereby terminate the peak value detection by the peak detecting circuit PD, whereafter it imparts a hold signal [.",
"].0.",
"H to the peak holding circuit PH to cause the same to hold the peak detection output VP of the peak detecting circuit PD at this point of time.",
"When the peak value VP is held by the peak holding circuit PH, the comparators CP 1 and CP 2 compare the held peak value VP with the upper limit and lower limit reference voltages V MAX and V MIN , and put out the result of the comparison as a high or low logic signal.",
"Generally, good control of the integration time of the image sensing device disposed within the camera can be accomplished by the output of the metering photoelectric conversion element in the camera, but where the metering portion of the metering photoelectric conversion element is not the same as the light-receiving portion of the image sensing device, a scanning output of appropriate level may sometimes not be obtained from the image sensing device for the integration time controlled by the output of the metering photoelectric conversion element.",
"The present invention solves these problems and provides a method for obtaining a scanning output of appropriate level in a very short time.",
"According to the present invention, the initial integration time is set in an integration time setting circuit by the output of an exposure amount controlling photoelectric conversion element disposed within the camera, and whether the level of a scanning signal put out under such initial integration time is within the range of a predetermined signal level is discriminated and when only (and when) the level of the scanning signal is not within the range of the predetermined signal level, a new setting of the integration time is effected through the integration time setting circuit so that the level of the scanning signal is within the range of the predetermined signal level, whereby a scanning output of appropriate level is obtained in a very short time.",
"Now, assuming, for example, that the peak hold value VP in VP<V MIN , the output of the comparator CP 1 is low and the output of the comparator CP 2 is high and accordingly, the output of the inverter IV 1 is high, whereby the up-down counter UDC is set to the up count mode while, at the same time, the output of the OR gate OR 1 becomes high and at this time, the output of the exclusive OR gate EX also becomes high.",
"Accordingly, after the holding of the peak detection output VP of the peak detecting circuit PD by the peak holding circuit PH is completed, a count pulse CP is put out to the up-down counter UDC from the timing control circuit TCC as shown in FIG. 5, whereupon the count pulse CP is imparted to the count input of the up-down counter UDC through the AND gate AN 1 and the up-down counter UDC effects one count up and accordingly, as shown in FIG. 4, the outputs Q 1 -Q 3 thereof become high, high and low, respectively, whereby as shown in FIG. 4, the designated integration time of the solid state image sensing element SP is changed from the shortest time t 6 to the next time t 7 .",
"Thus, during the next cycle of scanning, the timing control circuit TCC controls the period of time t from the falling of the integration clear signal ICG to its low level till the rising of the shift pulse SH in accordance with the time t, whereby the integration time of the image scanning sections SD 1 -SD 3 is prolonged from t 6 to t 7 and the level of the scanning output VF obtained through the differential amplifier circuit is caused to rise from this.",
"This integration time changing operation is repeated until the condition that V MIN ≦VP≦V MAX is obtained and, when the condition that V MIN ≦VP≦V MAX is finally obtained, the outputs of the comparators CP 1 and CP 2 both become low, whereby the output of the OR gate OR 1 becomes low and the supply of the count pulse CP from the timing control circuit TCC to the up-down counter UDC is inhibited by the AND gate AN 1 and thus, at this point of time, the change of the integration time is stopped and the integration time is maintained at this proper time.",
"Of course, if the condition that VP<V MIN again arises during the time the scanning is repeated under this proper integration time, the integration time will be changed to a longer time by the above-described operation.",
"If, conversely, the condition that VP>V MAX arises, the output of the comparator CP 1 will become high and the output of the comparator CP 2 will become low and the output of the inverter IV 1 will become low, whereby the up-down counter UDC will be set to the down count mode and will effect one count down by the count pulse CP from the timing control circuit TCC, whereby the integration time will be changed to a shorter time.",
"Thus, through such operation, the integration time of the image scanning sections SD 1 -SD 3 is always controlled to a proper time, namely, such a time that the proper image signal level of V MIN ≦VP≦V MAX is obtained.",
"On the basis of the scanning outputs VF', VF"",
"and VF thus obtained from the image scanning sections SD 1 -SD 3 , detection of the focus is carried out in a focus detecting circuit PCK and, when the picture-taking lens is automatically or manually set to the in-focus position, the output of the terminal ED of the focus detecting circuit PCK assumes high level and shutter release becomes possible.",
"The focus detecting circuit PCK thus using the scanning signals from the three image scanning sections SD 1 -SD 3 to effect detection of the focus is fully disclosed in U.S. patent application Ser.",
"No. 310,483 entitled "Focus Detecting System"",
"filed on Oct. 9, 1981, assigned to the assignee hereof, abandoned in favor of continuation application U.S. Ser.",
"No. 572,972, filed Jan. 23, 1984, abandoned in favor of continuation application U.S. Ser.",
"No. 627,488, filed July 5, 1984, and U.S. patent applications Ser.",
"No. 313,579, entitled "Focus Detecting System", which was filed Oct. 21, 1981 and issued as U.S. Pat. No. 4,459,002 on July 10, 1984, U.S. Ser.",
"No. 313,582 "Camera System", filed Oct. 21, 1981, abandoned in favor of continuation application U.S. Ser.",
"No. 631,008, U.S. Ser.",
"No. 313,583 "Focus Detecting System", which was filed Oct. 21, 1981 and issued as U.S. Pat. No. 4,411,504 on Oct. 25, 1983, U.S. Ser.",
"No. 313,584 "Focus Detecting System", which was filed Oct. 21, 1981, abandoned in favor of continuation application U.S. Ser.",
"No. 577,329, which was filed Feb. 8, 1984 and issued as U.S. Pat. No. 4,475,800 on Oct. 9, 1984, and U.S. Ser.",
"No. 313,599 "Signal Processing System", which was filed Oct. 21, 1981 and issued as U.S. Pat. No. 4,437,743 on Mar. 10, 1984, all of which are assigned to the assignee of the present application.",
"When a shutter release button (not shown) is depressed in this condition, the switch SW 2 is closed and a transistor TR 1 is turned on by an inverter IV 2 and an AND gate AN 3 , so that the charge stored in a capacitor C 6 is discharged through a resistor 24 and a magnet Mg3 is energized to start the release of the shutter ST.",
"According to the present invention, a scanning output of appropriate level can be obtained in a very short time and therefore, where the image scanning system of the present invention is applied, for example, to the focus detecting portion of an automatic focus camera, there can be obtained a great advantage that focusing is accomplished in a short time to enable photography."
] |
BACKGROUND OF INVENTION
[0001] Portable electrical power is used in many situations from construction sites, to concerts, festivals and mobile carnivals. In such situations power from a source such as a portable generator or commercial source must be distributed to numerous devices that require electricity to operate. Although these devices may run on, for example, the same voltages, they often have vastly different requirements for amperage. Because of these differences, power often must be distributed to the various devices via power distribution “boxes” or other devices. However, these prior art devices do not lend themselves to flexibility as the users needs changes over the short or long term such as, for example, when new equipment requiring a different amperage to operate is purchased or more equipment is need at a particular job site. In these and other situations the user must purchase new power distribution “boxes” as their needs change.
[0002] Therefore, what is needed is a power distribution device that allows the user the flexibility to inexpensively change the distribution of power at a job site as the user's needs change.
SUMMARY OF INVENTION
[0003] In one aspect, the invention relates to a portable device for the distribution of electrical power in one or more interchangeable, predefined configurations. The power distribution device of the present invention comprises, in one embodiment, a housing having one or more bays within said housing. Electrical power is delivered to the power distribution device of the present invention from any suitable power source such as a generator or commercial power supply. The electrical power is distributed to one or more power distribution blocks, with one power distribution block for each bay of the device of the present invention. This is, for example, a first predefined configuration. In this way, the incoming power may be divided such that a predetermined amperage can be directed to each bay on the device. Within each bay a user may place an interchangeable tray or rack designed to distribute power in a second predefined configuration as detailed below.
[0004] In a preferred embodiment, the housing also comprises a front, back, side, floor and roof panels. In another embodiment, one or more doors are located in the front, back and side panels for access to internal components. In yet another embodiment, the doors may have locks or other security devices to prevent unauthorized entry.
[0005] In yet another embodiment, the doors of the present invention may have openings through which the switches of the device (e.g., breaker switches) may extend. With this design, the switches can be used without having to open the doors of the device. The doors of the device may be opened, e.g., to service or rewire the device. In yet another embodiment, the rear or back panel (or any other panel) of the device may have a double door (i.e., a door-behind-a-door arrangement). With this arrangement, the outside door or first door, would block access to the device. The inside or second door would, for example, have the switches of the breakers extending through the door for easy access but prevent access into the inside of the device thereby preventing, for example, inexperienced persons from accessing the wiring of the device. In another embodiment, the device does not comprise a bottom panel or the bottom panel has slots or other perforations for cooling. Likewise, the bottom panel may be made of a screen, a screen-like material, a mesh or a mesh-like material.
[0006] In the present invention, bays are defined as areas in the housing where racks or trays can be placed. The bays typically have rails or other suitable supports at the side of the bay to support a rack or tray or they can have a complete floor to support the rack or tray. The racks or trays of the present invention, in one embodiment, slide into the bay. In another embodiment, the racks or trays have wheels for ease of insertion. Once placed in the bay, they can be locked in position by pins or insert and locking handles, cam-locks or other suitable locking devices, for example, which are known in the art. In a preferred embodiment, the locking device used to lock the tray/rack in position can be locked with a key to prevent unwanted removal of the tray/rack.
[0007] The racks (or trays) of the present invention are made and sized to slid into the bays of the housing. The racks are designed to have a predetermined configuration for power output. For example, the racks may have any combination of sockets equal to but not exceeding the amperage going to the bay. Thus, a rack may have, for example, two 100 amp sockets (outputs), four fifty amp sockets or twenty 10-amp sockets for a bay that has 200 amps delivered to the bay. The racks interconnect with the power source of the bay with, for example, male/female or female/male connectors or other suitable devices known in the art. In another embodiment, the sockets of the rack may be interchanged so that the user may remove, for example, a fifty amp socket and replace it with two twenty-five amp sockets. Numerous other suitable interchangeable combinations are also possible and can be practiced based on the teachings of the present specification.
[0008] The electrical power distribution device of the present invention comprises a primary breaker switch for shutting off power to the entire device. The device also comprises secondary breaker switches for each bay useful for shutting off power to each bay individually if, for example, a tray or rack needs to be changed. In one embodiment, power enters the device through one or more plugs or other connection devices. Power is then conducted (via wire or other conductive material, for example) to the primary circuit breaker. From the primary circuit breaker power is conducted to each bay or insertable tray or rack where the power is divided for delivery to each of the bays. In one embodiment, the amount of amperage that each bay receives is equal to each other bay. In another embodiment, the amount of amperage that each bay receives is different from one or more of the other bays of the device. Each bay has a secondary breaker switch suitable for shutting of power to that bay. Additionally, the sockets or groups of sockets on each tray may also have breakers to control (shut-off/start) power to each socket or groups of sockets.
[0009] Each bay is designed to accept a rack. Racks of the present invention are interchangeable with other racks. Racks may be made to handle the specific amperage of a particular bay. However, each rack may divide the power entering the bay into various secondary predetermined configurations. For example, if one bay is powered with 200 amperage (amps), the racks suitable for use in that bay would accept in input of 200 amps. However, any one of the those racks may divide the power up in different configurations. For example, one rack may divide the power into four 50 amp sockets, two fifty amp sockets and twenty-five amp sockets or forty-five amp sockets. The racks of the present invention are not limited to any particular predetermined power configuration. Each socket may, but need not have a switch for turning power on and off to that socket.
[0010] The trays are inserted into each bay and the connections on the back of the tray or rack meet with the connections at the back of the bay. The connections at the back of the bay, in one embodiment, have power cut off to them when the tray or rack is removed by, for example, tripping the breaker switch for that bay. This helps to prevent accidents or shorts from happening by not permitting the flow of current to the connectors at the back of the bay when a tray or rack is not in place. Suitable power connectors are known in the art and available commercially.
[0011] The racks or trays are held in place by, for example, cam-locks at the front of the trays. The cam-locks, may, for example, also work to push the tray further into the bay and thereby ensure that a solid contact has been made between the tray or rack and the connections at the back of the bay. An interlock in conjunction with the cam-locks would, for example, trip the secondary circuit breakers to the bays to cut power to the bays when the trays are removed. The interlocks may work, for example, similarly to the circuit breaker test trip switch found on bathroom style power sockets. Once the trays are inserted into the bay, the interlock may serve to reset the secondary breaker or, in another embodiment, it may be required that the secondary breaker be reset manually. The connectors between the trays or racks and the connectors at the back of the bays may comprise tabs, wires, plug-in or push-in (i.e., male/female-type or female/male type) connectors. The present invention is not limited to any particular type or connector and any suitable connector known in the art is contemplated by the present invention.
[0012] In another embodiment, the portable power distribution device of the present invention is constructed to conform to applicable electrical standards. Suitable components, manufactures, suppliers and standards may be found by referencing sources in the industry such as, for example, the National Electrical Manufacturers Association (www.nema.org) or Underwriters Laboratory (www.ul.com) and sources referenced therein. These sources are not intended to be limiting but rather are intended to illustrate the knowledge available in the art at the time of the conception of the present invention in regards to the safe construction of electrical devices as well as components commercially available to the inventor of the present invention.
[0013] In a non-limiting embodiment, the power input into the portable power distribution box of the present invention has a power input of 600 amperes. The power is then divided into bays wherein the power to each bay is of 100 or 200 hundred amperes each. Each tray can then divide the incoming power to sockets wherein each socket has a rating of 5, 10 20, 25, 50, 100 or 200 amperes. In one embodiment, it is contemplated that he input power source is rated between 50 and 2400 amperes. In another embodiment, it is contemplated that the power delivered to any one bay is between 50 and 600 amperes. In yet another embodiment, it is contemplated that the power delivered to any one socket of a tray or rack is between 5 and 600 amperes.
[0014] The housing of the present invention, in another embodiment, comprises at least two wheels to aid the user in moving the device. If two wheels are present, they are located at the base of the housing on one side with the wheel axles in line with each other. If four wheels are present then the wheels are located at each corner. In the four-wheeled version of the device, the two leading wheels, the two trailing wheels or all four wheels may pivot or swivel to aid the user in steering the device. The user may then grasp the housing of a handle provided on said housing to push or pull the device to a desired location. If the device has two wheels, the user may pivot the device onto the two wheels and then push or pull the device to a desired location. On devices with two wheels, the other end of the device may be held off of the ground with feet or other stationary means. The feet or other stationary means also keeps the device from moving or rolling when the user does not what or need the device moved. In devices with four wheels, one or more wheels may have wheel locks to prevent the device from moving when not desired. Wheel locks may also be present on two wheeled units. Wheel locks are, for example, friction devices that prevent the wheels from turning (rolling) when the wheel locks are used or activated. Examples of suitable wheel lock devices are found on handcarts, pull wagons, etc., and are well known in the art.
[0015] The present invention, in another embodiment, also comprises materials and methods for covering and protecting the device of the present invention. A cover conceals the device from persons who may damage the device or become injured on it. It also protects the device from inclement weather. In one embodiment, the housing comprises retractable rods designed to support a tent-like structure that can surround the device housing. In a preferred embodiment, the supports are located on the top panel of the housing. One support is located at each corner of the device housing and positioned so that when extended from the retracted position it extends from the corner of the housing essentially horizontal to the ground. The support can be extended when needed and can be locked in the retracted or extended position by, for example, a bolt, hitch clips, cotter pins or the like. Additionally, one or more supports may extend from the top of the housing oriented essentially vertical to the ground. The support can be, for example, a rod that is positioned into a receptacle located on the top (or roof) of the housing. If one support is used then the receptacle would be located essentially at the center of the housing roof. In a preferred embodiment, the covering is a tent or tent-like device that attaches to the support rods of the housing.
[0016] In one embodiment, the present invention contemplates a portable device for distributing electrical power in one or more interchangeable predefined configurations, said device comprising: a housing, said housing comprising a roof and sides, two or more wheels, a handle, a means for preventing the device from rolling when movement of the device is not desired, one or more doors located at the front, back and/or sides of the housing and a plurality of bays within said housing; wherein said electrical power is delivered to said bays in one or more first predefined configurations and wherein within said bays, interchangeable racks suitable for the distribution of electrical power in one or more second predefined configurations are interchangeably inserted.
[0017] In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations additionally comprises a primary breaker. In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations additionally comprises a secondary breaker for each bay. In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations additionally comprises a means (e.g., a socket or sockets) for connecting to an electrical power source. In yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations is connected to an electrical power source ranging from about 50 to 2400 amps. In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises from about 1 to 7 bays. In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a first predefined power configuration to said bays is from about 25 to 600 amps. In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises one or more sockets of about 5 to 600 amps each to a maximum amperage equal to that of the first predefined power configuration of the bay wherein said rack is inserted. In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises sockets wherein said sockets are interchangeable individually or in groups. In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a covering sized to fit over the device concealing it from view and wherein said covering is selected from a group consisting of being designed to attached to said device or being designed to be free standing. In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a means for the trays or racks to interface with electrical power from the housing comprises one or more of tabs, wires or plug-in connectors and that the trays or racks are locked into said bays with cam-locks. In still yet another embodiment, the present invention contemplates that the one or more doors located at one or more of the front, back and/or sides of the housing comprise a first door and a second door, said second door located behind said first door and covered by said first door when said first door is closed.
[0018] In one embodiment, the present invention contemplates a portable device for distributing electrical power in one or more interchangeable predefined configurations, said device comprising: a housing, said housing comprising a roof and sides, two or more wheels, a handle, a means for preventing the device from rolling when movement of the device is not desired, one or more doors located at the front, back and/or sides of the housing and a plurality of bays within said housing; wherein said electrical power is delivered to said bays in one or more first predefined configurations and wherein within said bays, interchangeable racks suitable for the distribution of electrical power in one or more second predefined configurations are interchangeably inserted; wherein said racks are locked into said bays with cam-locks; wherein said means for the racks to interface with electrical power from the housing comprises one or more of tabs, wires, plug-in or push-in connectors; and wherein at least one socket in one tray/rack is interchangeable with one or more other sockets.
[0019] In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a means for the racks to interface with electrical power from the housing comprises plug-in or push-in connectors. In yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a covering sized to fit over the device concealing it from view and wherein said covering is selected from a group consisting of being designed to attached to said device or being designed to be free standing of said.
[0020] In one embodiment, the present invention contemplates a method of distributing electrical power in predefined interchangeable configurations, comprising: providing: i) the device of the present invention, ii) a power source and, iii) one or more electrical devices wherein each electrical device is in need of electrical power of a known amperage and wherein the power needed by the each of the one or more electrical devices is the same or different from the other electrical devices; configuring the device of present invention in such a way to provide the amount of electrical power needed by each electrical device to each electrical device; connecting the device of present invention to the power source and to the one or electrical devices in need of electrical power; and provide electrical power to the device of present invention through the power source.
[0021] In another embodiment, the present invention contemplates that the device of the present invention and methods of use of the present invention comprise user instructions and/or service manuals and/or repair guides.
[0022] Other features and advantages of the invention will be apparent from the following description.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 shows a front view of one embodiment of the present invention with the door closed.
[0024] FIG. 2 shows the front view of one embodiment of the present invention with the door opened.
[0025] FIG. 3 shows back view of one embodiment of the present invention with the door opened. An exemplification of the visible wiring is also shown.
[0026] FIG. 4 shows a side view of one embodiment of the present invention with the door opened.
[0027] FIG. 5 shows a top view of one embodiment of the present invention with the support arms for the cover shown.
[0028] FIG. 6 shows a ¾ front view of one embodiment of the present invention with one of the interchangeable racks removed.
[0029] FIG. 7 shows a wiring diagram of showing a schematic of the distribution of power from the feed lines into the device to the connectors that interface with the trays or racks. Power configurations are exemplary only.
[0030] FIG. 8 shows a wiring diagram of one exemplary tray or rack.
[0031] FIG. 9 shows a wiring diagram of a second exemplary tray or rack.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] The invention will now be described in detail with reference to a few preferred embodiments, as illustrated in accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the invention may be practiced without some or all of these specific details. In other instances, well-known features and/or process steps have not been described in detail in order to not unnecessarily obscure the invention. The features and advantages of the invention may be better understood with reference to the drawings and discussions that follow.
[0033] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein.
[0034] FIG. 1 shows one embodiment of the device of the present invention with the door closed. Shown in this exemplary embodiment are the handle 10 , the door 12 , the locking devices for the door 14 , feet 16 , a support for a post useful in supporting a covering over the top of the device of the present invention 17 , and four supports useful for holding a covering way from the sides of the device of the present invention 18 .
[0035] FIG. 2 shows one embodiment of the device of the present invention with the front door open. Visible in this exemplary embodiment are the locking devices for the door 14 , the feet 16 , three removable/interchangeable trays/racks suitable for plugging in electrical devices into the present invention, 20 A, 20 B, 20 C. The device is not limited to any particular number of removable/interchangeable trays/racks. In other embodiments of the present invention the number of trays/racks may number, for example, from 1 to 7 (or more). The trays/racks of the present invention are held in place by, for example, cam-locks 21 with one cam-lock on each front edge of the tray/rack. The cam-locks of the present invention also may be useful in pushing the tray/rack further into the bay thereby ensuring that the electrical contacts/connectors at the rear of the tray/rack make secure contact with the appropriate electrical contacts/connectors in the rear of the bay. The trays/racks of the present invention are slid into the bay on supports 26 , and rest on the supports when positioned in the bay. Power is inputted into the device on panel 24 , where input connectors are present for equipment ground, system ground and one power input for each available rack or tray. Also shown are feed-through, pass-through or output plugs suitable for connecting, for example, a second device of the present invention or other electrical device.
[0036] FIG. 3 shows one embodiment of the rear panel of the device of the present invention. Shown in this exemplary embodiment are the handle 10 , corner supports for a cover 18 , the rear door 32 , locking devices for the rear door 34 , secondary circuit breakers 38 for each tray/rack and wheels 36 . Also visible is one embodiment of the wiring of the device. The three sets of wires on the left of the figure are the power conducting wires. The two sets of wires on the right are the tray/rack equipment and system grounds.
[0037] FIG. 4 shows one embodiment of a side view of the device of the present invention. Visible in this exemplary embodiment are the door 42 , the locking device for the door 44 , the handle 10 , corner supports 18 for a cover for the device, one of two feet 16 , one of two wheels 36 and the sides of each tray/rack ( 40 A, 40 B and 40 C) showing circuit breakers for specific electrical sockets in the respective trays/racks.
[0038] FIG. 5 shows one embodiment of a top view of the device of the present invention. Shown in this exemplary embodiment are four corner supports for a cover 18 , a center support for a post for supporting a cover 17 , the handle 10 , extendable support rods 19 , and thumb screws or other suitable devices 15 for holding the extendable support rods in position. The insert picture shows an extendable rod 19 of a corner support 18 of the present invention in the extended position.
[0039] FIG. 6 shows a ¾ cut-away view of the device of the present invention. Shown in this exemplary embodiment are the front door 12 , the side door 44 , the feet 16 , one of two wheels 36 , trays/racks 20 A and 20 B, one tray/rack support 26 , and circuit breaker panels 40 A and 40 B on trays/racks 20 A and 20 B, respectively. Number 50 shows the top of tray/rack 20 A which may be closed, opened or partially closed or opened depending on the configuration chosen by the builder or user.
[0040] FIGS. 7 , 8 and 9 show exemplary wiring diagrams for the present invention. Conventional symbols and nomenclature known in the art are used. | In one aspect, the invention relates to a portable device for the distribution of electrical power in one or more interchangeable, predefined configurations and methods of use. | Briefly summarize the main idea's components and working principles as described in the context. | [
"BACKGROUND OF INVENTION [0001] Portable electrical power is used in many situations from construction sites, to concerts, festivals and mobile carnivals.",
"In such situations power from a source such as a portable generator or commercial source must be distributed to numerous devices that require electricity to operate.",
"Although these devices may run on, for example, the same voltages, they often have vastly different requirements for amperage.",
"Because of these differences, power often must be distributed to the various devices via power distribution “boxes”",
"or other devices.",
"However, these prior art devices do not lend themselves to flexibility as the users needs changes over the short or long term such as, for example, when new equipment requiring a different amperage to operate is purchased or more equipment is need at a particular job site.",
"In these and other situations the user must purchase new power distribution “boxes”",
"as their needs change.",
"[0002] Therefore, what is needed is a power distribution device that allows the user the flexibility to inexpensively change the distribution of power at a job site as the user's needs change.",
"SUMMARY OF INVENTION [0003] In one aspect, the invention relates to a portable device for the distribution of electrical power in one or more interchangeable, predefined configurations.",
"The power distribution device of the present invention comprises, in one embodiment, a housing having one or more bays within said housing.",
"Electrical power is delivered to the power distribution device of the present invention from any suitable power source such as a generator or commercial power supply.",
"The electrical power is distributed to one or more power distribution blocks, with one power distribution block for each bay of the device of the present invention.",
"This is, for example, a first predefined configuration.",
"In this way, the incoming power may be divided such that a predetermined amperage can be directed to each bay on the device.",
"Within each bay a user may place an interchangeable tray or rack designed to distribute power in a second predefined configuration as detailed below.",
"[0004] In a preferred embodiment, the housing also comprises a front, back, side, floor and roof panels.",
"In another embodiment, one or more doors are located in the front, back and side panels for access to internal components.",
"In yet another embodiment, the doors may have locks or other security devices to prevent unauthorized entry.",
"[0005] In yet another embodiment, the doors of the present invention may have openings through which the switches of the device (e.g., breaker switches) may extend.",
"With this design, the switches can be used without having to open the doors of the device.",
"The doors of the device may be opened, e.g., to service or rewire the device.",
"In yet another embodiment, the rear or back panel (or any other panel) of the device may have a double door (i.e., a door-behind-a-door arrangement).",
"With this arrangement, the outside door or first door, would block access to the device.",
"The inside or second door would, for example, have the switches of the breakers extending through the door for easy access but prevent access into the inside of the device thereby preventing, for example, inexperienced persons from accessing the wiring of the device.",
"In another embodiment, the device does not comprise a bottom panel or the bottom panel has slots or other perforations for cooling.",
"Likewise, the bottom panel may be made of a screen, a screen-like material, a mesh or a mesh-like material.",
"[0006] In the present invention, bays are defined as areas in the housing where racks or trays can be placed.",
"The bays typically have rails or other suitable supports at the side of the bay to support a rack or tray or they can have a complete floor to support the rack or tray.",
"The racks or trays of the present invention, in one embodiment, slide into the bay.",
"In another embodiment, the racks or trays have wheels for ease of insertion.",
"Once placed in the bay, they can be locked in position by pins or insert and locking handles, cam-locks or other suitable locking devices, for example, which are known in the art.",
"In a preferred embodiment, the locking device used to lock the tray/rack in position can be locked with a key to prevent unwanted removal of the tray/rack.",
"[0007] The racks (or trays) of the present invention are made and sized to slid into the bays of the housing.",
"The racks are designed to have a predetermined configuration for power output.",
"For example, the racks may have any combination of sockets equal to but not exceeding the amperage going to the bay.",
"Thus, a rack may have, for example, two 100 amp sockets (outputs), four fifty amp sockets or twenty 10-amp sockets for a bay that has 200 amps delivered to the bay.",
"The racks interconnect with the power source of the bay with, for example, male/female or female/male connectors or other suitable devices known in the art.",
"In another embodiment, the sockets of the rack may be interchanged so that the user may remove, for example, a fifty amp socket and replace it with two twenty-five amp sockets.",
"Numerous other suitable interchangeable combinations are also possible and can be practiced based on the teachings of the present specification.",
"[0008] The electrical power distribution device of the present invention comprises a primary breaker switch for shutting off power to the entire device.",
"The device also comprises secondary breaker switches for each bay useful for shutting off power to each bay individually if, for example, a tray or rack needs to be changed.",
"In one embodiment, power enters the device through one or more plugs or other connection devices.",
"Power is then conducted (via wire or other conductive material, for example) to the primary circuit breaker.",
"From the primary circuit breaker power is conducted to each bay or insertable tray or rack where the power is divided for delivery to each of the bays.",
"In one embodiment, the amount of amperage that each bay receives is equal to each other bay.",
"In another embodiment, the amount of amperage that each bay receives is different from one or more of the other bays of the device.",
"Each bay has a secondary breaker switch suitable for shutting of power to that bay.",
"Additionally, the sockets or groups of sockets on each tray may also have breakers to control (shut-off/start) power to each socket or groups of sockets.",
"[0009] Each bay is designed to accept a rack.",
"Racks of the present invention are interchangeable with other racks.",
"Racks may be made to handle the specific amperage of a particular bay.",
"However, each rack may divide the power entering the bay into various secondary predetermined configurations.",
"For example, if one bay is powered with 200 amperage (amps), the racks suitable for use in that bay would accept in input of 200 amps.",
"However, any one of the those racks may divide the power up in different configurations.",
"For example, one rack may divide the power into four 50 amp sockets, two fifty amp sockets and twenty-five amp sockets or forty-five amp sockets.",
"The racks of the present invention are not limited to any particular predetermined power configuration.",
"Each socket may, but need not have a switch for turning power on and off to that socket.",
"[0010] The trays are inserted into each bay and the connections on the back of the tray or rack meet with the connections at the back of the bay.",
"The connections at the back of the bay, in one embodiment, have power cut off to them when the tray or rack is removed by, for example, tripping the breaker switch for that bay.",
"This helps to prevent accidents or shorts from happening by not permitting the flow of current to the connectors at the back of the bay when a tray or rack is not in place.",
"Suitable power connectors are known in the art and available commercially.",
"[0011] The racks or trays are held in place by, for example, cam-locks at the front of the trays.",
"The cam-locks, may, for example, also work to push the tray further into the bay and thereby ensure that a solid contact has been made between the tray or rack and the connections at the back of the bay.",
"An interlock in conjunction with the cam-locks would, for example, trip the secondary circuit breakers to the bays to cut power to the bays when the trays are removed.",
"The interlocks may work, for example, similarly to the circuit breaker test trip switch found on bathroom style power sockets.",
"Once the trays are inserted into the bay, the interlock may serve to reset the secondary breaker or, in another embodiment, it may be required that the secondary breaker be reset manually.",
"The connectors between the trays or racks and the connectors at the back of the bays may comprise tabs, wires, plug-in or push-in (i.e., male/female-type or female/male type) connectors.",
"The present invention is not limited to any particular type or connector and any suitable connector known in the art is contemplated by the present invention.",
"[0012] In another embodiment, the portable power distribution device of the present invention is constructed to conform to applicable electrical standards.",
"Suitable components, manufactures, suppliers and standards may be found by referencing sources in the industry such as, for example, the National Electrical Manufacturers Association (www.",
"nema.org) or Underwriters Laboratory (www.",
"ul.com) and sources referenced therein.",
"These sources are not intended to be limiting but rather are intended to illustrate the knowledge available in the art at the time of the conception of the present invention in regards to the safe construction of electrical devices as well as components commercially available to the inventor of the present invention.",
"[0013] In a non-limiting embodiment, the power input into the portable power distribution box of the present invention has a power input of 600 amperes.",
"The power is then divided into bays wherein the power to each bay is of 100 or 200 hundred amperes each.",
"Each tray can then divide the incoming power to sockets wherein each socket has a rating of 5, 10 20, 25, 50, 100 or 200 amperes.",
"In one embodiment, it is contemplated that he input power source is rated between 50 and 2400 amperes.",
"In another embodiment, it is contemplated that the power delivered to any one bay is between 50 and 600 amperes.",
"In yet another embodiment, it is contemplated that the power delivered to any one socket of a tray or rack is between 5 and 600 amperes.",
"[0014] The housing of the present invention, in another embodiment, comprises at least two wheels to aid the user in moving the device.",
"If two wheels are present, they are located at the base of the housing on one side with the wheel axles in line with each other.",
"If four wheels are present then the wheels are located at each corner.",
"In the four-wheeled version of the device, the two leading wheels, the two trailing wheels or all four wheels may pivot or swivel to aid the user in steering the device.",
"The user may then grasp the housing of a handle provided on said housing to push or pull the device to a desired location.",
"If the device has two wheels, the user may pivot the device onto the two wheels and then push or pull the device to a desired location.",
"On devices with two wheels, the other end of the device may be held off of the ground with feet or other stationary means.",
"The feet or other stationary means also keeps the device from moving or rolling when the user does not what or need the device moved.",
"In devices with four wheels, one or more wheels may have wheel locks to prevent the device from moving when not desired.",
"Wheel locks may also be present on two wheeled units.",
"Wheel locks are, for example, friction devices that prevent the wheels from turning (rolling) when the wheel locks are used or activated.",
"Examples of suitable wheel lock devices are found on handcarts, pull wagons, etc.",
", and are well known in the art.",
"[0015] The present invention, in another embodiment, also comprises materials and methods for covering and protecting the device of the present invention.",
"A cover conceals the device from persons who may damage the device or become injured on it.",
"It also protects the device from inclement weather.",
"In one embodiment, the housing comprises retractable rods designed to support a tent-like structure that can surround the device housing.",
"In a preferred embodiment, the supports are located on the top panel of the housing.",
"One support is located at each corner of the device housing and positioned so that when extended from the retracted position it extends from the corner of the housing essentially horizontal to the ground.",
"The support can be extended when needed and can be locked in the retracted or extended position by, for example, a bolt, hitch clips, cotter pins or the like.",
"Additionally, one or more supports may extend from the top of the housing oriented essentially vertical to the ground.",
"The support can be, for example, a rod that is positioned into a receptacle located on the top (or roof) of the housing.",
"If one support is used then the receptacle would be located essentially at the center of the housing roof.",
"In a preferred embodiment, the covering is a tent or tent-like device that attaches to the support rods of the housing.",
"[0016] In one embodiment, the present invention contemplates a portable device for distributing electrical power in one or more interchangeable predefined configurations, said device comprising: a housing, said housing comprising a roof and sides, two or more wheels, a handle, a means for preventing the device from rolling when movement of the device is not desired, one or more doors located at the front, back and/or sides of the housing and a plurality of bays within said housing;",
"wherein said electrical power is delivered to said bays in one or more first predefined configurations and wherein within said bays, interchangeable racks suitable for the distribution of electrical power in one or more second predefined configurations are interchangeably inserted.",
"[0017] In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations additionally comprises a primary breaker.",
"In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations additionally comprises a secondary breaker for each bay.",
"In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations additionally comprises a means (e.g., a socket or sockets) for connecting to an electrical power source.",
"In yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations is connected to an electrical power source ranging from about 50 to 2400 amps.",
"In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises from about 1 to 7 bays.",
"In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a first predefined power configuration to said bays is from about 25 to 600 amps.",
"In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises one or more sockets of about 5 to 600 amps each to a maximum amperage equal to that of the first predefined power configuration of the bay wherein said rack is inserted.",
"In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises sockets wherein said sockets are interchangeable individually or in groups.",
"In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a covering sized to fit over the device concealing it from view and wherein said covering is selected from a group consisting of being designed to attached to said device or being designed to be free standing.",
"In still yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a means for the trays or racks to interface with electrical power from the housing comprises one or more of tabs, wires or plug-in connectors and that the trays or racks are locked into said bays with cam-locks.",
"In still yet another embodiment, the present invention contemplates that the one or more doors located at one or more of the front, back and/or sides of the housing comprise a first door and a second door, said second door located behind said first door and covered by said first door when said first door is closed.",
"[0018] In one embodiment, the present invention contemplates a portable device for distributing electrical power in one or more interchangeable predefined configurations, said device comprising: a housing, said housing comprising a roof and sides, two or more wheels, a handle, a means for preventing the device from rolling when movement of the device is not desired, one or more doors located at the front, back and/or sides of the housing and a plurality of bays within said housing;",
"wherein said electrical power is delivered to said bays in one or more first predefined configurations and wherein within said bays, interchangeable racks suitable for the distribution of electrical power in one or more second predefined configurations are interchangeably inserted;",
"wherein said racks are locked into said bays with cam-locks;",
"wherein said means for the racks to interface with electrical power from the housing comprises one or more of tabs, wires, plug-in or push-in connectors;",
"and wherein at least one socket in one tray/rack is interchangeable with one or more other sockets.",
"[0019] In another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a means for the racks to interface with electrical power from the housing comprises plug-in or push-in connectors.",
"In yet another embodiment, the present invention contemplates that the portable device for distributing electrical power in one or more interchangeable predefined configurations comprises a covering sized to fit over the device concealing it from view and wherein said covering is selected from a group consisting of being designed to attached to said device or being designed to be free standing of said.",
"[0020] In one embodiment, the present invention contemplates a method of distributing electrical power in predefined interchangeable configurations, comprising: providing: i) the device of the present invention, ii) a power source and, iii) one or more electrical devices wherein each electrical device is in need of electrical power of a known amperage and wherein the power needed by the each of the one or more electrical devices is the same or different from the other electrical devices;",
"configuring the device of present invention in such a way to provide the amount of electrical power needed by each electrical device to each electrical device;",
"connecting the device of present invention to the power source and to the one or electrical devices in need of electrical power;",
"and provide electrical power to the device of present invention through the power source.",
"[0021] In another embodiment, the present invention contemplates that the device of the present invention and methods of use of the present invention comprise user instructions and/or service manuals and/or repair guides.",
"[0022] Other features and advantages of the invention will be apparent from the following description.",
"BRIEF DESCRIPTION OF DRAWINGS [0023] FIG. 1 shows a front view of one embodiment of the present invention with the door closed.",
"[0024] FIG. 2 shows the front view of one embodiment of the present invention with the door opened.",
"[0025] FIG. 3 shows back view of one embodiment of the present invention with the door opened.",
"An exemplification of the visible wiring is also shown.",
"[0026] FIG. 4 shows a side view of one embodiment of the present invention with the door opened.",
"[0027] FIG. 5 shows a top view of one embodiment of the present invention with the support arms for the cover shown.",
"[0028] FIG. 6 shows a ¾ front view of one embodiment of the present invention with one of the interchangeable racks removed.",
"[0029] FIG. 7 shows a wiring diagram of showing a schematic of the distribution of power from the feed lines into the device to the connectors that interface with the trays or racks.",
"Power configurations are exemplary only.",
"[0030] FIG. 8 shows a wiring diagram of one exemplary tray or rack.",
"[0031] FIG. 9 shows a wiring diagram of a second exemplary tray or rack.",
"DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0032] The invention will now be described in detail with reference to a few preferred embodiments, as illustrated in accompanying drawings.",
"In the following description, numerous specific details are set forth in order to provide a thorough understanding of the invention.",
"However, it will be apparent to one skilled in the art that the invention may be practiced without some or all of these specific details.",
"In other instances, well-known features and/or process steps have not been described in detail in order to not unnecessarily obscure the invention.",
"The features and advantages of the invention may be better understood with reference to the drawings and discussions that follow.",
"[0033] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein.",
"[0034] FIG. 1 shows one embodiment of the device of the present invention with the door closed.",
"Shown in this exemplary embodiment are the handle 10 , the door 12 , the locking devices for the door 14 , feet 16 , a support for a post useful in supporting a covering over the top of the device of the present invention 17 , and four supports useful for holding a covering way from the sides of the device of the present invention 18 .",
"[0035] FIG. 2 shows one embodiment of the device of the present invention with the front door open.",
"Visible in this exemplary embodiment are the locking devices for the door 14 , the feet 16 , three removable/interchangeable trays/racks suitable for plugging in electrical devices into the present invention, 20 A, 20 B, 20 C. The device is not limited to any particular number of removable/interchangeable trays/racks.",
"In other embodiments of the present invention the number of trays/racks may number, for example, from 1 to 7 (or more).",
"The trays/racks of the present invention are held in place by, for example, cam-locks 21 with one cam-lock on each front edge of the tray/rack.",
"The cam-locks of the present invention also may be useful in pushing the tray/rack further into the bay thereby ensuring that the electrical contacts/connectors at the rear of the tray/rack make secure contact with the appropriate electrical contacts/connectors in the rear of the bay.",
"The trays/racks of the present invention are slid into the bay on supports 26 , and rest on the supports when positioned in the bay.",
"Power is inputted into the device on panel 24 , where input connectors are present for equipment ground, system ground and one power input for each available rack or tray.",
"Also shown are feed-through, pass-through or output plugs suitable for connecting, for example, a second device of the present invention or other electrical device.",
"[0036] FIG. 3 shows one embodiment of the rear panel of the device of the present invention.",
"Shown in this exemplary embodiment are the handle 10 , corner supports for a cover 18 , the rear door 32 , locking devices for the rear door 34 , secondary circuit breakers 38 for each tray/rack and wheels 36 .",
"Also visible is one embodiment of the wiring of the device.",
"The three sets of wires on the left of the figure are the power conducting wires.",
"The two sets of wires on the right are the tray/rack equipment and system grounds.",
"[0037] FIG. 4 shows one embodiment of a side view of the device of the present invention.",
"Visible in this exemplary embodiment are the door 42 , the locking device for the door 44 , the handle 10 , corner supports 18 for a cover for the device, one of two feet 16 , one of two wheels 36 and the sides of each tray/rack ( 40 A, 40 B and 40 C) showing circuit breakers for specific electrical sockets in the respective trays/racks.",
"[0038] FIG. 5 shows one embodiment of a top view of the device of the present invention.",
"Shown in this exemplary embodiment are four corner supports for a cover 18 , a center support for a post for supporting a cover 17 , the handle 10 , extendable support rods 19 , and thumb screws or other suitable devices 15 for holding the extendable support rods in position.",
"The insert picture shows an extendable rod 19 of a corner support 18 of the present invention in the extended position.",
"[0039] FIG. 6 shows a ¾ cut-away view of the device of the present invention.",
"Shown in this exemplary embodiment are the front door 12 , the side door 44 , the feet 16 , one of two wheels 36 , trays/racks 20 A and 20 B, one tray/rack support 26 , and circuit breaker panels 40 A and 40 B on trays/racks 20 A and 20 B, respectively.",
"Number 50 shows the top of tray/rack 20 A which may be closed, opened or partially closed or opened depending on the configuration chosen by the builder or user.",
"[0040] FIGS. 7 , 8 and 9 show exemplary wiring diagrams for the present invention.",
"Conventional symbols and nomenclature known in the art are used."
] |
TECHNICAL FIELD
The subject invention relates to a control assembly for actuating the parking brake of a vehicle, and more particularly to a completely mechanical control assembly having a remote manual actuator.
BACKGROUND ART
Manually operated park brake control assemblies are typically positioned in the passenger compartment of a vehicle adjacent the operator and present a hand or foot operated lever to be manually operated by the vehicle operator for applying, or setting, the park brake. Generally, the hand or foot operated lever is supported on a pivot and integrally attached to a ratchet mechanism for maintaining the control assembly in an actuated condition in order to hold the park brake in the brake applied condition. The park brake is released by triggering some form of independent release mechanism.
Such prior art park brake control assemblies have two significant disadvantages. First, the entire mechanism must be located inside the passenger compartment. The physical size of the control assembly inside the passenger compartment prevents optimal use of the space in which it is located. As vehicle designs seek to conserve and better utilize all available space in the passenger compartment, such large and bulky park brake control assemblies become a greater design burden. Therefore, the first deficiency in the prior art park brake control assemblies relates to their inherently large size coupled with the unavoidable requirement that they be positioned inside the passenger compartment.
Second, flexible motion transmitting core elements, or cables, are typically used to interconnect the park brake control assembly and the park brakes at the rear wheels of the vehicle. As one park brake is located at each of the two rear wheels of most vehicles, two such cables must extend the majority of the distance between the control assembly and the park brakes. These cables must be of relatively high tensile strength because tensile forces in excess of 90 pounds can be generated between the control assembly and park brake during actuation, and maintained therebetween for very long periods of time. It will be appreciated that such high tensile strength cables are costly, heavy, and in addition are difficult to install and service due to their stiffness.
The U.S. Pat. No. 4,795,002 to Burgei et al, issued Jan. 3, 1983, discloses an electronic park brake control assembly located adjacent the brakes and having a remote actuator located inside the passenger compartment. Such fully electronic systems have not gained wide acceptance due to unreliability and difficulty in diagnosing the cause of system failures. Purely mechanical control assemblies are preferred in most situations yet cannot be divorced of their above-described disadvantages.
SUMMARY OF THE INVENTION AND ADVANTAGES
The subject invention contemplates a manually operated vehicular park brake assembly comprising an actuator means for mechanically transmitting forces applied by a vehicle operator, and a control means for receiving forces from the actuator means and selectively maintaining a park brake in a brake applied condition in response to the forces. The invention is characterized by an isolator means for isolating the forces between the actuator means and the control means while the control means maintains the park brake in the brake applied condition to remove stresses from the actuator means and thereby improve the operating efficiency of the system.
The subject invention overcomes the disadvantages inherent in the prior art by providing the isolator means which allows the stresses which occur while the park brake is in a brake applied condition to be completely isolated from the actuator means. From this it follows that the actuator means can be fabricated from lower strength, lower cost materials and hence supplies the necessary incentive to space the isolator means and the actuator means apart from each other as far as possible. The isolator means of the subject invention makes advantageous separating the actuator means from the control means so that only the actuator means need be provided inside the passenger compartment of the vehicle. The control means and the isolator means, on the other hand, can be located outside the vehicle, inside the vehicle trunk, or in some other ergonometricly advantageous position.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is an environmental view of the subject invention disposed for use in a vehicle;
FIG. 2 is a plan view of an actuator according to the invention, with the cover removed to show the control means and isolator means;
FIG. 3 is a view similar to FIG. 2, but partially schematicized to show the invention in an unactuated condition;
FIG. 4 is a view similar to FIG. 3, with the invention shown in the brake applied condition with the actuator means fully actuated;
FIG. 5 is a view similar to FIG. 4, with the subject invention shown in the brake applied condition with the actuator returned to an unactuated position;
FIG. 6 is a view similar to FIG. 5, with the subject invention shown with the actuator means reactuated to disengage the pawl from the lock sector and return the assembly to the unactuated condition;
FIG. 7 is an enlarged detail view of the ratchet means of the subject invention shown in the unactuated condition corresponding to FIGS. 2 and 3;
FIG. 8 is a view similar to FIG. 7, with the lock sector moving into ratcheting engagement with the pawl;
FIG. 9 is a view similar to FIG. 8, with the pawl in engagement with the lock sector corresponding to FIG. 4;
FIG. 10 is a view similar to FIG. 9, showing the trip spring moving over center of the pin to prepare the pawl for disengagement corresponding to FIG. 5;
FIG. 11 is a view similar to FIG. 10, showing the pawl disengaged from the lock sector corresponding to FIG. 6; and
FIG. 12 is a view similar to FIG. 11, showing the recock arm preparing to move the pawl over center of the pin as the control crank moves back to the unactuated position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, the subject park brake assembly is generally indicated at 20. In FIG. 1, the assembly 20 is shown in connection with a vehicle, generally indicated at 22. The vehicle 22 includes two rear wheels 24 each having a brake assembly. Each of the brake assemblies is provided with a park brake 26 used by the vehicle operator to set the vehicle 22 in a braked condition while not in use. The rear wheels 24 may be supported on a common axle 28, as is well known in the art.
The subject assembly 20 is manually operated and therefore includes an actuator means, generally indicated at 30, for mechanically transmitting forces applied by a vehicle operator to the park brakes 26. As shown in FIGS. 1 and 3-6, the actuator means 30 includes a lever 32 which is pivoted about a fulcrum 34 thereof in response to the forces applied by the vehicle operator. Although the lever 32 is shown in the accompanying Figures as being of the foot operated type, it will be appreciated by those skilled in the art that a hand operated actuator operates in substantially the same manner to yield the same result as the disclosed foot operated lever 32. The lever 32 is disposed inside the passenger compartment of the vehicle 22 in an easily accessed location for the vehicle operator, such as underneath the dashboard in the case of a foot operated lever 32, or alternatively underneath the dashboard or adjacent the driver's seat in the case of a hand operated lever.
The subject invention also includes a control means, generally indicated at 36, which is supported substantially within a protective housing 38, shown with its cover removed for clarity. The control means 36 receives forces from the actuator means 30 and selectively maintains the park brake 26 in a brake applied condition in response to such forces. In other words, as the operator rotates the lever 32 about its fulcrum 34, forces are mechanically transferred to the control means 36, which then transmits such mechanical forces to the park brake to maintain the park brake in a brake applied condition.
The subject invention is characterized by including an isolator means, generally indicated at 40, which is also disposed within the housing 38. The isolator means 40 functions to isolate the forces between the actuator means 30 and the control means 36 while the control means 36 maintains the park brake 26 in the brake applied condition to thereby remove stresses from the actuator means 30 and improve the operating efficiency of the assembly 20. The isolator means 40 is disposed between and interconnects the actuator means 30 and the control means 36 and prevents the feedback of stresses to the actuator means 30 while the control means 36 holds the park brake 26 in the brake applied condition. Therefore, the stress isolating function of the isolator means 40 operates only when the control means 36 maintains the park brake 26 in the brake applied condition.
Referring now to FIGS. 2-6, the isolator means 40 includes an input means, generally indicated at 42, for interconnecting the actuator means 30 and the isolator means 40. The isolator means 40 also includes an output means, generally indicated at 44, for interconnecting the control means 36 and the isolator means 40. The isolator means 40 includes a lost motion connection, generally indicated at 46, which is disposed between and interconnects the input means 42 and the output means 44. Therefore, the lost motion connection 46 is disposed between the actuator means 30 and the control means 36.
The input means 42 includes a bell-shaped drive reel 48 which is pivotally supported for arcuate movement about an isolator pivot 50. As shown in the Figures, the bell-shape of the drive reel 48 is formed by two straight edges 52 intersecting at an apex and joining to a common curved camming edge 54. The isolator pivot 50 is disposed between the two edges 52 adjacent the apex, with the camming edge 54 forming a concentric arc segment about the isolator pivot 50.
The output means 44 includes an isolator crank arm 56 which is also pivotally supported for arcuate movement about the isolator pivot 50 but is independently moveable of the drive reel 48. That is, the drive reel 48 and isolator crank 56 are moveable relative to each other in arcuate paths about the isolator pivot 50.
The lost motion connection 46 interconnects the drive reel 48 and the isolator crank 56. More specifically, as best shown in FIGS. 2-6, the lost motion connection 46 includes an arcuate slot 58 which is formed in the drive reel 48 and disposed concentrically about the isolator pivot 50. A finger 60 extends from the distal, free swinging, end of the isolator crank 56 and is disposed within the arcuate slot 58. The finger 60 is confined at all times within the slot 58 for movement between a first 62 and a second 64 terminal end of the arcuate slot 58.
The isolator means 40 further includes a biasing means 66 which interconnects the drive reel 48 and the isolator crank 56. The biasing means 66 urges the drive reel 48 in a first predetermined arcuate direction, clockwise as viewed in FIGS. 2-6, relative to the isolator crank 56. More particularly, the biasing means 66 comprises a flat wound coil spring, also known as a spiral torsion spring, having a radially displaced end operatively connected to the finger 60 and another end adjacent its center connected to the drive reel 48. The spring 66 constantly urges the drive reel 48 clockwise about the isolator pivot 50 but, due to the housing 38, is prevented from clockwise movement past the position shown in FIG. 2.
Referring to FIGS. 1-6, the actuator means 30 includes an elongated motion transmitting means 68 which interconnects the lever 32 and the drive reel 48 for mechanically transmitting motion between the lever 32 and the drive wheel 48 along a curved path. More specifically, the motion transmitting means 68 comprises a flexible cable having a first end 70 connected to the lever 32 and a second end 72 connected to the drive reel 48 at a connection 74. The second end 72 of the cable 68 is wound about the exterior of the drive reel 48, i.e., about the camming edge 54, in order to effect rotation of the drive reel 48 about the isolator pivot 50 in response to pivotal movement of the lever 32 about its fulcrum 34. As the vehicle operator urges the lever 32 to pivot about its fulcrum 34 when applying the park brake, the cable 68 is displaced a corresponding distance and mechanically urges the drive wheel 48 to rotate about the isolator pivot 50.
In FIGS. 2-6, the control means 36 is shown including a control crank arm 76 which is operatively connected to the isolator crank 56 for arcuate movement about a control pivot 78. A rigid link 80 extends between opposite ends thereof with one of the ends being pivotally connected to the isolator crank 56 and the other end pivotally connected to the control crank 76. Therefore, as the isolator crank 56 rotates about the isolator pivot 50, the control crank 76 is urged to rotate about the control pivot 78. The control pivot 78 and the isolator pivot 50 are spaced from one another and so disposed as to rotate the respective control crank 76 and isolator crank 56 in parallel planes.
The control means 36 includes at least one, and preferably two, brake throws 82, 84 which extend radially outwardly of the control pivot 78 and are integrally connected to the control crank 76. The two brake throws 82, 84 are disposed on opposite sides of the control pivot 78. The control crank 76 extends radially outwardly from between the two brake throws 82, 84, at an angle slightly less than 90° from the one brake throw 82 and slightly greater than 90° from the other brake throw 84.
The control means 36 further includes two cables 86, 86' having one end connected to one of the brake throws 82, 84 and the other ends operatively connected to a respective park brake 26 at one of the two rear wheels 24. Each cable 86, 86' is connected to one of the brake throws 82, 84 for interconnecting the associated brake throw 82, 84 with one of the park brakes 26. A slug 88, 88' is disposed on the end of each of the cables, 86' for attachment to the respective rake throw 82, 84.
An automatic fastener means, generally indicated at 90, 90' in FIG. 2, is provided for, automatically fastening the slug 88, 88' of each cable 86, 86' to its associated brake throw 82, 84 in response to a coupling force applied to interconnect two elements. The automatic fastener means 90, 90' each includes a resilient latch 92, 92' extending integrally from each brake throw 82, 84. A cup shaped pocket 94 is provided in each brake throw 82, 84 for receiving the slugs 88, 88'. The latches, 92' are resiliently disposed to support the slug 88, 88' in the respective pockets 94 yet allow easy insertion of the slugs ,88' into the pockets 94 for installation purposes. Cable passages 96' are provided through the housing 38 for each of the cables, 86, 86'. Similarly, a flexible element passage 98 is provided through the housing 38 for the flexible cable 68.
Referring now to FIGS. 2-12, the control means 36 is shown including a ratchet means, generally indicated at 100, for locking the control crank 76 in an angular position in response to a first applied force from the actuator means 30 and for unlocking the control crank 76 in response to a second successively applied force from the actuator means 30. The ratchet means 100 operates in toggle fashion by locking the control crank 76 in a brake applied condition in response to a first applied force from the actuator means 30, and then reversing itself and automatically unlocking the control crank 76 solely in response to a second successively applied force from the actuator means 30.
The ratchet means 100 includes a saw-toothed lock sector 102 comprising a series of ramps, or barbs, which coact with a pawl 104. The pawl 104 is supported on a pin 106 and adapted to engage the teeth of the lock sector 102 in ratcheting fashion. As perhaps best shown in FIGS. 8-12, the pawl 104 includes an elongated slot 108 which surrounds the pin 106 and serves to interconnect the pawl 104 and the pin 106.
The ratchet means 100 further includes a strategically located trip spring 110 which exerts a compressive force between the housing 38 and the pawl 104 for urging the pawl 104 to ratchetingly engage the lock sector 102 in response to the first applied force from the actuator means 30, and then for urging the pawl 104 to disengage from the lock sector 102 in response to a second applied force from the actuator means 30.
More particularly, in FIG. 7 the pawl 104 is shown in spacial relation to the lock sector 102 in an unactuated condition corresponding to FIGS. 2 and 3. As the lever 32 is pivoted about its fulcrum 34 to apply a first force to the control crank 76, the lock sector 102 rotates about the control pivot 78 until the pawl 104 makes initial contact with the lock sector 102 as shown in FIG. 8. This causes the pawl 104 to move relative to the pin 106 from the position shown in FIG. 7, wherein the pin 106 is generally centered in the elongated slot 108 to the position shown in FIG. 8, where the pin 106 is disposed in engagement with the rearward edge of the elongated slot 108.
This movement of the pawl 104 relative to the pin 106 causes the trip spring 110 to direct its biasing force on one side of the pin 106 and thereby apply a force on the pawl 104 tending to urge it in the clockwise direction, in ratcheting engagement with the lock sector 102. Therefore, as the lock sector 102 continues to rotate about the control pivot 78, the pawl 104 and lock sector 102 ratchet to the position shown in FIG. 9. FIG. 9 corresponds to the schematic illustration of FIG. 4 wherein the lever 32 has been fully actuated and the park brakes 26 have been placed in a brake applied condition.
As the vehicle operator releases the first applied force on the lever 32 the lock sector 102 rotates in reverse, or counter clockwise, direction about the control pivot 78, causing the pawl 104 to move rearwardly relative to the pin 106 until the pin 106 engages the forward edge of the elongated slot 108. This causes the trip spring 110 to move onto the opposite side of the pin 106 and thereby urges the pawl 104 to rotate in a counter clockwise direction about the pin 106. However, because the pawl 104 is engaged with the teeth of the lock sector 102, the pawl 104 and lock sector 102 remain operatively engaged to maintain the brake throws 82, 84 in a brake applied condition, as illustrated in FIG. 10.
When the operator applies a second successive force to the lever 32, as represented in FIG. 6, to move the lock sector 102 slightly about the control pivot 78 in a clockwise direction, the trip spring 110 urges the pawl 104 to disengage the lock sector 102 as shown in FIG. 11. With this, the isolator means 40 ceases to isolate the forces between the control means 36 and the actuator means 30 as that the vehicle operator may gradually move the park brakes 26 from the brake applied condition back to an unactuated condition as shown in FIGS. 2 and 3.
The control crank 76 includes a recock arm 112 for urging the pawl 104 to engage the lock sector 102 after the second force has been applied by the actuator means 30. More particularly, the recock arm 112 and the pawl 104 include coacting camming surfaces which urge the pawl 104 to move relative to the pin 106 within the slot 108 so that the trip spring 110 will once again urge the pawl 104 in a clockwise direction about the pin 106 to ratchet with the lock sector 102.
OPERATION OF THE PREFERRED EMBODIMENT
Referring to the Figures, the operation of the preferred embodiment will be addressed presently. From the unactuated position shown in FIGS. 2 and 3, the vehicle operator applies a force to the lever 32 rotating it about its fulcrum 34. This, in turn, displaces the cable 68 such that the attached drive reel 48 is caused to rotate about the isolator pivot 50. With the first end 62 of the arcuate slot 58 in engagement with the finger 60, movement of the drive reel 48 concurrently urges the isolator crank 56 about the isolator pivot 50. By way of the rigid link 80, the control crank 76 is caused to rotate in a clockwise direction about the crank pivot 78 in response to counter clockwise movement of the isolator crank 56 about the isolator pivot 50. Such movement of the control crank 76 simultaneously causes each of the brake throws 82, 84 to displace their associated cables 86, 86', thereby actuating the park brake 26 and causing the lock sector 102 to ratchetingly engage the pawl 104.
As the brake throws 82, 84 rotate about the control pivot 78, they apply an increasingly greater leverage about the control pivot 78 upon the cables 86, 86'. That is, as the brake throws 82, 84 rotate toward the brake applied condition, each of the cables 86, 86' begin to move closer to the control pivot 78, thereby increasing the leverage while decreasing the displacement of the cables 86, 86'. In the preferred embodiment, the ratio will increase from the unactuated condition shown in FIGS. 2 and 3 at about 3.5:1 to a ratio as high as 4:1 in the fully applied condition as shown in FIGS. 4-6.
While the pawl 104 is engaged with the lock sector 102 to maintain the park brake 26 in a brake applied condition, the biasing means 66 urges the drive reel 48 to rotate in a clockwise direction back toward an unactuated position as shown in FIG. 5. Such retracting movement of the drive reel 48 urges the lever 32 back toward its unactuated position via the cable 68.
To release the park brakes 26 from the brake applied condition, the lever 32 is urged back toward its brake applied position until the first end 62 of the arcuate slot 58 contacts and slightly displaces the finger 60. This slight displacement of the finger 60 causes the control crank 76 to move a small arcuate degree in the clockwise direction about the control pivot 78 allowing the pawl 104 to disengage from the lock sector 102. The lever 32 is then slowly moved by the vehicle operator from the position shown in FIG. 6 back to the position shown in FIG. 3 and thereby gradually releasing the park brake 26 to an unactuated condition.
The primary advantage of the subject invention is that the isolator means 40 completely isolates the lever 32 and flexible cable 68 from the forces on the control means 36 while the park brakes 26 are maintained in a brake applied condition. More specifically, tensile forces of 90 pounds or greater may be required to maintain park brakes 26 in a brake applied condition. Hence, each of the cables 86 are required to withstand such a 90 pound tensile load for extended periods of time, and therefore must be constructed of very durable material. However, as the cable 68 is never required to maintain such a tensile load for any length of time greater than the brief moment required to actuate or deactuate the park brakes 26, the cable 68 can be fabricated from a much less durable, lighter and less expensive material.
Hence, the isolator means 40 supplies the necessary incentive to design the assembly 20 with the inexpensive flexible cable 68 spanning the greatest distance and the two heavy and expensive cables 86, 86' spanning a minimal distance. Therefore, as shown in FIG. 1, the housing 38 can be positioned adjacent the rear axle 28 with each of the cables 86, 86' extending a relatively short distance to their associated park brake 26. The inexpensive and light flexible cable 68, on the other hand, can be routed from the housing 38 adjacent the rear axle 28 to the lever 32 disposed within the passenger compartment of the vehicle. Additionally, the only structure required inside the passenger compartment of the vehicle 22 is the lever 32 and its support fulcrum 34. The relatively bulky control means 36 is positioned in an unobtrusive space, freeing the valuable interior space for maximum occupant comfort.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described. | A park brake assembly (20) provides a hand or foot operated park brake actuator (30) connected to a drive reel (48) via a flexible motion transmitting core element (68). The drive reel (48) is connected to an isolator crank (56) via a lost motion connection (46). The isolator crank (56) is operatively connected to a control crank (76) which, in turn, directly actuates the park brake (26). The control crank (76) includes a lock sector (102) which coacts with a pawl (104) to selectively maintain the park brake (26) in a brake applied condition. When in the brake applied condition, the lost motion connection (46) allows the drive reel (48) to return to an unactuated position thereby eliminating all stresses from the actuator (30). The pawl (104) includes an elongated slot (108) and a trip spring (110) which coact to alternatively ratchet the pawl (104) against the lock sector (102) and then to disengage the pawl (104) from the lock sector (102) without requiring an independent release mechanism. | Concisely explain the essential features and purpose of the invention. | [
"TECHNICAL FIELD The subject invention relates to a control assembly for actuating the parking brake of a vehicle, and more particularly to a completely mechanical control assembly having a remote manual actuator.",
"BACKGROUND ART Manually operated park brake control assemblies are typically positioned in the passenger compartment of a vehicle adjacent the operator and present a hand or foot operated lever to be manually operated by the vehicle operator for applying, or setting, the park brake.",
"Generally, the hand or foot operated lever is supported on a pivot and integrally attached to a ratchet mechanism for maintaining the control assembly in an actuated condition in order to hold the park brake in the brake applied condition.",
"The park brake is released by triggering some form of independent release mechanism.",
"Such prior art park brake control assemblies have two significant disadvantages.",
"First, the entire mechanism must be located inside the passenger compartment.",
"The physical size of the control assembly inside the passenger compartment prevents optimal use of the space in which it is located.",
"As vehicle designs seek to conserve and better utilize all available space in the passenger compartment, such large and bulky park brake control assemblies become a greater design burden.",
"Therefore, the first deficiency in the prior art park brake control assemblies relates to their inherently large size coupled with the unavoidable requirement that they be positioned inside the passenger compartment.",
"Second, flexible motion transmitting core elements, or cables, are typically used to interconnect the park brake control assembly and the park brakes at the rear wheels of the vehicle.",
"As one park brake is located at each of the two rear wheels of most vehicles, two such cables must extend the majority of the distance between the control assembly and the park brakes.",
"These cables must be of relatively high tensile strength because tensile forces in excess of 90 pounds can be generated between the control assembly and park brake during actuation, and maintained therebetween for very long periods of time.",
"It will be appreciated that such high tensile strength cables are costly, heavy, and in addition are difficult to install and service due to their stiffness.",
"The U.S. Pat. No. 4,795,002 to Burgei et al, issued Jan. 3, 1983, discloses an electronic park brake control assembly located adjacent the brakes and having a remote actuator located inside the passenger compartment.",
"Such fully electronic systems have not gained wide acceptance due to unreliability and difficulty in diagnosing the cause of system failures.",
"Purely mechanical control assemblies are preferred in most situations yet cannot be divorced of their above-described disadvantages.",
"SUMMARY OF THE INVENTION AND ADVANTAGES The subject invention contemplates a manually operated vehicular park brake assembly comprising an actuator means for mechanically transmitting forces applied by a vehicle operator, and a control means for receiving forces from the actuator means and selectively maintaining a park brake in a brake applied condition in response to the forces.",
"The invention is characterized by an isolator means for isolating the forces between the actuator means and the control means while the control means maintains the park brake in the brake applied condition to remove stresses from the actuator means and thereby improve the operating efficiency of the system.",
"The subject invention overcomes the disadvantages inherent in the prior art by providing the isolator means which allows the stresses which occur while the park brake is in a brake applied condition to be completely isolated from the actuator means.",
"From this it follows that the actuator means can be fabricated from lower strength, lower cost materials and hence supplies the necessary incentive to space the isolator means and the actuator means apart from each other as far as possible.",
"The isolator means of the subject invention makes advantageous separating the actuator means from the control means so that only the actuator means need be provided inside the passenger compartment of the vehicle.",
"The control means and the isolator means, on the other hand, can be located outside the vehicle, inside the vehicle trunk, or in some other ergonometricly advantageous position.",
"BRIEF DESCRIPTION OF THE DRAWINGS Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: FIG. 1 is an environmental view of the subject invention disposed for use in a vehicle;",
"FIG. 2 is a plan view of an actuator according to the invention, with the cover removed to show the control means and isolator means;",
"FIG. 3 is a view similar to FIG. 2, but partially schematicized to show the invention in an unactuated condition;",
"FIG. 4 is a view similar to FIG. 3, with the invention shown in the brake applied condition with the actuator means fully actuated;",
"FIG. 5 is a view similar to FIG. 4, with the subject invention shown in the brake applied condition with the actuator returned to an unactuated position;",
"FIG. 6 is a view similar to FIG. 5, with the subject invention shown with the actuator means reactuated to disengage the pawl from the lock sector and return the assembly to the unactuated condition;",
"FIG. 7 is an enlarged detail view of the ratchet means of the subject invention shown in the unactuated condition corresponding to FIGS. 2 and 3;",
"FIG. 8 is a view similar to FIG. 7, with the lock sector moving into ratcheting engagement with the pawl;",
"FIG. 9 is a view similar to FIG. 8, with the pawl in engagement with the lock sector corresponding to FIG. 4;",
"FIG. 10 is a view similar to FIG. 9, showing the trip spring moving over center of the pin to prepare the pawl for disengagement corresponding to FIG. 5;",
"FIG. 11 is a view similar to FIG. 10, showing the pawl disengaged from the lock sector corresponding to FIG. 6;",
"and FIG. 12 is a view similar to FIG. 11, showing the recock arm preparing to move the pawl over center of the pin as the control crank moves back to the unactuated position.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, the subject park brake assembly is generally indicated at 20.",
"In FIG. 1, the assembly 20 is shown in connection with a vehicle, generally indicated at 22.",
"The vehicle 22 includes two rear wheels 24 each having a brake assembly.",
"Each of the brake assemblies is provided with a park brake 26 used by the vehicle operator to set the vehicle 22 in a braked condition while not in use.",
"The rear wheels 24 may be supported on a common axle 28, as is well known in the art.",
"The subject assembly 20 is manually operated and therefore includes an actuator means, generally indicated at 30, for mechanically transmitting forces applied by a vehicle operator to the park brakes 26.",
"As shown in FIGS. 1 and 3-6, the actuator means 30 includes a lever 32 which is pivoted about a fulcrum 34 thereof in response to the forces applied by the vehicle operator.",
"Although the lever 32 is shown in the accompanying Figures as being of the foot operated type, it will be appreciated by those skilled in the art that a hand operated actuator operates in substantially the same manner to yield the same result as the disclosed foot operated lever 32.",
"The lever 32 is disposed inside the passenger compartment of the vehicle 22 in an easily accessed location for the vehicle operator, such as underneath the dashboard in the case of a foot operated lever 32, or alternatively underneath the dashboard or adjacent the driver's seat in the case of a hand operated lever.",
"The subject invention also includes a control means, generally indicated at 36, which is supported substantially within a protective housing 38, shown with its cover removed for clarity.",
"The control means 36 receives forces from the actuator means 30 and selectively maintains the park brake 26 in a brake applied condition in response to such forces.",
"In other words, as the operator rotates the lever 32 about its fulcrum 34, forces are mechanically transferred to the control means 36, which then transmits such mechanical forces to the park brake to maintain the park brake in a brake applied condition.",
"The subject invention is characterized by including an isolator means, generally indicated at 40, which is also disposed within the housing 38.",
"The isolator means 40 functions to isolate the forces between the actuator means 30 and the control means 36 while the control means 36 maintains the park brake 26 in the brake applied condition to thereby remove stresses from the actuator means 30 and improve the operating efficiency of the assembly 20.",
"The isolator means 40 is disposed between and interconnects the actuator means 30 and the control means 36 and prevents the feedback of stresses to the actuator means 30 while the control means 36 holds the park brake 26 in the brake applied condition.",
"Therefore, the stress isolating function of the isolator means 40 operates only when the control means 36 maintains the park brake 26 in the brake applied condition.",
"Referring now to FIGS. 2-6, the isolator means 40 includes an input means, generally indicated at 42, for interconnecting the actuator means 30 and the isolator means 40.",
"The isolator means 40 also includes an output means, generally indicated at 44, for interconnecting the control means 36 and the isolator means 40.",
"The isolator means 40 includes a lost motion connection, generally indicated at 46, which is disposed between and interconnects the input means 42 and the output means 44.",
"Therefore, the lost motion connection 46 is disposed between the actuator means 30 and the control means 36.",
"The input means 42 includes a bell-shaped drive reel 48 which is pivotally supported for arcuate movement about an isolator pivot 50.",
"As shown in the Figures, the bell-shape of the drive reel 48 is formed by two straight edges 52 intersecting at an apex and joining to a common curved camming edge 54.",
"The isolator pivot 50 is disposed between the two edges 52 adjacent the apex, with the camming edge 54 forming a concentric arc segment about the isolator pivot 50.",
"The output means 44 includes an isolator crank arm 56 which is also pivotally supported for arcuate movement about the isolator pivot 50 but is independently moveable of the drive reel 48.",
"That is, the drive reel 48 and isolator crank 56 are moveable relative to each other in arcuate paths about the isolator pivot 50.",
"The lost motion connection 46 interconnects the drive reel 48 and the isolator crank 56.",
"More specifically, as best shown in FIGS. 2-6, the lost motion connection 46 includes an arcuate slot 58 which is formed in the drive reel 48 and disposed concentrically about the isolator pivot 50.",
"A finger 60 extends from the distal, free swinging, end of the isolator crank 56 and is disposed within the arcuate slot 58.",
"The finger 60 is confined at all times within the slot 58 for movement between a first 62 and a second 64 terminal end of the arcuate slot 58.",
"The isolator means 40 further includes a biasing means 66 which interconnects the drive reel 48 and the isolator crank 56.",
"The biasing means 66 urges the drive reel 48 in a first predetermined arcuate direction, clockwise as viewed in FIGS. 2-6, relative to the isolator crank 56.",
"More particularly, the biasing means 66 comprises a flat wound coil spring, also known as a spiral torsion spring, having a radially displaced end operatively connected to the finger 60 and another end adjacent its center connected to the drive reel 48.",
"The spring 66 constantly urges the drive reel 48 clockwise about the isolator pivot 50 but, due to the housing 38, is prevented from clockwise movement past the position shown in FIG. 2. Referring to FIGS. 1-6, the actuator means 30 includes an elongated motion transmitting means 68 which interconnects the lever 32 and the drive reel 48 for mechanically transmitting motion between the lever 32 and the drive wheel 48 along a curved path.",
"More specifically, the motion transmitting means 68 comprises a flexible cable having a first end 70 connected to the lever 32 and a second end 72 connected to the drive reel 48 at a connection 74.",
"The second end 72 of the cable 68 is wound about the exterior of the drive reel 48, i.e., about the camming edge 54, in order to effect rotation of the drive reel 48 about the isolator pivot 50 in response to pivotal movement of the lever 32 about its fulcrum 34.",
"As the vehicle operator urges the lever 32 to pivot about its fulcrum 34 when applying the park brake, the cable 68 is displaced a corresponding distance and mechanically urges the drive wheel 48 to rotate about the isolator pivot 50.",
"In FIGS. 2-6, the control means 36 is shown including a control crank arm 76 which is operatively connected to the isolator crank 56 for arcuate movement about a control pivot 78.",
"A rigid link 80 extends between opposite ends thereof with one of the ends being pivotally connected to the isolator crank 56 and the other end pivotally connected to the control crank 76.",
"Therefore, as the isolator crank 56 rotates about the isolator pivot 50, the control crank 76 is urged to rotate about the control pivot 78.",
"The control pivot 78 and the isolator pivot 50 are spaced from one another and so disposed as to rotate the respective control crank 76 and isolator crank 56 in parallel planes.",
"The control means 36 includes at least one, and preferably two, brake throws 82, 84 which extend radially outwardly of the control pivot 78 and are integrally connected to the control crank 76.",
"The two brake throws 82, 84 are disposed on opposite sides of the control pivot 78.",
"The control crank 76 extends radially outwardly from between the two brake throws 82, 84, at an angle slightly less than 90° from the one brake throw 82 and slightly greater than 90° from the other brake throw 84.",
"The control means 36 further includes two cables 86, 86'",
"having one end connected to one of the brake throws 82, 84 and the other ends operatively connected to a respective park brake 26 at one of the two rear wheels 24.",
"Each cable 86, 86'",
"is connected to one of the brake throws 82, 84 for interconnecting the associated brake throw 82, 84 with one of the park brakes 26.",
"A slug 88, 88'",
"is disposed on the end of each of the cables, 86'",
"for attachment to the respective rake throw 82, 84.",
"An automatic fastener means, generally indicated at 90, 90'",
"in FIG. 2, is provided for, automatically fastening the slug 88, 88'",
"of each cable 86, 86'",
"to its associated brake throw 82, 84 in response to a coupling force applied to interconnect two elements.",
"The automatic fastener means 90, 90'",
"each includes a resilient latch 92, 92'",
"extending integrally from each brake throw 82, 84.",
"A cup shaped pocket 94 is provided in each brake throw 82, 84 for receiving the slugs 88, 88'.",
"The latches, 92'",
"are resiliently disposed to support the slug 88, 88'",
"in the respective pockets 94 yet allow easy insertion of the slugs ,88'",
"into the pockets 94 for installation purposes.",
"Cable passages 96'",
"are provided through the housing 38 for each of the cables, 86, 86'.",
"Similarly, a flexible element passage 98 is provided through the housing 38 for the flexible cable 68.",
"Referring now to FIGS. 2-12, the control means 36 is shown including a ratchet means, generally indicated at 100, for locking the control crank 76 in an angular position in response to a first applied force from the actuator means 30 and for unlocking the control crank 76 in response to a second successively applied force from the actuator means 30.",
"The ratchet means 100 operates in toggle fashion by locking the control crank 76 in a brake applied condition in response to a first applied force from the actuator means 30, and then reversing itself and automatically unlocking the control crank 76 solely in response to a second successively applied force from the actuator means 30.",
"The ratchet means 100 includes a saw-toothed lock sector 102 comprising a series of ramps, or barbs, which coact with a pawl 104.",
"The pawl 104 is supported on a pin 106 and adapted to engage the teeth of the lock sector 102 in ratcheting fashion.",
"As perhaps best shown in FIGS. 8-12, the pawl 104 includes an elongated slot 108 which surrounds the pin 106 and serves to interconnect the pawl 104 and the pin 106.",
"The ratchet means 100 further includes a strategically located trip spring 110 which exerts a compressive force between the housing 38 and the pawl 104 for urging the pawl 104 to ratchetingly engage the lock sector 102 in response to the first applied force from the actuator means 30, and then for urging the pawl 104 to disengage from the lock sector 102 in response to a second applied force from the actuator means 30.",
"More particularly, in FIG. 7 the pawl 104 is shown in spacial relation to the lock sector 102 in an unactuated condition corresponding to FIGS. 2 and 3.",
"As the lever 32 is pivoted about its fulcrum 34 to apply a first force to the control crank 76, the lock sector 102 rotates about the control pivot 78 until the pawl 104 makes initial contact with the lock sector 102 as shown in FIG. 8. This causes the pawl 104 to move relative to the pin 106 from the position shown in FIG. 7, wherein the pin 106 is generally centered in the elongated slot 108 to the position shown in FIG. 8, where the pin 106 is disposed in engagement with the rearward edge of the elongated slot 108.",
"This movement of the pawl 104 relative to the pin 106 causes the trip spring 110 to direct its biasing force on one side of the pin 106 and thereby apply a force on the pawl 104 tending to urge it in the clockwise direction, in ratcheting engagement with the lock sector 102.",
"Therefore, as the lock sector 102 continues to rotate about the control pivot 78, the pawl 104 and lock sector 102 ratchet to the position shown in FIG. 9. FIG. 9 corresponds to the schematic illustration of FIG. 4 wherein the lever 32 has been fully actuated and the park brakes 26 have been placed in a brake applied condition.",
"As the vehicle operator releases the first applied force on the lever 32 the lock sector 102 rotates in reverse, or counter clockwise, direction about the control pivot 78, causing the pawl 104 to move rearwardly relative to the pin 106 until the pin 106 engages the forward edge of the elongated slot 108.",
"This causes the trip spring 110 to move onto the opposite side of the pin 106 and thereby urges the pawl 104 to rotate in a counter clockwise direction about the pin 106.",
"However, because the pawl 104 is engaged with the teeth of the lock sector 102, the pawl 104 and lock sector 102 remain operatively engaged to maintain the brake throws 82, 84 in a brake applied condition, as illustrated in FIG. 10.",
"When the operator applies a second successive force to the lever 32, as represented in FIG. 6, to move the lock sector 102 slightly about the control pivot 78 in a clockwise direction, the trip spring 110 urges the pawl 104 to disengage the lock sector 102 as shown in FIG. 11.",
"With this, the isolator means 40 ceases to isolate the forces between the control means 36 and the actuator means 30 as that the vehicle operator may gradually move the park brakes 26 from the brake applied condition back to an unactuated condition as shown in FIGS. 2 and 3.",
"The control crank 76 includes a recock arm 112 for urging the pawl 104 to engage the lock sector 102 after the second force has been applied by the actuator means 30.",
"More particularly, the recock arm 112 and the pawl 104 include coacting camming surfaces which urge the pawl 104 to move relative to the pin 106 within the slot 108 so that the trip spring 110 will once again urge the pawl 104 in a clockwise direction about the pin 106 to ratchet with the lock sector 102.",
"OPERATION OF THE PREFERRED EMBODIMENT Referring to the Figures, the operation of the preferred embodiment will be addressed presently.",
"From the unactuated position shown in FIGS. 2 and 3, the vehicle operator applies a force to the lever 32 rotating it about its fulcrum 34.",
"This, in turn, displaces the cable 68 such that the attached drive reel 48 is caused to rotate about the isolator pivot 50.",
"With the first end 62 of the arcuate slot 58 in engagement with the finger 60, movement of the drive reel 48 concurrently urges the isolator crank 56 about the isolator pivot 50.",
"By way of the rigid link 80, the control crank 76 is caused to rotate in a clockwise direction about the crank pivot 78 in response to counter clockwise movement of the isolator crank 56 about the isolator pivot 50.",
"Such movement of the control crank 76 simultaneously causes each of the brake throws 82, 84 to displace their associated cables 86, 86', thereby actuating the park brake 26 and causing the lock sector 102 to ratchetingly engage the pawl 104.",
"As the brake throws 82, 84 rotate about the control pivot 78, they apply an increasingly greater leverage about the control pivot 78 upon the cables 86, 86'.",
"That is, as the brake throws 82, 84 rotate toward the brake applied condition, each of the cables 86, 86'",
"begin to move closer to the control pivot 78, thereby increasing the leverage while decreasing the displacement of the cables 86, 86'.",
"In the preferred embodiment, the ratio will increase from the unactuated condition shown in FIGS. 2 and 3 at about 3.5:1 to a ratio as high as 4:1 in the fully applied condition as shown in FIGS. 4-6.",
"While the pawl 104 is engaged with the lock sector 102 to maintain the park brake 26 in a brake applied condition, the biasing means 66 urges the drive reel 48 to rotate in a clockwise direction back toward an unactuated position as shown in FIG. 5. Such retracting movement of the drive reel 48 urges the lever 32 back toward its unactuated position via the cable 68.",
"To release the park brakes 26 from the brake applied condition, the lever 32 is urged back toward its brake applied position until the first end 62 of the arcuate slot 58 contacts and slightly displaces the finger 60.",
"This slight displacement of the finger 60 causes the control crank 76 to move a small arcuate degree in the clockwise direction about the control pivot 78 allowing the pawl 104 to disengage from the lock sector 102.",
"The lever 32 is then slowly moved by the vehicle operator from the position shown in FIG. 6 back to the position shown in FIG. 3 and thereby gradually releasing the park brake 26 to an unactuated condition.",
"The primary advantage of the subject invention is that the isolator means 40 completely isolates the lever 32 and flexible cable 68 from the forces on the control means 36 while the park brakes 26 are maintained in a brake applied condition.",
"More specifically, tensile forces of 90 pounds or greater may be required to maintain park brakes 26 in a brake applied condition.",
"Hence, each of the cables 86 are required to withstand such a 90 pound tensile load for extended periods of time, and therefore must be constructed of very durable material.",
"However, as the cable 68 is never required to maintain such a tensile load for any length of time greater than the brief moment required to actuate or deactuate the park brakes 26, the cable 68 can be fabricated from a much less durable, lighter and less expensive material.",
"Hence, the isolator means 40 supplies the necessary incentive to design the assembly 20 with the inexpensive flexible cable 68 spanning the greatest distance and the two heavy and expensive cables 86, 86'",
"spanning a minimal distance.",
"Therefore, as shown in FIG. 1, the housing 38 can be positioned adjacent the rear axle 28 with each of the cables 86, 86'",
"extending a relatively short distance to their associated park brake 26.",
"The inexpensive and light flexible cable 68, on the other hand, can be routed from the housing 38 adjacent the rear axle 28 to the lever 32 disposed within the passenger compartment of the vehicle.",
"Additionally, the only structure required inside the passenger compartment of the vehicle 22 is the lever 32 and its support fulcrum 34.",
"The relatively bulky control means 36 is positioned in an unobtrusive space, freeing the valuable interior space for maximum occupant comfort.",
"The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.",
"Obviously, many modifications and variations of the present invention are possible in light of the above teachings.",
"It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a thermal head driver system for electrically driving a thermal head, and also relates to an image-forming apparatus having such a thermal head and such a thermal head driver incorporated therein.
2. Description of the Related Art
A thermal head driver system for electrically driving a thermal head is well known. For example, the thermal head is arranged as a line type of thermal head having a plurality of electric resistance elements aligned with each other, and the thermal head driver system is constituted such that the electric resistance elements are selectively and electrically energized in accordance with a single-line of digital image-pixel signals, thereby producing an image on, for example, a thermal sensitive recording sheet.
Usually, the thermal head driver system includes a shift register, and a latch circuit connected in parallel to the shift register. The single-line of digital image-pixel signals is serially inputted to and is temporarily stored in the shift register, and the stored digital image-pixel signals are then shifted to the latch circuit. The shifted digital image-pixel signals are latched by the latch circuit, and are stably held therein. The latch circuit is provided with a plurality of output terminals corresponding to a number of the digital image-pixel signals held therein, and each of the output terminals outputs a high-level signal only when a corresponding digital image-pixel signal has a value “1”.
The thermal head driver system also includes a plurality of AND-gate circuits each having two input terminals and an output terminal, and a plurality of switching circuits associated with the AND-gate circuits, respectively. One of the input terminals of each AND-gate circuit is connected to a corresponding one of the output terminals of the latch circuit, and the other input terminal of each AND-gate circuit is wired so as to receive a strobe signal having a predetermined pulse width. The output terminal of each AND-gate circuit is connected to the switching circuit associated therewith. Each of the electric resistance elements of the line thermal head is connected to an electric power source through a corresponding switching circuit.
With this arrangement of the thermal head driver system, when one of the digital image-pixel signals held in the latch circuit has a value “1”, so that a high-level signal is outputted from a corresponding output terminal of the latch circuit, a corresponding AND-gate circuit is opened so that a corresponding switching circuit is turned ON, whereby a corresponding electric resistance element is electrically energized over a period corresponding to the pulse width of the strobe signal so as to be heated to a predetermined temperature. On the other hand, when one of the digital image-pixel signals held in the latch circuit has a value “0”, a corresponding AND-gate circuit is maintained at a closed state, so that a corresponding switching circuit also maintains an OFF state, whereby a corresponding electric resistance element cannot be electrically energized.
Conventionally, one thermal head necessarily involves one thermal head driver system as mentioned above, and these two elements are inseparably related to each other. In other words, a thermal head driver system is provided for the purpose of driving only a single thermal head.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel thermal head driver system arranged to selectively drive at least two thermal heads in accordance with at least two types of image information data, respectively, without a thermal head driver system being necessary for each thermal head.
Another object of the present invention is to provide a thermal image-forming apparatus including at least two thermal heads, which are selectively driven by the above-mentioned novel thermal head driver system in accordance with at least two types of image information data.
In accordance with an aspect of the present invention, there is provided a thermal head driver system that cyclically and independently drives each of at least two thermal heads having each a plurality of electric resistance elements. The thermal head driver system comprises a storage system that cyclically stores an image information data, the image information data cyclically being each of at least two types of image information data, respectively corresponding to the at least two thermal heads, and a selector system that cyclically and correspondingly selects which thermal head should be driven in accordance with the cyclical storage of the at least two types of image information data in the storage system, such that the electric resistance elements of the thermal head, selected by the selector system, are selectively and electrically energized in accordance with a corresponding type of image information data cyclically stored in the storage system. Preferably, the thermal head driver system further comprises a determiner system that determines a time period over which the thermal head, selected by the selector system, is driven.
The selector system may comprise a signal generator that generates at least two selection-control signals, each of which changes between a first level and a second level, and the cyclical selection of the driving of the at least two thermal heads is performed in accordance with a combination of the levels of the at least two selection-control signals. In this case, when at least one of the at least two selection-control signals is changed from the first level to the second level, one of the thermal heads is correspondingly selected to be driven by the selector system. Also, when the at least two selection-control signals are kept at the first level, none of the thermal heads are selected to be driven by the selector system.
In accordance with another aspect of the present invention, there is provided an image-forming apparatus that forms an image on an image-forming substrate that includes a base member and a layer of microcapsules, coated over the base member, containing a first type of microcapsule filled with a first monochromatic dye, and a second type of microcapsule filled with a second monochromatic dye, the first type of microcapsule exhibiting a first pressure/temperature characteristic such that, when the first type of microcapsule is squashed under a first pressure at a first temperature, the first type of microcapsule breaks discharging the first dye, the second type of microcapsule exhibiting a second pressure/temperature characteristic such that, when the second type of microcapsule is squashed under a second pressure at a second temperature, the second type of microcapsule breaks discharging the second dye. The image-forming apparatus comprises a first pressure applicator that locally exerts the first pressure on the layer of microcapsules, a second pressure applicator that locally exerts the second pressure on the layer of microcapsules, a first thermal head that is driven such that a first localized area of the layer of microcapsules, on which the first pressure is exerted by the first pressure applicator, is heated to the first temperature in accordance with a first image-information data, such that the first type of microcapsule in the first localized area is selectively broken, a second thermal head that is driven such that a second localized area of the layer of microcapsules, on which the second pressure is exerted by the second pressure applicator, is heated to the second temperature in accordance with a second image-information data, such that the second type of microcapsule in the second localized area is selectively squashed, and a thermal head driver system that cyclically and independently controls the driving of the first and second thermal heads, and that is arranged in accordance with the first-mentioned aspect of the present invention.
The layer of microcapsules may further contains a third type of microcapsule filled with a third monochromatic dye, the third type of microcapsule exhibiting a third pressure/temperature characteristic such that, when the third type of microcapsule is squashed under a third pressure at a third temperature, the third type of microcapsule breaks discharging the third dye. In this case, the image-forming apparatus comprises further comprises a third pressure applicator that locally exerts the third pressure on the layer of microcapsules, and a third thermal head that is driven such that a third localized area of the layer of microcapsules, on which the third pressure is exerted by the third pressure applicator, is heated to the third temperature in accordance with a third image-information data, such that the third type of microcapsule in the third localized area is selectively squashed. Also, the thermal head driver system cyclically and independently controls the driving of the first, second and third thermal heads, the storage system cyclically stores an image information data, the image information data cyclically being each of the first, second and third image information data, and the selector system cyclically and correspondingly selects which thermal head should be driven in accordance with the cyclical storage of the first, second and third image information data in the storage system.
The selector system may comprise a signal generator that generates two selection-control signals, each of which changes between a first level and a second level, and the cyclical selection of the driving of the first, second and third thermal heads is performed in accordance with a combination of the levels of the selection-control signals. When at least one of the two selection-control signals is changed from the first level to the second level, one of the first, second and third thermal heads is correspondingly selected to be driven by the selector system. Also, when all of the two selection-control signals are kept at the first level, none of the first, second and third thermal heads is selected to be driven by the selector system.
BRIEF DESCRIPTION OF THE DRAWINGS
These objects and other objects of the present invention will be better understood from the following description, with reference to the accompanying drawings in which:
FIG. 1 is a schematic conceptual cross-sectional view showing an image-forming substrate, comprising a layer of microcapsules including a first type of cyan microcapsules filled with a cyan dye, a second type of magenta microcapsules filled with a magenta dye and a third type of yellow microcapsules filled with a yellow dye, used in an image-forming apparatus according to the present invention;
FIG. 2 is a graph showing a characteristic curve of a longitudinal elasticity coefficient of a shape memory resin;
FIG. 3 is a graph showing pressure/temperature breaking characteristics of the respective cyan, magenta and yellow microcapsules shown in FIG. 1, with each of a cyan-developing area, a magenta-developing area and a yellow-developing are indicated as a hatched area;
FIG. 4 is a schematic cross-sectional view showing different shell wall thicknesses of the respective cyan, magenta and yellow microcapsules;
FIG. 5 is a schematic conceptual cross-sectional view similar to FIG. 1, showing only a selective breakage of a cyan microcapsule in the layer of microcapsules;
FIG. 6 a schematic cross-sectional view of an image-forming apparatus, according to the present invention, for forming a color image on the image-forming substrate shown in FIG. 1;
FIG. 7 is a partial schematic block diagram of three line-type thermal heads and a thermal head driver circuit therefor incorporated in the color printer of FIG. 6;
FIG. 8 is a schematic block diagram of a control circuit board of the color printer shown in FIG. 6;
FIG. 9 is a partial schematic wiring diagram of the thermal head driver circuit of FIGS. 7 and 8;
FIG. 10 is a table for explaining how one of the three thermal heads to be driven is selected by a combination of levels of two selection-control signals inputted to the thermal head driver circuit;
FIG. 11 is a part of a flowchart of a thermal-head-driver control routine executed in a printer control circuit of FIG. 8;
FIG. 12 is the remaining part of the flowchart of the thermal-head-driver control routine executed in the printer control circuit of FIG. 8; and
FIG. 13 is a timing chart used to explain the thermal-head-driver control routine shown in FIGS. 11 and 12 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an image-forming substrate, generally indicated by reference 10 , which is used in an image-forming apparatus according to the present invention. The image-forming substrate 10 is produced in a form of a paper sheet. Namely, the image-forming substrate or sheet 10 comprises a sheet of paper 12 , a layer of microcapsules 14 coated over a surface of the paper sheet 12 , and a sheet of protective transparent film 16 covering the microcapsule layer 14 .
The microcapsule layer 14 is formed from three types of microcapsules: a first type of microcapsules 18 C filled with cyan liquid dye or ink, a second type of microcapsules 18 M filled with magenta liquid dye or ink, and a third type of microcapsules 18 Y filled with yellow liquid dye or ink, and these microcapsules 18 C, 18 M and 18 Y are uniformly distributed in the microcapsule layer 14 . In each type of microcapsule ( 18 C, 18 M, 18 Y), a shell wall of a microcapsule is formed of a synthetic resin material, usually colored white. Also, each type of microcapsule ( 18 C, 18 M, 18 Y) may be produced by a well-known polymerization method, such as interfacial polymerization, in-situ polymerization or the like, and may have an average diameter of several microns, for example, 5 μm to 10 μm.
Note, when the paper sheet 12 is colored with a single color pigment, the resin material of the microcapsules 18 C, 18 M and 18 Y may be colored by the same single color pigment.
For the uniform formation of the microcapsule layer 14 , for example, the same amounts of cyan, magenta and yellow microcapsules 18 C, 18 M and 18 Y are homogeneously mixed with a suitable binder solution to form a suspension, and the paper sheet 12 is coated with the binder solution, containing the suspension of microcapsules 18 C, 18 M and 18 Y, by using an atomizer.
Note, in FIG. 1, for the convenience of illustration, although the microcapsule layer 14 is shown as having a thickness corresponding to the diameter of the microcapsules 18 C, 18 M and 18 Y, in reality, the three types of microcapsules 18 C, 18 M and 18 Y overlay each other, and thus the microcapsule layer 14 has a larger thickness than the diameter of a single microcapsule 18 C, 18 M or 18 Y.
In the image-forming sheet 10 , for the resin material of each type of microcapsule ( 18 C, 18 M, 18 Y), a shape memory resin may be utilized. As is well known, for example, the shape memory resin is represented by a polyurethane-based-resin, such as polynorbornene, trans-1,4-polyisoprene polyurethane. As other types of shape memory resin, a polyimide-based resin, a polyamide-based resin, a polyvinylchloride-based resin, a polyester-based resin and so on are also known.
In general, as is apparent from a graph of FIG. 2, the shape memory resin exhibits a coefficient of longitudinal elasticity, which abruptly changes at a glass-transition temperature boundary T g . In the shape memory resin, Brownian movement of the molecular chains is stopped in a low-temperature area “a”, which is less than the glass-transition temperature T g , and thus the shape memory resin exhibits a glass-like phase. On the other hand, Brownian movement of the molecular chains becomes increasingly energetic in a high-temperature area “b”, which is higher than the glass-transition temperature T g , and thus the shape memory resin exhibits a rubber elasticity.
The shape memory resin is named due to the following shape memory characteristic: after a mass of the shape memory resin is worked into a shaped article in the low-temperature area “a”, when such a shaped article is heated over the glass-transition temperature T g , the article becomes freely deformable. After the shaped article is deformed into another shape, when the deformed article is cooled to below the glass-transition temperature T g , the other shape of the article is fixed and maintained. Nevertheless, when the deformed article is again heated to above the glass-transition temperature T g , without being subjected to any load or external force, the deformed article returns to the original shape.
In the image-forming sheet 10 , the shape memory characteristic per se is not utilized, but the characteristic abrupt change of the shape memory resin in the longitudinal elasticity coefficient is utilized, such that the three types of microcapsules 18 C, 18 M and 18 Y can be selectively squashed and broken at different temperatures and under different pressures, respectively.
As shown in a graph of FIG. 3, a shape memory resin of the cyan microcapsules 18 C is prepared so as to exhibit a characteristic longitudinal elasticity coefficient, indicated by a solid line, having a glass-transition temperature T 1 ; a shape memory resin of the magenta microcapsules 18 M is prepared so as to exhibit a characteristic longitudinal elasticity coefficient, indicated by a single-chained line, having a glass-transition temperature T 2 ; and a shape memory resin of the yellow microcapsules 18 Y is prepared so as to exhibit a characteristic longitudinal elasticity coefficient, indicated by a double-chained line, having a glass-transition temperature T 3 .
Note, by suitably varying compositions of the shape memory resin and/or by selecting a suitable one from among various types of shape memory resin, it is possible to obtain the respective shape memory resins, with the glass-transition temperatures T 1 , T 2 and T 3 . For example, the glass-transition temperatures T 1 , T 2 and T 3 may be set to 70° C., 110° C. and 130° C., respectively.
As shown in FIG. 4, the microcapsule walls of the cyan microcapsules 18 C, magenta microcapsules 18 M, and yellow microcapsules 18 Y have differing thicknesses W C , W M and W Y , respectively. Namely, the thickness W C of cyan microcapsules 18 C is larger than the thickness W M of magenta microcapsules 18 M, and the thickness W M of magenta microcapsules 18 M is larger than the thickness W Y of yellow microcapsules 18 Y.
Also, the wall thickness W C of the cyan microcapsules 18 C is selected such that each cyan microcapsule 18 C is compacted and broken under a breaking pressure that lies between a critical breaking pressure P 3 and an upper limit pressure P UL (FIG. 3 ), when each cyan microcapsule 18 C is heated to a temperature between the glass-transition temperatures T 1 and T 2 ; the wall thickness W M of the magenta microcapsules 18 M is selected such that each magenta microcapsule 18 M is compacted and broken under a breaking pressure that lies between a critical breaking pressure P 2 and the critical breaking pressure P 3 (FIG. 3 ), when each magenta microcapsule 18 M is heated to a temperature between the glass-transition temperatures T 2 and T 3 ; and the wall thickness W Y of the yellow microcapsules 18 Y is selected such that each yellow microcapsule 18 Y is compacted and broken under a breaking pressure that lies between a critical breaking pressure P 1 and the critical breaking pressure P 2 (FIG. 3 ), when each yellow microcapsule 18 Y is heated to a temperature between the glass-transition temperature T 3 and an upper limit temperature T UL .
Note, for example, the breaking-pressures P 1 , P 2 , P 3 and P UL may be set to 0.02, 0.2, 2.0 and 20 MPa, respectively, and a wall thickness of a microcapsule ( 18 C, 18 M, 18 Y) concerned is selected such that it is compacted and broken under a given breaking pressure when it is heated to a given temperature. Also, note, the upper limit temperature T UL is suitably set to, for example, 150° C.
Thus, by suitably selecting a heating temperature and a breaking pressure, which should be exerted on the image-forming sheet 10 , it is possible to selectively squash and break the cyan, magenta and yellow microcapsules 18 C, 18 M and 18 Y.
For example, if the selected heating temperature and breaking pressure fall within a hatched cyan-developing area C (FIG. 3 ), defined by a temperature ranging between the glass-transition temperatures T 1 and T 2 and by a pressure ranging between the critical breaking pressure P 3 and the upper limit pressure P UL , only the cyan microcapsules 18 C are squashed and broken, as representatively shown in FIG. 5 . Also, if the selected heating temperature and breaking pressure fall within a hatched magenta-developing area M, defined by a temperature ranging between the glass-transition temperatures T 2 and T 3 and by a pressure ranging between the critical breaking pressures P 2 and P 3 , only the magenta microcapsules 18 M are squashed and broken. Further, if the selected heating temperature and breaking pressure fall within a hatched yellow-developing area Y, defined by a temperature ranging between the glass-transition temperature T 3 and the upper limit temperature T UL and by a pressure ranging between the critical breaking pressures P 1 and P 2 , only the yellow microcapsules 18 Y are squashed and broken.
Accordingly, if the selection of a heating temperature and a breaking pressure, which should be exerted on the image-forming sheet 10 , are suitably controlled in accordance with a series of digital color image-pixel signals: digital cyan image-pixel signals, digital magenta image-pixel signals and digital yellow image-pixel signals, it is possible to form a color image on the image-forming sheet 10 on the basis of the digital color image-pixel signals.
With reference to FIG. 6, the image-forming apparatus according to the present invention is schematically shown, and is constituted as a line color printer so as to form a color image on the aforementioned image-forming sheet 10 .
The color printer comprises a rectangular parallelopiped housing 20 having an entrance opening 22 and an exit opening 24 formed in a top wall and a side wall of the housing 20 , respectively. The image-forming sheet 10 (not shown in FIG. 6) is introduced into the housing 20 through the entrance opening 22 , and is then discharged from the exit opening 24 after the formation of a color image on the image-forming sheet 10 . Note, in FIG. 6, a path 26 for movement of the image-forming sheet 10 is indicated by a chained line.
A guide plate 28 is provided in the housing 20 so as to define a part of the path 26 for the movement of the image-forming sheet 10 , and a first thermal head 30 C, a second thermal head 30 M and a third thermal head 30 Y are securely attached to a surface of the guide plate 28 . Each thermal head ( 30 C, 30 M, 30 Y) is formed as a line thermal head perpendicularly extended with respect to a direction of the movement of the image-forming sheet 10 .
As conceptually shown in FIG. 7, the line thermal head 30 C includes a plurality of heater elements or electric resistance elements R c1 to R cn (where n=1, 2, 3, . . . ), and these electric resistance elements R c1 to R cn are linearly aligned with respect to each other along a length of the line thermal head 30 C. Also, the line thermal head 30 M includes a plurality of electric resistance elements R m1 to R mn (where n=1, 2, 3, . . . ), and these electric resistance elements R m1 to R mn are linearly aligned with respect to each other along a length of the line thermal head 30 M. Similarly, the line thermal head 30 Y includes a plurality of electric resistance elements R y1 to R yn (where n=1, 2, 3, . . . ), and these resistance elements are linearly aligned with respect to each other along a length of the line thermal head 30 Y.
According to the present invention, each of the electric resistance elements (R c1 to R cn ; R m1 to R mn ; and R y1 to R yn ) is selectively energized by a thermal head driver circuit 31 in accordance with a corresponding monochromatic (cyan, yellow, magenta) digital image-pixel signal in a manner as stated in detail hereinafter. Of course, when a digital cyan image-pixel signal has a value “1”, a corresponding electric resistance element R cn is heated to a temperature, which falls in the range between the glass-transition temperatures T 1 and T 2 ; when a digital magenta image-pixel signal has a value “1”, a corresponding electric resistance element R mn is heated to a temperature, which falls in the range between the glass-transition temperatures T 2 and T 3 ; when the digital yellow image-pixel signal has a value “1”, the corresponding electric resistance element R yn is heated to a temperature, which falls in the range between the glass-transition temperature T 3 and the upper limit temperature T UL .
Note, the line thermal heads 30 C, 30 M and 30 Y are arranged in sequence so that the respective heating temperatures increase in the movement direction of the image-forming substrate 10 .
As shown in FIG. 6, the color printer further comprises a first roller platen 32 C, a second roller platen 32 M and a third roller platen 32 Y associated with the first, second and third thermal heads 30 C, 30 M and 30 Y, respectively, and each of the roller platens 32 C, 32 M and 32 Y may be formed of a suitable hard rubber material. The first roller platen 32 C is provided with a first spring-biasing unit 34 C so as to be elastically pressed against the first thermal head 30 C at a pressure between the critical compacting-pressure P 3 and the upper limit pressure P UL ; the second roller platen 32 M is provided with a second spring-biasing unit 34 M so as to be elastically pressed against the second thermal head 30 M at a pressure between the critical compacting-pressures P 2 and P 3 ; and the third roller platen 32 Y is provided with a third spring-biasing unit 34 Y so as to be elastically pressed against the second thermal head 30 Y at a pressure between the critical compacting-pressures P 1 and P 2 .
During a printing operation, the respective roller platens 32 C, 32 M and 32 Y are intermittently rotated in a counterclockwise direction (FIG. 6) with a same peripheral speed. Accordingly, the image-forming sheet 10 , introduced through the entrance opening 22 , intermittently moves toward the exit opening 24 along the path 26 . Thus, the image-forming sheet 10 is subjected to pressure ranging between the critical breaking-pressure P 3 and the upper limit pressure P UL when passing between the first line thermal head 30 C and the first roller platen 32 C; to pressure ranging between the critical breaking-pressures P 2 and P 3 when passing between the second line thermal head 30 M and the second roller platen 32 M; and to pressure ranging between the critical breaking-pressures P 1 and P 2 when passing between the third line thermal head 30 Y and the third roller platen 32 Y. Namely, the roller platens 32 C, 32 M and 32 Y are arranged in sequence so that the respective pressures, exerted by the platens 32 C, 32 M and 32 Y on the line thermal heads 30 C, 30 M and 30 Y, decrease in the movement direction of the image-forming substrate 10 .
Note, the introduction of the image-forming sheet 10 into the entrance opening 22 of the printer is carried out such that the transparent protective film sheet 16 of the image-forming sheet 10 comes into contact with the thermal heads 30 C, 30 M and 30 Y.
With the arrangement of the above-mentioned line printer, for example, when one of the electric resistance elements R cn is heated to a temperature in the range between the glass-transition temperatures T 1 and T 2 , a cyan dot, having a dot size (diameter) of 50 μm to 100 μm, is developed on the microcapsule layer 14 of the image-forming sheet 10 , because only the cyan microcapsules 18 C are squashed and broken at a dot area heated by the resistance element (R cn ) concerned. Of course, although a plurality of cyan, magenta and yellow microcapsules 18 C, 18 M and 18 Y are uniformly included in a dot area (50 μm to 100 μm) to be developed on the microcapsule layer 14 , it is possible to squash and break only the cyan microcapsules 18 C, because the heating temperature is within the range between the glass-transition temperatures T 1 and T 2 .
In FIG. 6, reference 36 indicates a control circuit board for controlling a printing operation of the color printer, and reference 38 indicates an electrical main power source for electrically energizing the control circuit board 36 .
FIG. 8 shows a schematic block diagram of the control circuit board 36 . As shown in this drawing, the control circuit board 36 comprises a printer control circuit 40 including a microcomputer. The printer control circuit 40 receives a series of digital color image-pixel signals from a personal computer or a word processor (not shown) through an interface circuit (I/F) 42 . The received digital color image-pixel signals are suitably processed and are converted into a frame of digital cyan image-pixel signals, a frame of digital magenta image-pixel signals, and a frame of digital yellow image-pixel signals, and these frames of digital color image-pixel signals are once stored in a memory 44 .
Also, the control circuit board 36 is provided with a motor driver circuit 46 for driving three electric motors 48 C, 48 M and 48 Y, which are used to rotationally drive the roller platens 32 C, 32 M and 32 Y, respectively. In this embodiment of the color printer, each of the motors 48 C, 48 M and 48 Y is a stepping motor, which is driven in accordance with a series of drive pulses outputted from the motor driver circuit 46 , the outputting of drive pulses from the motor driver circuit 46 to the motors 48 C, 48 M and 48 Y being controlled by the printer control circuit 40 .
As shown in FIG. 8, the thermal head driver circuit 31 for the line thermal heads 30 C, 30 M and 30 Y is included in the control circuit board 36 , and is controlled by a set of selection-control signals “ST1” and “ST2”, a series of clock pulses “CLK”, a low-active latch signal “LATCH” and a series of digital color image-pixel signals “DATA”, which are outputted from the printer control circuit 40 .
FIG. 9 partially shows an arrangement of the thermal head driver circuit 31 . As is apparent from this drawing, the thermal head driver circuit 31 comprises a shift register 50 including a plurality of D-type flip-flops 50 1 to 50 n (where n=1, 2, 3, . . . ), and a latch circuit 52 including a plurality of D-type latches 52 1 to 52 n (where n=1, 2, 3, . . . ). During a printing operation, a single-line of monochromatic (cyan, magenta, yellow) digital image-pixel signals “DATA” is read from the memory 44 , and is then inputted to the shift register 50 .
While the series of monochromatic digital image-pixel signals “DATA” is inputted to the shift register 50 , these digital image-pixel signals are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”. Then, the respective monochromatic image-pixel signals held by the flip-flops 50 1 to 50 n are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by outputting the low-active latch signal “LATCH” from the printer control circuit 40 to the latch circuit 52 through an invertor 53 (FIG. 9 ), whereby the respective digital image-pixel signals are stably held in the latches 52 1 to 52 n . Thus, either a high-level signal or a low-level signal is stably outputted from a Q-terminal of each latch ( 52 1 , . . . , 52 n ) in accordance with binary values of a corresponding monochromatic digital image-pixel signal held therein. Namely, when the digital image-pixel signal has a value “1”, the high-level signal is outputted from the Q-terminal of the corresponding latch ( 52 1 , . . . , 52 n ), and, when the digital image-pixel signal has a value “0”, the low-level signal is outputted from the Q-terminal of the corresponding latch ( 52 1 , . . . , 52 n ).
The thermal head driver circuit 31 further comprises a plurality of driver circuit elements 54 1 to 54 n (where n=1, 2, 3, . . . ). Each of the driver circuit elements 54 1 to 54 n includes a set of AND-gate circuits 56 C, 56 M and 56 Y, a set of field-effect transistors (FET) 58 C, 58 M and 58 Y, and a pair of invertors 60 A and 60 B, all being wired in a manner as shown in FIG. 9 .
In particular, each of the AND-gate circuits 56 C, 56 M and 56 Y has three input terminals, one of which is connected to the Q-terminal of the corresponding latch ( 52 1 , . . . , 52 n ), and the respective remaining input terminals of each AND-gate circuit ( 56 C, 56 M, 56 Y) are connected to two signal lines SL 1 and SL 2 , through which the selection-control signals “ST1” and “ST1” are fed, respectively. Note, as shown in FIG. 9, the invertor 60 A is interposed between the signal line SL 1 and the corresponding input terminal of the AND-gate circuit 56 C, and the inverter 60 B is interposed between the signal line SL 2 and the corresponding input terminal of the AND-gate circuit 56 M.
Also, each of the AND-gate circuits 56 C, 56 M and 56 Y has an output terminal, which is connected to a gate (G) of the corresponding FET ( 58 C, 58 M, 58 Y) A source (S) of each FET ( 58 C, 58 M, 58 Y) is connected to an electric power source (V h ), and respective drains (D) of the FETs 58 C, 58 M and 58 Y are connected to the electric resistance elements R cn , R mn and R yn . Of course, when an output level of each AND gate circuit ( 56 C, 56 M, 56 Y) is changed from a low-level to a high-level, the corresponding FET ( 58 C, 58 M, 58 Y) is turned ON, so that the corresponding electric resistance element (R cn , R mn , R yn ) is electrically energized.
With the arrangement of the aforementioned thermal head driver circuit 31 , usually both the selection-control signals “ST1” and “ST2” are maintained at a low-level under control of the printer control circuit 40 , so that all the output levels of the AND-gate circuit ( 56 C, 56 M and 56 Y) are also maintained at the low-level, whereby all the electric resistance elements R cn , R mn and R yn cannot be electrically energized.
When the digital cyan image-pixel signals included in the single-line are held in the respective latches 52 1 to 52 n , and when these latches 52 1 to 52 n are latched, only an output level of the selection-control signal “ST2” is changed from the low-level to a high-level, so that only the respective electric resistance elements R c1 to R cn are selectively energized in accordance with the digital cyan image-pixel signals held in the latches 52 1 to 52 n . Namely, for example, when the digital cyan image-pixel signal held in the latch 52 1 has a value “1”, the output level of the corresponding AND-gate circuit 56 C is changed from the low-level to the high-level, whereby the corresponding electric resistance element R c1 is electrically energized. On the other hand, when the digital cyan image-pixel signal held in the latch 52 1 has a value “0”, the output level of the corresponding AND-gate circuit 56 C is maintained at the low-level, whereby the corresponding electric resistance element R c1 cannot be electrically energized.
When the digital magenta image-pixel signals included in the single-line are held in the respective latches 52 1 to 52 n , and when these latches 52 1 to 52 n are latched, only an output level of the selection-control signal “ST1” is changed from the low-level to a high-level, so that only the respective electric resistance elements R m1 to R mn are selectively energized in accordance with the digital magenta image-pixel signals held in the latches 52 1 to 52 n . Namely, for example, when the digital magenta image-pixel signal held in the latch 52 1 has a value “1”, the output level of the corresponding AND-gate circuit 56 M is changed from the low-level to the high-level, whereby the corresponding electric resistance element R m1 is electrically energized. On the other hand, when the digital magenta image-pixel signal held in the latch 52 1 has a value “0”, the output level of the corresponding AND-gate circuit 56 M is maintained at the low-level, whereby the corresponding electric resistance element R m1 cannot be electrically energized.
When the digital yellow image-pixel signals included in the single-line are held in the respective latches 52 1 to 52 n , and when these latches 52 1 to 52 n are latched, both output levels of the selection-control signals “ST1” and “ST2” are changed from the low-level to the high-level, so that only the respective electric resistance elements R y1 to R yn are selectively energized in accordance with the digital yellow image-pixel signals held in the latches 52 1 to 52 n . Namely, for example, when the digital yellow image-pixel signal held in the latch 52 1 has a value “1”, the output level of the corresponding AND-gate circuit 56 Y is changed from the low-level to the high-level, whereby the corresponding electric resistance element R y1 is electrically energized. On the other hand, when the digital yellow image-pixel signal held in the latch 52 1 has a value “0”, the output level of the corresponding AND-gate circuit 56 Y is maintained at the low-level, whereby the corresponding electric resistance element R y1 cannot be electrically energized.
In short, by a combination of the levels of the selection-control signals “ST1” and “ST2”, it is possible to select which thermal head ( 30 C, 30 M, 30 Y) should be driven so that the electric resistance elements (R c1 to R cn ; R m1 to R mn ; R y1 to R yn ) included in the corresponding thermal head ( 30 C, 30 M, 30 Y) are selectively and electrically energized, as shown in a TABLE of FIG. 10 .
Whenever the electric resistance elements R c1 to R cn are selectively and electrically energized, the electrical energization is continued until the electrically-energized electric resistance elements (R cn ) are heated to a temperature between the glass-transition temperatures T 1 and T 2 , and the electrical energization is stopped by returning the high-level of the selection-control signal “ST2” to the low-level when the heated resistance elements (R cn ) have reached the temperature between the glass-transition temperatures T 1 and T 2 . For example, a period of the electrical energization of the electric resistance elements (R cn ) may be set to 3 ms.
Whenever the electric resistance elements R m1 to R mn are selectively and electrically energized, the electrical energization is continued until the electrically-energized electric resistance elements (R mn ) are heated to a temperature between the glass-transition temperatures T 2 and T 3 , and the electrical energization is stopped by returning the high-level of the selection-control signal “ST1” to the low-level when the heated resistance elements (R mn ) have reached the temperature between the glass-transition temperatures T 2 and T 3 . For example, a period of the electrical energization of the electric resistance elements (R mn ) may be set to 4 ms.
Whenever the electric resistance elements R y1 to R yn are selectively and electrically energized, the electrical energization is continued until the electrically-energized electric resistance elements (R yn ) are heated to a temperature between the glass-transition temperature T 3 and the upper limit temperature T UL , and the electrical energization is stopped by returning the high-levels of the selection-control signals “ST1” and “ST2” to the low-levels when the heated resistance elements (R yn ) have reached the temperature between the glass-transition temperature T 3 and the upper limit temperature T UL . For example, a period of the electrical energization of the electric resistance elements (R cn ) may be set to 5 ms.
FIGS. 11 and 12 show a flowchart of a thermal-head-driver control routine executed by the printer control circuit 40 . This thermal-head-driver control routine is constituted as a time-interruption routine which is repeatedly executed at regular intervals of, for example, 5 μs, and the execution of this routine is started when the printer control circuit 40 receives a printing-operation-start signal from a personal computer or a word processor (not shown) through the interface circuit (I/F) 42 .
In this embodiment, the execution of the thermal-head-driver control routine is performed under the following conditions:
(a) During the printing operation, three single-lines three-primary color (cyan, magenta and yellow) digital image-pixel signals are successively read in a cycle from the memory 44 , and are outputted from the printer control circuit 40 to the shift register 50 in the order of a single-line of cyan digital image-pixel signals, a single-line of magenta digital image-pixel signals and a single-line of yellow digital image-pixel signals, before the cycle is again repeated. Also, the low-active latch signal “LATCH” cyclically produces three latch pulses: a first latch pulse for latching the cyan digital image-pixel signals, a second latch pulse for latching the magenta digital image-pixel signals, and a third latch pulse the yellow digital image-pixel signals;
(b) The thermal heads 30 C, 30 M and 30 Y are spaced apart from each other by a distance corresponding to, for example, 200 single-lines of image-dots recorded on the image-forming sheet 10 . For this reason, the single-line of magenta digital image-pixel signals is repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the first single-line of cyan image-dots, recorded by the alignment of electric resistance elements R c1 to R cn of the thermal head 30 C, reaches the alignment of electric resistance elements R m1 to R mn of the thermal head 30 M, and the single-line of yellow digital image-pixel signals is also repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the first single-line of cyan image-dots, recorded by the alignment of electric resistance elements R c1 to R cn of the thermal head 30 C, reaches the alignment of electric resistance elements R y1 to R yn of the thermal head 30 Y; and
(c) For the same reason, the single-line of cyan digital image-pixel signals is repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the last single-line of cyan image-dots, recorded by the alignment of electric resistance elements R c1 to R cn of the thermal head 30 C, reaches the alignment of electric resistance elements R y1 to R yn of the thermal head 30 Y, and the single-line of magenta digital image-pixel signals is also repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the last single-line of magenta image-dots, recorded by the alignment of electric resistance elements R m1 to R mn of the thermal head 30 M reaches the alignment of electric resistance elements R y1 to R yn of the thermal head 30 Y.
With reference to a timing chart shown in FIG. 13, the thermal-head-driver control routine will be now explained below.
At step 101 , it is determined whether a flag F 1 is “0” or “1”. At an initial stage in which the printing operation has just begun, since F 1 =0, the control proceeds to step 102 , and it is determined whether a first latch pulse of the low-active latch signal “LATCH”, indicated by reference LAT 1 in the timing chart of FIG. 13, is outputted from the printer control circuit 40 to the latch circuit 52 . If the outputting of the first latch pulse “LAT1” is not confirmed, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the first latch pulse “LAT1” is confirmed.
In the beginning of the printing operation, a first single-line of digital cyan image-pixel signals, indicated by reference C 1 (DATA), is inputted in the shift register 50 , and these digital cyan image-pixel signals C 1 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 . Then, the respective digital cyan image-pixel signals C 1 (DATA) held by the flip-flops 50 1 to 50 n are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by an outputting of the first latch pulse “LAT1”.
At step 102 , when the outputting of the first latch pulse “LAT1” is confirmed, the control proceeds to step 103 , in which the flag F 1 is made to be “1”. Then, at step 104 , it is determined whether a flag F 2 is “0” or “1”. At the initial stage, since F 2 =0, the control proceeds to step 105 , in which the selection-control signal “ST2” is made to be high, whereby only the electric resistance elements R c1 to R cn of the thermal head 30 C are selectively and electrically energized in accordance with the cyan image-pixel signals C 1 (DATA) held in the latches 52 1 to 52 n of the latch circuit 52 .
At step 106 , it is determined whether a count number of a counter CC has reached a numerical value of 600, which corresponds to a time period of 3 ms (3 ms/5 μs=600). At the initial stage, since CC=0, the control proceeds to step 107 , in which the count number of the counter CC is incremented by “1”. Then, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, the incrementing of the count number of the counter CC is merely carried out until the count number of the counter CC reaches the numerical value of 600 (with F 1 =1 and F 2 =0).
At step 106 , when it is confirmed that the count number of the counter CC has reached the numerical value of 600, the control proceeds from step 106 to step 108 , in which the selection-control signal “ST2” is returned to the low-level, so that the selective and electrical energization of the electric resistance elements R c1 to R cn of the thermal head 30 C is stopped.
At step 109 , the counter CC is reset to “0”. Then, at step 110 , the flag F 1 is made to be “0”, and the flag F 2 is made to be “1”. Thus, the routine once ends.
When the routine is executed after the time of 5 μs has elapsed, the control proceeds to step 102 via step 101 (F 1 =0 at step 110 ), in which it is determined whether a second latch pulse of the low-active latch signal “LATCH”, indicated by reference LAT 2 in the timing chart of FIG. 13, is outputted from the printer control circuit 40 to the latch circuit 52 . If the outputting of the second latch pulse “LAT2” is not confirmed, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the second latch pulse “LAT2” is confirmed.
As is apparent from the timing chart of FIG. 13, during the selective and electrical energization of the electric resistance elements R c1 to R cn of the thermal head 30 C, a first single-line of digital magenta image-pixel signals, indicated by reference M 1 (DATA), is inputted to the shift register 50 , and these digital magenta image-pixel signals M 1 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 . Then, the respective digital magenta image-pixel signals M 1 (DATA) held by the flip-flops 50 1 to 50 are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by an outputting of the second latch pulse “LAT2”.
At step 102 , when the outputting of the second latch pulse “LAT2” is confirmed, the control proceeds to step 103 , in which the flag F 1 is made to be “1”. Then, the control jumps from step 104 to step 111 (F 2 =1), in which it is determined whether a flag F 3 is “0” or “1”. At the initial stage, since F 3 =0, the control proceeds to step 112 , in which the selection-control signal “ST1” is made to be high, whereby only the electric resistance elements R m1 to R mn of the thermal head 30 M are selectively and electrically energized in accordance with the magenta image-pixel signals M 1 (DATA) held in the latches 52 1 to 52 n of the latch circuit 52 .
At step 113 , it is determined whether a count number of a counter MC has reached a numerical value of 800, which corresponds to a time period of 4 ms (4 ms/5 μs=800). At the initial stage, since MC=0, the control proceeds to step 114 , in which the count number of the counter MC is incremented by “1”. Then, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, the incrementing of the count number of the counter MC is merely carried out until the count number of the counter MC reaches the numerical value of 800 (with F 1 =1 and F 2 =1).
At step 113 , when it is confirmed that the count number of the counter MC has reached the numerical value of 800, the control proceeds from step 113 to step 115 , in which the selection-control signal “ST1” is returned to the low-level, so that the selective and electrical energization of the electric resistance elements R m1 to R mn of the thermal head 30 M is stopped.
At step 116 , the counter MC is reset to “0”. Then, at step 117 , the flag F 1 is made to be “0”, and the flag F 3 is made to be “1”. Thus, the routine once ends.
When the routine is executed after the time of 5 μs has elapsed, the control proceeds to step 102 via step 101 (F 1 =0 at step 117 ), in which it is determined whether a third latch pulse of the low-active latch signal “LATCH”, indicated by reference LAT 3 in the timing chart of FIG. 13, is outputted from the printer control circuit 40 to the latch circuit 52 . If the outputting of the third latch pulse “LAT3” is not confirmed, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the third latch pulse “LAT3” is confirmed.
As is apparent from the timing chart of FIG. 13, during the selective and electrical energization of the electric resistance elements R m1 to R mn of the thermal head 30 M, a first single-line of digital yellow image-pixel signals, indicated by reference Y 1 (DATA), is inputted to the shift register 50 , and these digital yellow image-pixel signals Y 1 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 . Then, the respective digital yellow image-pixel signals Y 1 (DATA) held by the flip-flops 50 1 to 50 n are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by outputting the third latch pulse “LAT3”.
At step 102 , when the outputting of the third latch pulse “LAT3” is confirmed, the control proceeds to step 103 , in which the flag F 1 is made to be “1”. Then, the control jumps from step 104 to step 111 (F 2 =1), and further jumps from step 111 to step 118 (F 3 =1), in which the selection-control signals “ST1” and “ST2” are made to be high, whereby only the electric resistance elements R y1 to R yn of the thermal head 30 Y are selectively and electrically energized in the accordance with the magenta image-pixel signals Y 1 (DATA) held in the latches 52 1 to 52 n of the latch circuit 52 .
At step 119 , it is determined whether a count number of a counter YC has reached a numerical value of 1000, which corresponds to a time period of 5 ms (5 ms/5 μs=1000). At the initial stage, since YC=0, the control proceeds to step 120 , in which the count number of the counter YC is incremented by “1”. Then, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, the incrementing of the count number of the counter YC is merely carried out until the count number of the counter YC reaches the numerical value of 1000 (with F 1 =1, F 2 =1 and F 3 =1).
At step 119 , when it is confirmed that the count number of the counter YC has reached the numerical value of 1000, the control proceeds from step 119 to step 121 , in which the selection-control signals “ST1” and “ST2” are returned to the low-level, so that the selective and electrical energization of the electric resistance elements R y1 to R yn of the thermal head 30 Y is stopped.
At step 122 , the counter YC is reset to “0”. Then, at step 123 , the flag F 1 is made to be “0”, the flag F 2 is made to be “0”, and the flag F 3 is made to be “0”. Thus, the routine once ends. Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the first latch pulse “LAT1” is again confirmed.
As is apparent from the timing chart of FIG. 13, during the selective and electrical energization of the electric resistance elements R y1 to R yn of the thermal head 30 Y, a second single-line of digital cyan signals, indicated by reference C 2 (DATA), is inputted to the shift register 50 , and these digital cyan image-pixel signals C 2 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 .
On the other hand, as soon as the selective and electrical energization of the electric resistance elements R y1 to R yn of the thermal head 30 Y is completed (step 121 ), the motors 48 C, 48 M and 48 Y are driven in accordance with the series of drive pulses outputted from the motor driver circuit 46 , such that the image-forming sheet 10 is intermittently fed by a distance corresponding to the single-line of image-dots recorded on the image-forming sheet 10 .
After the intermittent movement of the image-forming sheet 10 is completed, once the first latch pulse “LAT1” is again outputted from the printer control circuit 40 to the latch circuit 52 , the selective and electrical energization of the electric resistance elements (R cl to R cn ; R ml to R mn ; and R y1 to R yn ) are cyclically repeated in accordance with the aforesaid execution of the routine in FIGS. 11 and 12 until a color image is completely recorded on the image-forming sheet 10 .
As is apparent from the foregoing, according to the present invention, plural thermal heads ( 30 C, 30 M, 30 Y) have a common single shift register ( 50 ) and a common single latch circuit ( 52 ). Accordingly, in comparison to a conventional case where a thermal head driver system is provided for each thermal head, it is possible to reduce a production cost of the thermal head driver system according to the present invention.
In the aforesaid embodiment of the present invention, although the three thermal heads 30 C, 30 M and 30 Y are selectively driven by the combination of the levels of the two selection-control signals “ST1” and “ST2”, of course, it is possible to perform a selective driving of two thermal heads by the combination of the levels of the two selection-control signals “ST1” and “ST2”. On the other hand, in a case where a combination of levels of three selection-control signals are utilized, it is possible to selectively drive at least seven thermal heads in accordance with at least seven types of digital image-pixel signals. Namely, when n selection-control signals are utilized, it is possible to selectively drive a number of thermal heads, being (2 n −1).
Finally, it will be understood by those skilled in the art that the foregoing description is of preferred embodiments of the system and the apparatus, and that various changes and modifications may be made to the present invention without departing from the spirit and scope thereof.
The present disclosure relates to a subject matter contained in Japanese Patent Application No. 10-106137 (filed on Apr. 16, 1998) which is expressly incorporated herein, by reference, in its entirety. | A thermal head driver system cyclically and independently drives at least two thermal heads having each a plurality of electric resistance elements. A storage system cyclically stores an image information data, the image information data cyclically being each of at least two types of image information data, respectively corresponding to the thermal heads. A selector system cyclically and correspondingly selects which thermal head should be driven in accordance with the cyclical storage of the types of image information data in the storage system, such that the electric resistance elements of the thermal head, selected by the selector system, are selectively and electrically energized in accordance with a corresponding type of image information data cyclically stored in the storage system. | Briefly describe the main invention outlined in the provided context. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention The present invention relates to a thermal head driver system for electrically driving a thermal head, and also relates to an image-forming apparatus having such a thermal head and such a thermal head driver incorporated therein.",
"Description of the Related Art A thermal head driver system for electrically driving a thermal head is well known.",
"For example, the thermal head is arranged as a line type of thermal head having a plurality of electric resistance elements aligned with each other, and the thermal head driver system is constituted such that the electric resistance elements are selectively and electrically energized in accordance with a single-line of digital image-pixel signals, thereby producing an image on, for example, a thermal sensitive recording sheet.",
"Usually, the thermal head driver system includes a shift register, and a latch circuit connected in parallel to the shift register.",
"The single-line of digital image-pixel signals is serially inputted to and is temporarily stored in the shift register, and the stored digital image-pixel signals are then shifted to the latch circuit.",
"The shifted digital image-pixel signals are latched by the latch circuit, and are stably held therein.",
"The latch circuit is provided with a plurality of output terminals corresponding to a number of the digital image-pixel signals held therein, and each of the output terminals outputs a high-level signal only when a corresponding digital image-pixel signal has a value “1.”",
"The thermal head driver system also includes a plurality of AND-gate circuits each having two input terminals and an output terminal, and a plurality of switching circuits associated with the AND-gate circuits, respectively.",
"One of the input terminals of each AND-gate circuit is connected to a corresponding one of the output terminals of the latch circuit, and the other input terminal of each AND-gate circuit is wired so as to receive a strobe signal having a predetermined pulse width.",
"The output terminal of each AND-gate circuit is connected to the switching circuit associated therewith.",
"Each of the electric resistance elements of the line thermal head is connected to an electric power source through a corresponding switching circuit.",
"With this arrangement of the thermal head driver system, when one of the digital image-pixel signals held in the latch circuit has a value “1”, so that a high-level signal is outputted from a corresponding output terminal of the latch circuit, a corresponding AND-gate circuit is opened so that a corresponding switching circuit is turned ON, whereby a corresponding electric resistance element is electrically energized over a period corresponding to the pulse width of the strobe signal so as to be heated to a predetermined temperature.",
"On the other hand, when one of the digital image-pixel signals held in the latch circuit has a value “0”, a corresponding AND-gate circuit is maintained at a closed state, so that a corresponding switching circuit also maintains an OFF state, whereby a corresponding electric resistance element cannot be electrically energized.",
"Conventionally, one thermal head necessarily involves one thermal head driver system as mentioned above, and these two elements are inseparably related to each other.",
"In other words, a thermal head driver system is provided for the purpose of driving only a single thermal head.",
"SUMMARY OF THE INVENTION An object of the present invention is to provide a novel thermal head driver system arranged to selectively drive at least two thermal heads in accordance with at least two types of image information data, respectively, without a thermal head driver system being necessary for each thermal head.",
"Another object of the present invention is to provide a thermal image-forming apparatus including at least two thermal heads, which are selectively driven by the above-mentioned novel thermal head driver system in accordance with at least two types of image information data.",
"In accordance with an aspect of the present invention, there is provided a thermal head driver system that cyclically and independently drives each of at least two thermal heads having each a plurality of electric resistance elements.",
"The thermal head driver system comprises a storage system that cyclically stores an image information data, the image information data cyclically being each of at least two types of image information data, respectively corresponding to the at least two thermal heads, and a selector system that cyclically and correspondingly selects which thermal head should be driven in accordance with the cyclical storage of the at least two types of image information data in the storage system, such that the electric resistance elements of the thermal head, selected by the selector system, are selectively and electrically energized in accordance with a corresponding type of image information data cyclically stored in the storage system.",
"Preferably, the thermal head driver system further comprises a determiner system that determines a time period over which the thermal head, selected by the selector system, is driven.",
"The selector system may comprise a signal generator that generates at least two selection-control signals, each of which changes between a first level and a second level, and the cyclical selection of the driving of the at least two thermal heads is performed in accordance with a combination of the levels of the at least two selection-control signals.",
"In this case, when at least one of the at least two selection-control signals is changed from the first level to the second level, one of the thermal heads is correspondingly selected to be driven by the selector system.",
"Also, when the at least two selection-control signals are kept at the first level, none of the thermal heads are selected to be driven by the selector system.",
"In accordance with another aspect of the present invention, there is provided an image-forming apparatus that forms an image on an image-forming substrate that includes a base member and a layer of microcapsules, coated over the base member, containing a first type of microcapsule filled with a first monochromatic dye, and a second type of microcapsule filled with a second monochromatic dye, the first type of microcapsule exhibiting a first pressure/temperature characteristic such that, when the first type of microcapsule is squashed under a first pressure at a first temperature, the first type of microcapsule breaks discharging the first dye, the second type of microcapsule exhibiting a second pressure/temperature characteristic such that, when the second type of microcapsule is squashed under a second pressure at a second temperature, the second type of microcapsule breaks discharging the second dye.",
"The image-forming apparatus comprises a first pressure applicator that locally exerts the first pressure on the layer of microcapsules, a second pressure applicator that locally exerts the second pressure on the layer of microcapsules, a first thermal head that is driven such that a first localized area of the layer of microcapsules, on which the first pressure is exerted by the first pressure applicator, is heated to the first temperature in accordance with a first image-information data, such that the first type of microcapsule in the first localized area is selectively broken, a second thermal head that is driven such that a second localized area of the layer of microcapsules, on which the second pressure is exerted by the second pressure applicator, is heated to the second temperature in accordance with a second image-information data, such that the second type of microcapsule in the second localized area is selectively squashed, and a thermal head driver system that cyclically and independently controls the driving of the first and second thermal heads, and that is arranged in accordance with the first-mentioned aspect of the present invention.",
"The layer of microcapsules may further contains a third type of microcapsule filled with a third monochromatic dye, the third type of microcapsule exhibiting a third pressure/temperature characteristic such that, when the third type of microcapsule is squashed under a third pressure at a third temperature, the third type of microcapsule breaks discharging the third dye.",
"In this case, the image-forming apparatus comprises further comprises a third pressure applicator that locally exerts the third pressure on the layer of microcapsules, and a third thermal head that is driven such that a third localized area of the layer of microcapsules, on which the third pressure is exerted by the third pressure applicator, is heated to the third temperature in accordance with a third image-information data, such that the third type of microcapsule in the third localized area is selectively squashed.",
"Also, the thermal head driver system cyclically and independently controls the driving of the first, second and third thermal heads, the storage system cyclically stores an image information data, the image information data cyclically being each of the first, second and third image information data, and the selector system cyclically and correspondingly selects which thermal head should be driven in accordance with the cyclical storage of the first, second and third image information data in the storage system.",
"The selector system may comprise a signal generator that generates two selection-control signals, each of which changes between a first level and a second level, and the cyclical selection of the driving of the first, second and third thermal heads is performed in accordance with a combination of the levels of the selection-control signals.",
"When at least one of the two selection-control signals is changed from the first level to the second level, one of the first, second and third thermal heads is correspondingly selected to be driven by the selector system.",
"Also, when all of the two selection-control signals are kept at the first level, none of the first, second and third thermal heads is selected to be driven by the selector system.",
"BRIEF DESCRIPTION OF THE DRAWINGS These objects and other objects of the present invention will be better understood from the following description, with reference to the accompanying drawings in which: FIG. 1 is a schematic conceptual cross-sectional view showing an image-forming substrate, comprising a layer of microcapsules including a first type of cyan microcapsules filled with a cyan dye, a second type of magenta microcapsules filled with a magenta dye and a third type of yellow microcapsules filled with a yellow dye, used in an image-forming apparatus according to the present invention;",
"FIG. 2 is a graph showing a characteristic curve of a longitudinal elasticity coefficient of a shape memory resin;",
"FIG. 3 is a graph showing pressure/temperature breaking characteristics of the respective cyan, magenta and yellow microcapsules shown in FIG. 1, with each of a cyan-developing area, a magenta-developing area and a yellow-developing are indicated as a hatched area;",
"FIG. 4 is a schematic cross-sectional view showing different shell wall thicknesses of the respective cyan, magenta and yellow microcapsules;",
"FIG. 5 is a schematic conceptual cross-sectional view similar to FIG. 1, showing only a selective breakage of a cyan microcapsule in the layer of microcapsules;",
"FIG. 6 a schematic cross-sectional view of an image-forming apparatus, according to the present invention, for forming a color image on the image-forming substrate shown in FIG. 1;",
"FIG. 7 is a partial schematic block diagram of three line-type thermal heads and a thermal head driver circuit therefor incorporated in the color printer of FIG. 6;",
"FIG. 8 is a schematic block diagram of a control circuit board of the color printer shown in FIG. 6;",
"FIG. 9 is a partial schematic wiring diagram of the thermal head driver circuit of FIGS. 7 and 8;",
"FIG. 10 is a table for explaining how one of the three thermal heads to be driven is selected by a combination of levels of two selection-control signals inputted to the thermal head driver circuit;",
"FIG. 11 is a part of a flowchart of a thermal-head-driver control routine executed in a printer control circuit of FIG. 8;",
"FIG. 12 is the remaining part of the flowchart of the thermal-head-driver control routine executed in the printer control circuit of FIG. 8;",
"and FIG. 13 is a timing chart used to explain the thermal-head-driver control routine shown in FIGS. 11 and 12 .",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an image-forming substrate, generally indicated by reference 10 , which is used in an image-forming apparatus according to the present invention.",
"The image-forming substrate 10 is produced in a form of a paper sheet.",
"Namely, the image-forming substrate or sheet 10 comprises a sheet of paper 12 , a layer of microcapsules 14 coated over a surface of the paper sheet 12 , and a sheet of protective transparent film 16 covering the microcapsule layer 14 .",
"The microcapsule layer 14 is formed from three types of microcapsules: a first type of microcapsules 18 C filled with cyan liquid dye or ink, a second type of microcapsules 18 M filled with magenta liquid dye or ink, and a third type of microcapsules 18 Y filled with yellow liquid dye or ink, and these microcapsules 18 C, 18 M and 18 Y are uniformly distributed in the microcapsule layer 14 .",
"In each type of microcapsule ( 18 C, 18 M, 18 Y), a shell wall of a microcapsule is formed of a synthetic resin material, usually colored white.",
"Also, each type of microcapsule ( 18 C, 18 M, 18 Y) may be produced by a well-known polymerization method, such as interfacial polymerization, in-situ polymerization or the like, and may have an average diameter of several microns, for example, 5 μm to 10 μm.",
"Note, when the paper sheet 12 is colored with a single color pigment, the resin material of the microcapsules 18 C, 18 M and 18 Y may be colored by the same single color pigment.",
"For the uniform formation of the microcapsule layer 14 , for example, the same amounts of cyan, magenta and yellow microcapsules 18 C, 18 M and 18 Y are homogeneously mixed with a suitable binder solution to form a suspension, and the paper sheet 12 is coated with the binder solution, containing the suspension of microcapsules 18 C, 18 M and 18 Y, by using an atomizer.",
"Note, in FIG. 1, for the convenience of illustration, although the microcapsule layer 14 is shown as having a thickness corresponding to the diameter of the microcapsules 18 C, 18 M and 18 Y, in reality, the three types of microcapsules 18 C, 18 M and 18 Y overlay each other, and thus the microcapsule layer 14 has a larger thickness than the diameter of a single microcapsule 18 C, 18 M or 18 Y. In the image-forming sheet 10 , for the resin material of each type of microcapsule ( 18 C, 18 M, 18 Y), a shape memory resin may be utilized.",
"As is well known, for example, the shape memory resin is represented by a polyurethane-based-resin, such as polynorbornene, trans-1,4-polyisoprene polyurethane.",
"As other types of shape memory resin, a polyimide-based resin, a polyamide-based resin, a polyvinylchloride-based resin, a polyester-based resin and so on are also known.",
"In general, as is apparent from a graph of FIG. 2, the shape memory resin exhibits a coefficient of longitudinal elasticity, which abruptly changes at a glass-transition temperature boundary T g .",
"In the shape memory resin, Brownian movement of the molecular chains is stopped in a low-temperature area “a”, which is less than the glass-transition temperature T g , and thus the shape memory resin exhibits a glass-like phase.",
"On the other hand, Brownian movement of the molecular chains becomes increasingly energetic in a high-temperature area “b”, which is higher than the glass-transition temperature T g , and thus the shape memory resin exhibits a rubber elasticity.",
"The shape memory resin is named due to the following shape memory characteristic: after a mass of the shape memory resin is worked into a shaped article in the low-temperature area “a”, when such a shaped article is heated over the glass-transition temperature T g , the article becomes freely deformable.",
"After the shaped article is deformed into another shape, when the deformed article is cooled to below the glass-transition temperature T g , the other shape of the article is fixed and maintained.",
"Nevertheless, when the deformed article is again heated to above the glass-transition temperature T g , without being subjected to any load or external force, the deformed article returns to the original shape.",
"In the image-forming sheet 10 , the shape memory characteristic per se is not utilized, but the characteristic abrupt change of the shape memory resin in the longitudinal elasticity coefficient is utilized, such that the three types of microcapsules 18 C, 18 M and 18 Y can be selectively squashed and broken at different temperatures and under different pressures, respectively.",
"As shown in a graph of FIG. 3, a shape memory resin of the cyan microcapsules 18 C is prepared so as to exhibit a characteristic longitudinal elasticity coefficient, indicated by a solid line, having a glass-transition temperature T 1 ;",
"a shape memory resin of the magenta microcapsules 18 M is prepared so as to exhibit a characteristic longitudinal elasticity coefficient, indicated by a single-chained line, having a glass-transition temperature T 2 ;",
"and a shape memory resin of the yellow microcapsules 18 Y is prepared so as to exhibit a characteristic longitudinal elasticity coefficient, indicated by a double-chained line, having a glass-transition temperature T 3 .",
"Note, by suitably varying compositions of the shape memory resin and/or by selecting a suitable one from among various types of shape memory resin, it is possible to obtain the respective shape memory resins, with the glass-transition temperatures T 1 , T 2 and T 3 .",
"For example, the glass-transition temperatures T 1 , T 2 and T 3 may be set to 70° C., 110° C. and 130° C., respectively.",
"As shown in FIG. 4, the microcapsule walls of the cyan microcapsules 18 C, magenta microcapsules 18 M, and yellow microcapsules 18 Y have differing thicknesses W C , W M and W Y , respectively.",
"Namely, the thickness W C of cyan microcapsules 18 C is larger than the thickness W M of magenta microcapsules 18 M, and the thickness W M of magenta microcapsules 18 M is larger than the thickness W Y of yellow microcapsules 18 Y. Also, the wall thickness W C of the cyan microcapsules 18 C is selected such that each cyan microcapsule 18 C is compacted and broken under a breaking pressure that lies between a critical breaking pressure P 3 and an upper limit pressure P UL (FIG.",
"3 ), when each cyan microcapsule 18 C is heated to a temperature between the glass-transition temperatures T 1 and T 2 ;",
"the wall thickness W M of the magenta microcapsules 18 M is selected such that each magenta microcapsule 18 M is compacted and broken under a breaking pressure that lies between a critical breaking pressure P 2 and the critical breaking pressure P 3 (FIG.",
"3 ), when each magenta microcapsule 18 M is heated to a temperature between the glass-transition temperatures T 2 and T 3 ;",
"and the wall thickness W Y of the yellow microcapsules 18 Y is selected such that each yellow microcapsule 18 Y is compacted and broken under a breaking pressure that lies between a critical breaking pressure P 1 and the critical breaking pressure P 2 (FIG.",
"3 ), when each yellow microcapsule 18 Y is heated to a temperature between the glass-transition temperature T 3 and an upper limit temperature T UL .",
"Note, for example, the breaking-pressures P 1 , P 2 , P 3 and P UL may be set to 0.02, 0.2, 2.0 and 20 MPa, respectively, and a wall thickness of a microcapsule ( 18 C, 18 M, 18 Y) concerned is selected such that it is compacted and broken under a given breaking pressure when it is heated to a given temperature.",
"Also, note, the upper limit temperature T UL is suitably set to, for example, 150° C. Thus, by suitably selecting a heating temperature and a breaking pressure, which should be exerted on the image-forming sheet 10 , it is possible to selectively squash and break the cyan, magenta and yellow microcapsules 18 C, 18 M and 18 Y. For example, if the selected heating temperature and breaking pressure fall within a hatched cyan-developing area C (FIG.",
"3 ), defined by a temperature ranging between the glass-transition temperatures T 1 and T 2 and by a pressure ranging between the critical breaking pressure P 3 and the upper limit pressure P UL , only the cyan microcapsules 18 C are squashed and broken, as representatively shown in FIG. 5 .",
"Also, if the selected heating temperature and breaking pressure fall within a hatched magenta-developing area M, defined by a temperature ranging between the glass-transition temperatures T 2 and T 3 and by a pressure ranging between the critical breaking pressures P 2 and P 3 , only the magenta microcapsules 18 M are squashed and broken.",
"Further, if the selected heating temperature and breaking pressure fall within a hatched yellow-developing area Y, defined by a temperature ranging between the glass-transition temperature T 3 and the upper limit temperature T UL and by a pressure ranging between the critical breaking pressures P 1 and P 2 , only the yellow microcapsules 18 Y are squashed and broken.",
"Accordingly, if the selection of a heating temperature and a breaking pressure, which should be exerted on the image-forming sheet 10 , are suitably controlled in accordance with a series of digital color image-pixel signals: digital cyan image-pixel signals, digital magenta image-pixel signals and digital yellow image-pixel signals, it is possible to form a color image on the image-forming sheet 10 on the basis of the digital color image-pixel signals.",
"With reference to FIG. 6, the image-forming apparatus according to the present invention is schematically shown, and is constituted as a line color printer so as to form a color image on the aforementioned image-forming sheet 10 .",
"The color printer comprises a rectangular parallelopiped housing 20 having an entrance opening 22 and an exit opening 24 formed in a top wall and a side wall of the housing 20 , respectively.",
"The image-forming sheet 10 (not shown in FIG. 6) is introduced into the housing 20 through the entrance opening 22 , and is then discharged from the exit opening 24 after the formation of a color image on the image-forming sheet 10 .",
"Note, in FIG. 6, a path 26 for movement of the image-forming sheet 10 is indicated by a chained line.",
"A guide plate 28 is provided in the housing 20 so as to define a part of the path 26 for the movement of the image-forming sheet 10 , and a first thermal head 30 C, a second thermal head 30 M and a third thermal head 30 Y are securely attached to a surface of the guide plate 28 .",
"Each thermal head ( 30 C, 30 M, 30 Y) is formed as a line thermal head perpendicularly extended with respect to a direction of the movement of the image-forming sheet 10 .",
"As conceptually shown in FIG. 7, the line thermal head 30 C includes a plurality of heater elements or electric resistance elements R c1 to R cn (where n=1, 2, 3, .",
"), and these electric resistance elements R c1 to R cn are linearly aligned with respect to each other along a length of the line thermal head 30 C. Also, the line thermal head 30 M includes a plurality of electric resistance elements R m1 to R mn (where n=1, 2, 3, .",
"), and these electric resistance elements R m1 to R mn are linearly aligned with respect to each other along a length of the line thermal head 30 M. Similarly, the line thermal head 30 Y includes a plurality of electric resistance elements R y1 to R yn (where n=1, 2, 3, .",
"), and these resistance elements are linearly aligned with respect to each other along a length of the line thermal head 30 Y. According to the present invention, each of the electric resistance elements (R c1 to R cn ;",
"R m1 to R mn ;",
"and R y1 to R yn ) is selectively energized by a thermal head driver circuit 31 in accordance with a corresponding monochromatic (cyan, yellow, magenta) digital image-pixel signal in a manner as stated in detail hereinafter.",
"Of course, when a digital cyan image-pixel signal has a value “1”, a corresponding electric resistance element R cn is heated to a temperature, which falls in the range between the glass-transition temperatures T 1 and T 2 ;",
"when a digital magenta image-pixel signal has a value “1”, a corresponding electric resistance element R mn is heated to a temperature, which falls in the range between the glass-transition temperatures T 2 and T 3 ;",
"when the digital yellow image-pixel signal has a value “1”, the corresponding electric resistance element R yn is heated to a temperature, which falls in the range between the glass-transition temperature T 3 and the upper limit temperature T UL .",
"Note, the line thermal heads 30 C, 30 M and 30 Y are arranged in sequence so that the respective heating temperatures increase in the movement direction of the image-forming substrate 10 .",
"As shown in FIG. 6, the color printer further comprises a first roller platen 32 C, a second roller platen 32 M and a third roller platen 32 Y associated with the first, second and third thermal heads 30 C, 30 M and 30 Y, respectively, and each of the roller platens 32 C, 32 M and 32 Y may be formed of a suitable hard rubber material.",
"The first roller platen 32 C is provided with a first spring-biasing unit 34 C so as to be elastically pressed against the first thermal head 30 C at a pressure between the critical compacting-pressure P 3 and the upper limit pressure P UL ;",
"the second roller platen 32 M is provided with a second spring-biasing unit 34 M so as to be elastically pressed against the second thermal head 30 M at a pressure between the critical compacting-pressures P 2 and P 3 ;",
"and the third roller platen 32 Y is provided with a third spring-biasing unit 34 Y so as to be elastically pressed against the second thermal head 30 Y at a pressure between the critical compacting-pressures P 1 and P 2 .",
"During a printing operation, the respective roller platens 32 C, 32 M and 32 Y are intermittently rotated in a counterclockwise direction (FIG.",
"6) with a same peripheral speed.",
"Accordingly, the image-forming sheet 10 , introduced through the entrance opening 22 , intermittently moves toward the exit opening 24 along the path 26 .",
"Thus, the image-forming sheet 10 is subjected to pressure ranging between the critical breaking-pressure P 3 and the upper limit pressure P UL when passing between the first line thermal head 30 C and the first roller platen 32 C;",
"to pressure ranging between the critical breaking-pressures P 2 and P 3 when passing between the second line thermal head 30 M and the second roller platen 32 M;",
"and to pressure ranging between the critical breaking-pressures P 1 and P 2 when passing between the third line thermal head 30 Y and the third roller platen 32 Y. Namely, the roller platens 32 C, 32 M and 32 Y are arranged in sequence so that the respective pressures, exerted by the platens 32 C, 32 M and 32 Y on the line thermal heads 30 C, 30 M and 30 Y, decrease in the movement direction of the image-forming substrate 10 .",
"Note, the introduction of the image-forming sheet 10 into the entrance opening 22 of the printer is carried out such that the transparent protective film sheet 16 of the image-forming sheet 10 comes into contact with the thermal heads 30 C, 30 M and 30 Y. With the arrangement of the above-mentioned line printer, for example, when one of the electric resistance elements R cn is heated to a temperature in the range between the glass-transition temperatures T 1 and T 2 , a cyan dot, having a dot size (diameter) of 50 μm to 100 μm, is developed on the microcapsule layer 14 of the image-forming sheet 10 , because only the cyan microcapsules 18 C are squashed and broken at a dot area heated by the resistance element (R cn ) concerned.",
"Of course, although a plurality of cyan, magenta and yellow microcapsules 18 C, 18 M and 18 Y are uniformly included in a dot area (50 μm to 100 μm) to be developed on the microcapsule layer 14 , it is possible to squash and break only the cyan microcapsules 18 C, because the heating temperature is within the range between the glass-transition temperatures T 1 and T 2 .",
"In FIG. 6, reference 36 indicates a control circuit board for controlling a printing operation of the color printer, and reference 38 indicates an electrical main power source for electrically energizing the control circuit board 36 .",
"FIG. 8 shows a schematic block diagram of the control circuit board 36 .",
"As shown in this drawing, the control circuit board 36 comprises a printer control circuit 40 including a microcomputer.",
"The printer control circuit 40 receives a series of digital color image-pixel signals from a personal computer or a word processor (not shown) through an interface circuit (I/F) 42 .",
"The received digital color image-pixel signals are suitably processed and are converted into a frame of digital cyan image-pixel signals, a frame of digital magenta image-pixel signals, and a frame of digital yellow image-pixel signals, and these frames of digital color image-pixel signals are once stored in a memory 44 .",
"Also, the control circuit board 36 is provided with a motor driver circuit 46 for driving three electric motors 48 C, 48 M and 48 Y, which are used to rotationally drive the roller platens 32 C, 32 M and 32 Y, respectively.",
"In this embodiment of the color printer, each of the motors 48 C, 48 M and 48 Y is a stepping motor, which is driven in accordance with a series of drive pulses outputted from the motor driver circuit 46 , the outputting of drive pulses from the motor driver circuit 46 to the motors 48 C, 48 M and 48 Y being controlled by the printer control circuit 40 .",
"As shown in FIG. 8, the thermal head driver circuit 31 for the line thermal heads 30 C, 30 M and 30 Y is included in the control circuit board 36 , and is controlled by a set of selection-control signals “ST1”",
"and “ST2”, a series of clock pulses “CLK”, a low-active latch signal “LATCH”",
"and a series of digital color image-pixel signals “DATA”, which are outputted from the printer control circuit 40 .",
"FIG. 9 partially shows an arrangement of the thermal head driver circuit 31 .",
"As is apparent from this drawing, the thermal head driver circuit 31 comprises a shift register 50 including a plurality of D-type flip-flops 50 1 to 50 n (where n=1, 2, 3, .",
"), and a latch circuit 52 including a plurality of D-type latches 52 1 to 52 n (where n=1, 2, 3, .",
"During a printing operation, a single-line of monochromatic (cyan, magenta, yellow) digital image-pixel signals “DATA”",
"is read from the memory 44 , and is then inputted to the shift register 50 .",
"While the series of monochromatic digital image-pixel signals “DATA”",
"is inputted to the shift register 50 , these digital image-pixel signals are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK.”",
"Then, the respective monochromatic image-pixel signals held by the flip-flops 50 1 to 50 n are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by outputting the low-active latch signal “LATCH”",
"from the printer control circuit 40 to the latch circuit 52 through an invertor 53 (FIG.",
"9 ), whereby the respective digital image-pixel signals are stably held in the latches 52 1 to 52 n .",
"Thus, either a high-level signal or a low-level signal is stably outputted from a Q-terminal of each latch ( 52 1 , .",
", 52 n ) in accordance with binary values of a corresponding monochromatic digital image-pixel signal held therein.",
"Namely, when the digital image-pixel signal has a value “1”, the high-level signal is outputted from the Q-terminal of the corresponding latch ( 52 1 , .",
", 52 n ), and, when the digital image-pixel signal has a value “0”, the low-level signal is outputted from the Q-terminal of the corresponding latch ( 52 1 , .",
", 52 n ).",
"The thermal head driver circuit 31 further comprises a plurality of driver circuit elements 54 1 to 54 n (where n=1, 2, 3, .",
"Each of the driver circuit elements 54 1 to 54 n includes a set of AND-gate circuits 56 C, 56 M and 56 Y, a set of field-effect transistors (FET) 58 C, 58 M and 58 Y, and a pair of invertors 60 A and 60 B, all being wired in a manner as shown in FIG. 9 .",
"In particular, each of the AND-gate circuits 56 C, 56 M and 56 Y has three input terminals, one of which is connected to the Q-terminal of the corresponding latch ( 52 1 , .",
", 52 n ), and the respective remaining input terminals of each AND-gate circuit ( 56 C, 56 M, 56 Y) are connected to two signal lines SL 1 and SL 2 , through which the selection-control signals “ST1”",
"and “ST1”",
"are fed, respectively.",
"Note, as shown in FIG. 9, the invertor 60 A is interposed between the signal line SL 1 and the corresponding input terminal of the AND-gate circuit 56 C, and the inverter 60 B is interposed between the signal line SL 2 and the corresponding input terminal of the AND-gate circuit 56 M. Also, each of the AND-gate circuits 56 C, 56 M and 56 Y has an output terminal, which is connected to a gate (G) of the corresponding FET ( 58 C, 58 M, 58 Y) A source (S) of each FET ( 58 C, 58 M, 58 Y) is connected to an electric power source (V h ), and respective drains (D) of the FETs 58 C, 58 M and 58 Y are connected to the electric resistance elements R cn , R mn and R yn .",
"Of course, when an output level of each AND gate circuit ( 56 C, 56 M, 56 Y) is changed from a low-level to a high-level, the corresponding FET ( 58 C, 58 M, 58 Y) is turned ON, so that the corresponding electric resistance element (R cn , R mn , R yn ) is electrically energized.",
"With the arrangement of the aforementioned thermal head driver circuit 31 , usually both the selection-control signals “ST1”",
"and “ST2”",
"are maintained at a low-level under control of the printer control circuit 40 , so that all the output levels of the AND-gate circuit ( 56 C, 56 M and 56 Y) are also maintained at the low-level, whereby all the electric resistance elements R cn , R mn and R yn cannot be electrically energized.",
"When the digital cyan image-pixel signals included in the single-line are held in the respective latches 52 1 to 52 n , and when these latches 52 1 to 52 n are latched, only an output level of the selection-control signal “ST2”",
"is changed from the low-level to a high-level, so that only the respective electric resistance elements R c1 to R cn are selectively energized in accordance with the digital cyan image-pixel signals held in the latches 52 1 to 52 n .",
"Namely, for example, when the digital cyan image-pixel signal held in the latch 52 1 has a value “1”, the output level of the corresponding AND-gate circuit 56 C is changed from the low-level to the high-level, whereby the corresponding electric resistance element R c1 is electrically energized.",
"On the other hand, when the digital cyan image-pixel signal held in the latch 52 1 has a value “0”, the output level of the corresponding AND-gate circuit 56 C is maintained at the low-level, whereby the corresponding electric resistance element R c1 cannot be electrically energized.",
"When the digital magenta image-pixel signals included in the single-line are held in the respective latches 52 1 to 52 n , and when these latches 52 1 to 52 n are latched, only an output level of the selection-control signal “ST1”",
"is changed from the low-level to a high-level, so that only the respective electric resistance elements R m1 to R mn are selectively energized in accordance with the digital magenta image-pixel signals held in the latches 52 1 to 52 n .",
"Namely, for example, when the digital magenta image-pixel signal held in the latch 52 1 has a value “1”, the output level of the corresponding AND-gate circuit 56 M is changed from the low-level to the high-level, whereby the corresponding electric resistance element R m1 is electrically energized.",
"On the other hand, when the digital magenta image-pixel signal held in the latch 52 1 has a value “0”, the output level of the corresponding AND-gate circuit 56 M is maintained at the low-level, whereby the corresponding electric resistance element R m1 cannot be electrically energized.",
"When the digital yellow image-pixel signals included in the single-line are held in the respective latches 52 1 to 52 n , and when these latches 52 1 to 52 n are latched, both output levels of the selection-control signals “ST1”",
"and “ST2”",
"are changed from the low-level to the high-level, so that only the respective electric resistance elements R y1 to R yn are selectively energized in accordance with the digital yellow image-pixel signals held in the latches 52 1 to 52 n .",
"Namely, for example, when the digital yellow image-pixel signal held in the latch 52 1 has a value “1”, the output level of the corresponding AND-gate circuit 56 Y is changed from the low-level to the high-level, whereby the corresponding electric resistance element R y1 is electrically energized.",
"On the other hand, when the digital yellow image-pixel signal held in the latch 52 1 has a value “0”, the output level of the corresponding AND-gate circuit 56 Y is maintained at the low-level, whereby the corresponding electric resistance element R y1 cannot be electrically energized.",
"In short, by a combination of the levels of the selection-control signals “ST1”",
"and “ST2”, it is possible to select which thermal head ( 30 C, 30 M, 30 Y) should be driven so that the electric resistance elements (R c1 to R cn ;",
"R m1 to R mn ;",
"R y1 to R yn ) included in the corresponding thermal head ( 30 C, 30 M, 30 Y) are selectively and electrically energized, as shown in a TABLE of FIG. 10 .",
"Whenever the electric resistance elements R c1 to R cn are selectively and electrically energized, the electrical energization is continued until the electrically-energized electric resistance elements (R cn ) are heated to a temperature between the glass-transition temperatures T 1 and T 2 , and the electrical energization is stopped by returning the high-level of the selection-control signal “ST2”",
"to the low-level when the heated resistance elements (R cn ) have reached the temperature between the glass-transition temperatures T 1 and T 2 .",
"For example, a period of the electrical energization of the electric resistance elements (R cn ) may be set to 3 ms.",
"Whenever the electric resistance elements R m1 to R mn are selectively and electrically energized, the electrical energization is continued until the electrically-energized electric resistance elements (R mn ) are heated to a temperature between the glass-transition temperatures T 2 and T 3 , and the electrical energization is stopped by returning the high-level of the selection-control signal “ST1”",
"to the low-level when the heated resistance elements (R mn ) have reached the temperature between the glass-transition temperatures T 2 and T 3 .",
"For example, a period of the electrical energization of the electric resistance elements (R mn ) may be set to 4 ms.",
"Whenever the electric resistance elements R y1 to R yn are selectively and electrically energized, the electrical energization is continued until the electrically-energized electric resistance elements (R yn ) are heated to a temperature between the glass-transition temperature T 3 and the upper limit temperature T UL , and the electrical energization is stopped by returning the high-levels of the selection-control signals “ST1”",
"and “ST2”",
"to the low-levels when the heated resistance elements (R yn ) have reached the temperature between the glass-transition temperature T 3 and the upper limit temperature T UL .",
"For example, a period of the electrical energization of the electric resistance elements (R cn ) may be set to 5 ms.",
"FIGS. 11 and 12 show a flowchart of a thermal-head-driver control routine executed by the printer control circuit 40 .",
"This thermal-head-driver control routine is constituted as a time-interruption routine which is repeatedly executed at regular intervals of, for example, 5 μs, and the execution of this routine is started when the printer control circuit 40 receives a printing-operation-start signal from a personal computer or a word processor (not shown) through the interface circuit (I/F) 42 .",
"In this embodiment, the execution of the thermal-head-driver control routine is performed under the following conditions: (a) During the printing operation, three single-lines three-primary color (cyan, magenta and yellow) digital image-pixel signals are successively read in a cycle from the memory 44 , and are outputted from the printer control circuit 40 to the shift register 50 in the order of a single-line of cyan digital image-pixel signals, a single-line of magenta digital image-pixel signals and a single-line of yellow digital image-pixel signals, before the cycle is again repeated.",
"Also, the low-active latch signal “LATCH”",
"cyclically produces three latch pulses: a first latch pulse for latching the cyan digital image-pixel signals, a second latch pulse for latching the magenta digital image-pixel signals, and a third latch pulse the yellow digital image-pixel signals;",
"(b) The thermal heads 30 C, 30 M and 30 Y are spaced apart from each other by a distance corresponding to, for example, 200 single-lines of image-dots recorded on the image-forming sheet 10 .",
"For this reason, the single-line of magenta digital image-pixel signals is repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the first single-line of cyan image-dots, recorded by the alignment of electric resistance elements R c1 to R cn of the thermal head 30 C, reaches the alignment of electric resistance elements R m1 to R mn of the thermal head 30 M, and the single-line of yellow digital image-pixel signals is also repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the first single-line of cyan image-dots, recorded by the alignment of electric resistance elements R c1 to R cn of the thermal head 30 C, reaches the alignment of electric resistance elements R y1 to R yn of the thermal head 30 Y;",
"and (c) For the same reason, the single-line of cyan digital image-pixel signals is repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the last single-line of cyan image-dots, recorded by the alignment of electric resistance elements R c1 to R cn of the thermal head 30 C, reaches the alignment of electric resistance elements R y1 to R yn of the thermal head 30 Y, and the single-line of magenta digital image-pixel signals is also repeatedly outputted as a dummy single-line of image-pixel signals, all having a value “0”, until the last single-line of magenta image-dots, recorded by the alignment of electric resistance elements R m1 to R mn of the thermal head 30 M reaches the alignment of electric resistance elements R y1 to R yn of the thermal head 30 Y. With reference to a timing chart shown in FIG. 13, the thermal-head-driver control routine will be now explained below.",
"At step 101 , it is determined whether a flag F 1 is “0”",
"or “1.”",
"At an initial stage in which the printing operation has just begun, since F 1 =0, the control proceeds to step 102 , and it is determined whether a first latch pulse of the low-active latch signal “LATCH”, indicated by reference LAT 1 in the timing chart of FIG. 13, is outputted from the printer control circuit 40 to the latch circuit 52 .",
"If the outputting of the first latch pulse “LAT1”",
"is not confirmed, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the first latch pulse “LAT1”",
"is confirmed.",
"In the beginning of the printing operation, a first single-line of digital cyan image-pixel signals, indicated by reference C 1 (DATA), is inputted in the shift register 50 , and these digital cyan image-pixel signals C 1 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 .",
"Then, the respective digital cyan image-pixel signals C 1 (DATA) held by the flip-flops 50 1 to 50 n are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by an outputting of the first latch pulse “LAT1.”",
"At step 102 , when the outputting of the first latch pulse “LAT1”",
"is confirmed, the control proceeds to step 103 , in which the flag F 1 is made to be “1.”",
"Then, at step 104 , it is determined whether a flag F 2 is “0”",
"or “1.”",
"At the initial stage, since F 2 =0, the control proceeds to step 105 , in which the selection-control signal “ST2”",
"is made to be high, whereby only the electric resistance elements R c1 to R cn of the thermal head 30 C are selectively and electrically energized in accordance with the cyan image-pixel signals C 1 (DATA) held in the latches 52 1 to 52 n of the latch circuit 52 .",
"At step 106 , it is determined whether a count number of a counter CC has reached a numerical value of 600, which corresponds to a time period of 3 ms (3 ms/5 μs=600).",
"At the initial stage, since CC=0, the control proceeds to step 107 , in which the count number of the counter CC is incremented by “1.”",
"Then, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, the incrementing of the count number of the counter CC is merely carried out until the count number of the counter CC reaches the numerical value of 600 (with F 1 =1 and F 2 =0).",
"At step 106 , when it is confirmed that the count number of the counter CC has reached the numerical value of 600, the control proceeds from step 106 to step 108 , in which the selection-control signal “ST2”",
"is returned to the low-level, so that the selective and electrical energization of the electric resistance elements R c1 to R cn of the thermal head 30 C is stopped.",
"At step 109 , the counter CC is reset to “0.”",
"Then, at step 110 , the flag F 1 is made to be “0”, and the flag F 2 is made to be “1.”",
"Thus, the routine once ends.",
"When the routine is executed after the time of 5 μs has elapsed, the control proceeds to step 102 via step 101 (F 1 =0 at step 110 ), in which it is determined whether a second latch pulse of the low-active latch signal “LATCH”, indicated by reference LAT 2 in the timing chart of FIG. 13, is outputted from the printer control circuit 40 to the latch circuit 52 .",
"If the outputting of the second latch pulse “LAT2”",
"is not confirmed, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the second latch pulse “LAT2”",
"is confirmed.",
"As is apparent from the timing chart of FIG. 13, during the selective and electrical energization of the electric resistance elements R c1 to R cn of the thermal head 30 C, a first single-line of digital magenta image-pixel signals, indicated by reference M 1 (DATA), is inputted to the shift register 50 , and these digital magenta image-pixel signals M 1 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 .",
"Then, the respective digital magenta image-pixel signals M 1 (DATA) held by the flip-flops 50 1 to 50 are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by an outputting of the second latch pulse “LAT2.”",
"At step 102 , when the outputting of the second latch pulse “LAT2”",
"is confirmed, the control proceeds to step 103 , in which the flag F 1 is made to be “1.”",
"Then, the control jumps from step 104 to step 111 (F 2 =1), in which it is determined whether a flag F 3 is “0”",
"or “1.”",
"At the initial stage, since F 3 =0, the control proceeds to step 112 , in which the selection-control signal “ST1”",
"is made to be high, whereby only the electric resistance elements R m1 to R mn of the thermal head 30 M are selectively and electrically energized in accordance with the magenta image-pixel signals M 1 (DATA) held in the latches 52 1 to 52 n of the latch circuit 52 .",
"At step 113 , it is determined whether a count number of a counter MC has reached a numerical value of 800, which corresponds to a time period of 4 ms (4 ms/5 μs=800).",
"At the initial stage, since MC=0, the control proceeds to step 114 , in which the count number of the counter MC is incremented by “1.”",
"Then, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, the incrementing of the count number of the counter MC is merely carried out until the count number of the counter MC reaches the numerical value of 800 (with F 1 =1 and F 2 =1).",
"At step 113 , when it is confirmed that the count number of the counter MC has reached the numerical value of 800, the control proceeds from step 113 to step 115 , in which the selection-control signal “ST1”",
"is returned to the low-level, so that the selective and electrical energization of the electric resistance elements R m1 to R mn of the thermal head 30 M is stopped.",
"At step 116 , the counter MC is reset to “0.”",
"Then, at step 117 , the flag F 1 is made to be “0”, and the flag F 3 is made to be “1.”",
"Thus, the routine once ends.",
"When the routine is executed after the time of 5 μs has elapsed, the control proceeds to step 102 via step 101 (F 1 =0 at step 117 ), in which it is determined whether a third latch pulse of the low-active latch signal “LATCH”, indicated by reference LAT 3 in the timing chart of FIG. 13, is outputted from the printer control circuit 40 to the latch circuit 52 .",
"If the outputting of the third latch pulse “LAT3”",
"is not confirmed, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the third latch pulse “LAT3”",
"is confirmed.",
"As is apparent from the timing chart of FIG. 13, during the selective and electrical energization of the electric resistance elements R m1 to R mn of the thermal head 30 M, a first single-line of digital yellow image-pixel signals, indicated by reference Y 1 (DATA), is inputted to the shift register 50 , and these digital yellow image-pixel signals Y 1 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 .",
"Then, the respective digital yellow image-pixel signals Y 1 (DATA) held by the flip-flops 50 1 to 50 n are simultaneously shifted to the latches 52 1 to 52 n of the latch circuit 52 , and are latched by outputting the third latch pulse “LAT3.”",
"At step 102 , when the outputting of the third latch pulse “LAT3”",
"is confirmed, the control proceeds to step 103 , in which the flag F 1 is made to be “1.”",
"Then, the control jumps from step 104 to step 111 (F 2 =1), and further jumps from step 111 to step 118 (F 3 =1), in which the selection-control signals “ST1”",
"and “ST2”",
"are made to be high, whereby only the electric resistance elements R y1 to R yn of the thermal head 30 Y are selectively and electrically energized in the accordance with the magenta image-pixel signals Y 1 (DATA) held in the latches 52 1 to 52 n of the latch circuit 52 .",
"At step 119 , it is determined whether a count number of a counter YC has reached a numerical value of 1000, which corresponds to a time period of 5 ms (5 ms/5 μs=1000).",
"At the initial stage, since YC=0, the control proceeds to step 120 , in which the count number of the counter YC is incremented by “1.”",
"Then, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, the incrementing of the count number of the counter YC is merely carried out until the count number of the counter YC reaches the numerical value of 1000 (with F 1 =1, F 2 =1 and F 3 =1).",
"At step 119 , when it is confirmed that the count number of the counter YC has reached the numerical value of 1000, the control proceeds from step 119 to step 121 , in which the selection-control signals “ST1”",
"and “ST2”",
"are returned to the low-level, so that the selective and electrical energization of the electric resistance elements R y1 to R yn of the thermal head 30 Y is stopped.",
"At step 122 , the counter YC is reset to “0.”",
"Then, at step 123 , the flag F 1 is made to be “0”, the flag F 2 is made to be “0”, and the flag F 3 is made to be “0.”",
"Thus, the routine once ends.",
"Thereafter, although the routine is repeatedly executed at regular intervals of 5 μs, there is no progress until the outputting of the first latch pulse “LAT1”",
"is again confirmed.",
"As is apparent from the timing chart of FIG. 13, during the selective and electrical energization of the electric resistance elements R y1 to R yn of the thermal head 30 Y, a second single-line of digital cyan signals, indicated by reference C 2 (DATA), is inputted to the shift register 50 , and these digital cyan image-pixel signals C 2 (DATA) are successively shifted to the flip-flops 50 1 to 50 n in accordance with the series of clock pulses “CLK”, as shown in the timing chart of FIG. 13 .",
"On the other hand, as soon as the selective and electrical energization of the electric resistance elements R y1 to R yn of the thermal head 30 Y is completed (step 121 ), the motors 48 C, 48 M and 48 Y are driven in accordance with the series of drive pulses outputted from the motor driver circuit 46 , such that the image-forming sheet 10 is intermittently fed by a distance corresponding to the single-line of image-dots recorded on the image-forming sheet 10 .",
"After the intermittent movement of the image-forming sheet 10 is completed, once the first latch pulse “LAT1”",
"is again outputted from the printer control circuit 40 to the latch circuit 52 , the selective and electrical energization of the electric resistance elements (R cl to R cn ;",
"R ml to R mn ;",
"and R y1 to R yn ) are cyclically repeated in accordance with the aforesaid execution of the routine in FIGS. 11 and 12 until a color image is completely recorded on the image-forming sheet 10 .",
"As is apparent from the foregoing, according to the present invention, plural thermal heads ( 30 C, 30 M, 30 Y) have a common single shift register ( 50 ) and a common single latch circuit ( 52 ).",
"Accordingly, in comparison to a conventional case where a thermal head driver system is provided for each thermal head, it is possible to reduce a production cost of the thermal head driver system according to the present invention.",
"In the aforesaid embodiment of the present invention, although the three thermal heads 30 C, 30 M and 30 Y are selectively driven by the combination of the levels of the two selection-control signals “ST1”",
"and “ST2”, of course, it is possible to perform a selective driving of two thermal heads by the combination of the levels of the two selection-control signals “ST1”",
"and “ST2.”",
"On the other hand, in a case where a combination of levels of three selection-control signals are utilized, it is possible to selectively drive at least seven thermal heads in accordance with at least seven types of digital image-pixel signals.",
"Namely, when n selection-control signals are utilized, it is possible to selectively drive a number of thermal heads, being (2 n −1).",
"Finally, it will be understood by those skilled in the art that the foregoing description is of preferred embodiments of the system and the apparatus, and that various changes and modifications may be made to the present invention without departing from the spirit and scope thereof.",
"The present disclosure relates to a subject matter contained in Japanese Patent Application No. 10-106137 (filed on Apr. 16, 1998) which is expressly incorporated herein, by reference, in its entirety."
] |
BACKGROUND
[0001] Goggles are used in any number of applications ranging from sports such as skiing and snowboarding to protective eye wear for use in a lab or even a military situation. While each of type of goggle has different design considerations and performance requirements, those requirements may change during use. For example, a snowboarding goggle that may be appropriate for use during a bright day may be too dark when a storm blows in or as evening approaches. Therefore, a single goggle with a single lens may not provide adequate performance for all of the different situations a user may find themselves in.
SUMMARY
[0002] In one embodiment, a goggle may include a frame having an opening and a first lens disposed in the opening that may be selectively removed and replaced with a second lens while the goggle is worn. The selective removal and retention of the lenses may be provided through the use of a magnetic latch including at least one pair of retaining magnets correspondingly located on the goggle frame and lens.
[0003] In another embodiment, a goggle may include a frame having an opening with a top, a bottom, and opposite sides. A lens may be selectively removable from the opening. Furthermore, the lens may form a magnetic latch with at least one of the top side, bottom side, left side, or right side of the opening during insertion and removal. The frame may also include an overhang constructed and adapted to promote a pivoting movement of the magnetic latch and positioned over the magnetic latch.
[0004] In yet another embodiment, a goggle lens may include a lens and a first magnet coupled to the lens along a first side of the lens. The first magnet may have a first magnetic field direction. The lens may also include a second magnet coupled to the lens along a second side of the lens. The second magnet may have a second field direction that is substantially orthogonal to the first field direction.
[0005] In one embodiment, a goggle may include a frame and a first magnet coupled to the frame along a first side of the frame. The first magnet may have a first magnetic field direction. The frame may also include a second magnet coupled to the frame along a second side of the frame. The second magnet may have a second field direction that is substantially orthogonal to the first field direction.
[0006] In another embodiment, a goggle may include a frame and a lens. In addition, a first magnet may be coupled to the lens along a first side of the lens with a first field direction. The goggle may also include a second magnet coupled to the lens along a second side of the lens with a second field direction. The second field direction may be substantially orthogonal to the first field direction when the second magnet is coupled to the lens.
[0007] In yet another embodiment, a goggle may include a frame having an opening with a first and second side. The first side may include two lips extending along the first side and the second side may include a single lip extending along the second side. The goggle may also include a lens selectively disposed within the opening. Furthermore, the lens may be disposed between the two lips along the first side and it may be flush with the single lip along the second side.
[0008] In another embodiment, a method for replacing a goggle lens includes pivoting a lens about a pivot axis defined between a removable lens and a frame. The edge opposite the pivot axis pivots up and out during removal and in and down during insertion relative to a person when in the fitted state.
[0009] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In addition, all combinations of claimed subject matter are contemplated as being part of the inventive subject matter disclosed herein.
[0010] The foregoing and other aspects, embodiments, and features of the present teachings can be more fully understood from the following description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
[0012] FIGS. 1A-1C present front views of the goggle as the lens is removed from the frame;
[0013] FIGS. 2A-2C present isometric views of the goggle as the lens is removed from the frame;
[0014] FIGS. 3A-3C present side views of the goggle as the lens is removed from the frame;
[0015] FIGS. 4 and 5 present front and rear views of the lens;
[0016] FIG. 6 presents a perspective view of the frame detailing the overhanging projection and associated magnet;
[0017] FIG. 7 presents a rear perspective view of the lens detailing the magnetic field directions of the attached magnets;
[0018] FIGS. 8 and 9 present a front and perspective view of the frame detailing the magnets disposed in the frame;
[0019] FIG. 10 presents a perspective view of the frame detailing the lips present along the periphery of the opening in the frame; and
[0020] FIG. 11 presents a bottom view of the frame.
DETAILED DESCRIPTION
[0021] There are any number of instances where a person may want to change the performance of the lens in a goggle. Some reasons to change lenses may include, but are not limited to, changing the tinting for different light conditions, reducing glare, reducing fogging, increasing ballistic/shatter resistance, and/or to use a lens with a different chemical resistance to name a few non-limiting examples. Instead of providing a separate goggle for the different conditions a person may encounter it may be desirable to quickly and simply replace one lens with another with the desired performance characteristics. In view of the above, the inventors have appreciated the need to provide a goggle that may have the lens quickly and easily removed from the frame and replaced with another lens while the goggle is still worn by the person. More specifically, the inventors have recognized the advantages of providing a goggle with a magnetic latch with a corresponding overhang that permits the lens to be pivoted up and outwards to easily and smoothly remove the lens from the frame.
[0022] With regards to the disclosure discussed below, it should be understood that there are pairs of mating magnets present on the lens and frame in corresponding locations and orientations. However, for simplicity's sake, magnets located on the frame and lens will be referred to with the same numeral. It should be understood that a magnet present on one component labeled with an identifier will mate with a magnet, or another material attracted to the magnet, present on the other component labeled with the same identifier.
[0023] In one embodiment, the goggle 2 includes a frame 4 and lens 8 . The frame may include an opening 6 with a top 6 a, a bottom 6 b, left side 6 c, and right side 6 d. The lens may be shaped and sized so that it fits within the opening. The lens and frame may include corresponding retaining features such as pairs of magnets located along the periphery of the opening that may attract one another to retain the lens in place during use. These magnet pairs may include corresponding pairs of retaining magnets 12 located along the lower edge of the lens and opening and retaining magnets pairs 14 located on the opposite side along the top edge of the lens and frame opening. Another retaining magnet pair 16 may also be located along a lower edge of the lens and frame opening corresponding to a portion of a nose ridge. In the current embodiment, the various magnets are neodymium magnets. However, it should be understood that the magnets could be any type of magnet including, but not limited to, ceramic, Alnico, other rare earth magnets, and any other applicable magnet suitable for the design requirements of the specific goggle as would be apparent to one of skill in the art.
[0024] While the above noted retaining magnets and magnetic latch have been described with respect to mating pairs of magnets the current disclosure is not limited in this fashion. For example, it may be desirable, in some embodiments, to provide a single magnet on the frame or lens with a corresponding material on the other component that is attracted to the magnet. This material may include any magnetically susceptible material, such as iron, nickel, cobalt, magnetic alloys, and other applicable materials as would be apparent to one of skill in the art. For purposes of this patent, magnetic material includes magnets, materials attracted to magnets, and materials with magnetic properties. Therefore, the various magnetic latches, retaining features, and magnetic pairs disclosed herein may include various combinations of magnetic materials. Depending on the application, it may be also be desirable for the materials to be corrosion resistant. Therefore, the material may be a magnetic stainless steel, a ceramic based magnet, or any other corrosion resistant material with magnetic properties.
[0025] For aesthetic as well as functional purposes, the above noted retaining magnets may be disposed within an outer shell. In some embodiments, the shell may completely encase the magnets. In other embodiments, similar to those depicted in the figures, the shells may expose the mating surfaces of each pair. In addition, the shell may be made from a number of materials including nylon, polyethylene, or other appropriate materials. The shells may also be roughened, coated, knurled, or prepared in any other appropriate manner to facilitate removal of the lens from the frame. In other instances the shells associated with the retaining magnets 12 coupled to the lens 8 may be wedge shaped as seen in FIGS. 4 and 5 . It is believed that a wedge shape oriented towards the mating part on the frame may help guide the magnets and lens during insertion. However, other guiding shapes are also envisioned. The shell of the magnets associated with the frame may also include a dovetail, not depicted, that mates with a dovetailed receiving slot on the frame. The magnets may be assembled with the frame by deforming the frame and inserting the dovetail portion of the shell and associated magnet into the slot in the frame. In other embodiments, the coupling may be provided by a mechanical interference fit. An adhesive may also be used in addition to, or in place of, the various mechanical couplings disclosed above.
[0026] To reduce the removal force of the lens and increase the accuracy of placement, it may be desirable to remove the lens through a pivoting motion about a placement guide. By removing the lens in this manner the retaining force of the magnets may be overcome gradually rather than all at once. For example, if the lens were to pivot upwards the retaining forces on the bottom would be overcome prior to those on the top. Hence, the removal force may be decreased as compared to overcoming the retaining force of every magnet at once. FIGS. 1A-3C generally illustrate the concept of pivoting the lens relative to the goggle frame from several different viewpoints in different states of assembly. As best seen in FIGS. 3A-3C the lens may be pivoted upwards by pushing or prying retaining magnets 12 up and out from the frame. This will disengage the retaining magnets from the bottom edge of the opening and the lens may pivot about the magnetic latch 18 .
[0027] To promote the desired pivoting motion and obtain easy repeatable placement of the lens in the opening in the frame, one or more pairs of magnets may act as a magnetic latch 18 between the frame and lens. To further facilitate the desired pivoting motion of the lens during removal and insertion, the frame may include a projection 10 that overhangs the magnetic latch 18 . The portion of the magnetic latch 18 present on the lens may be positioned underneath the overhanging projection during insertion and use. In some embodiments, the overhanging projection may act as a physical guide for placement of the lens and may further promote pivoting of the lens during insertion and removal. As depicted in FIG. 6 , in some embodiments the overhanging projection 10 may include an angled surface 20 adjacent to the magnetic latch 18 . The angled surface may facilitate the pivoting motion of the lens during insertion and removal by providing a pivot point for the lens to rotate about until the two magnets disengage gradually using the mechanical advantage provided by pivoting the magnet about its edge and onto the angled surface. The angled surface may also act as a ramp intended to guide the portion of the magnetic latch on the lens smoothly towards the corresponding portion of the magnetic latch 18 disposed on the frame during insertion. In a preferred embodiment, the magnets comprising the magnetic latch and the overhanging projection may be located along the top edge of the opening. However, the current disclosure is not limited in this manner and the magnetic latch may be located along any side of the opening.
[0028] FIG. 7 illustrates the difference in the orientation of the magnetic field direction of the magnets disposed along the periphery of the lens 8 . The first magnetic field direction is directed substantially upwards in the figure as depicted by arrows 20 and is associated with the magnetic latch 18 and the retaining magnets 14 disposed along the upper edge of the lens. Without wishing to be bound by theory, while other magnetic field directions may be used, having the magnetic field direction associated with the magnetic latch oriented towards the pivot axis of the lens may reduce the torque applied by magnets 14 and 18 during lens removal. A reduced torque may result in less force being applied to pivot the lens which may help avoid damage to the lens and provide a more controlled feel to removing the lens without the need to pull the magnetic latch apart. Pivoting of the magnetic latch with minimal torque is further facilitated by angled surface 20 discussed above acting as a pivot point to avoid prematurely pulling the magnetic latch apart.
[0029] The second magnetic field direction is associated with retaining magnets 12 and 16 disposed along the lower edge of the lens and is depicted by the arrows 24 . As shown in FIG. 7 , the second magnetic field direction is substantially orthogonal to the first magnetic field direction. In certain embodiments, the first and second magnetic fields may be oriented between approximately 45 to 90 degrees relative to one another. While other orientations are possible, in one embodiment, the second magnetic field direction may also be substantially orthogonal to the pivot axis, e.g. inwards towards a person's face resisting pivoting of the lens about the magnetic latch 18 . Without wishing to be bound by theory, orienting the second magnetic field direction orthogonally towards the pivot axis may provide a larger torque to retain the lens within the frame for a given size magnet.
[0030] While only the magnetic field directions associated with the magnets on the lens have been shown, the portions of magnet pairs 12 , 14 , 16 , and 18 located on the frame will have corresponding magnetic field directions that are parallel and opposite to the magnetic field directions depicted with respect to the magnets on the lens shown in FIG. 7 . Therefore, the magnetic field directions associated with the magnets along the top of the frame opening, i.e. the magnet latch 18 and retaining magnets 14 , will be substantially orthogonal to the magnetic field directions associated with retaining magnets 12 and 16 located along the bottom of the frame opening. The locations of the above noted magnets on the frame is shown in FIGS. 8 and 9 .
[0031] Lenses for a goggle are generally disposed between interior 26 and exterior lips 28 running along the periphery of the opening in the frame to both retain the lens and seal the goggle. In some embodiments, the exterior lip may be flush with an exterior surface of the frame and the interior lip may be recessed from the exterior surface of the goggle. The seal is usually created by pressing the lens between the two lips. However, to provide easy removal of a lens it may be desirable to have at least one side of the opening that does not have an exterior lip. This may permit the lens to easily pivot upwards from at least one edge without being retained by an exterior lip 28 . Therefore, in a preferred embodiment, at least one side of the opening may only have an interior lip 26 and it may be located on the side of the frame opposite the location of the magnetic latch. In the embodiment presented in FIG. 10 , this corresponds to the bottom side of the frame which only has an interior lip 28 . Both top, left, and right edges of the frame include both interior and exterior lips 26 and 28 . Since a seal may not be made by pressing the lens between two lips, since only one lip is present along the bottom edge, it may be advantageous to create a seal by holding the lens flush against the interior lip. In one embodiment the retaining magnets 12 and 16 may be mounted to the lens and frame in such a way as to compress a flat surface of the lens against the interior lip to create a seal.
[0032] In another embodiment, due to the magnets located along the edge corresponding to the magnetic latch providing an upwards, instead of inwards force, the lens may not be as strongly retained as it is along the opposite edge. Therefore, it may be desirable to provide additional retention force for the lens along the edge corresponding to the location of the magnetic latch by providing both interior and exterior lips along this edge. This is clearly shown in FIG. 10 where the top edge of the opening corresponding to the magnetic latch has both interior and exterior lips 26 and 28 . While the interior and exterior lips are shown to include several pieces it is possible that each lip could be a single continuous piece, or there could be a plurality of lips spanning the edge, as the current disclosure is not limited in this fashion.
[0033] Although in the embodiments described above the goggle includes a single lens, the goggle may have two or more lenses arranged front to back (as with lenses having an insulating space between lenses to reduce fogging), side to side (as in typical spectacle-type goggles having one lens positioned in front of each eye) and/or other arrangements. Moreover, the frame need not have the particular shape shown in the figures, but instead may have any suitable shape, such as that found in safety glasses, welding goggles, and so on. That is, the frame may accommodate a single unitary lens, or separate lenses, and may have any suitable size, shape or other configuration. The frame also need not include a face gasket or wrap-around shape that closely conforms to the wearer's face, but instead may be formed much like ordinary spectacles. In addition, while the embodiments detailed above describe lenses disposed within an opening of a goggle frame the current disclosure is not limited in this manner. In some embodiments, the lens may be disposed against an exterior edge of the frame such that the lens is placed around the front face of the frame. Alternatively, the lens may simply lie flush against the front face of the frame such that the edges of the frame and lens substantially align with one another. It is also possible an embodiment could contain a combination of the above noted lens and frame arrangements such that different edges of the lens could overlie a frame edge, align with a frame edge, or be disposed within an opening of the frame as the current disclosure is meant to include any of these variations.
[0034] The corresponding portions of the retaining magnets and magnetic latch may be mounted to the lens and frame in any suitable way. In this embodiment, the frame and lens may create interference fits with the shells of the retaining magnets and magnetic latch. However, the lens and/or frame may have any suitable features, materials or devices to mount the retaining magnets and magnetic latch. For example, the retaining magnets and magnetic latch may be connected to the frame and/or lens using tabs, holes, pins, locking devices, slots, fasteners, adhesive, friction or snap fit, interference fit, etc.
[0035] The goggle may be held in place on a wearer's head in any suitable way. For example, a head support may include an elastic strap. However, the head support may include other features, such as tension adjustment buckles, earstems that extend from the frame to engage the sides and/or ears of a wearer, snaps, clips, hook-and-loop fasteners or other devices to secure the frames to a helmet or other headgear, and so on. In addition to the above, in some embodiments the frame may include adjustable arms located at the sides of the frame that the head support may be attached to. The adjustable arms may allow a user to adjust the fit of the goggle. While several types of head supports have been discussed above, the current disclosure is not limited in this fashion. Instead, the currently disclosed goggle with replaceable lens may be used with any type of head support that allows the goggle to be retained on the head of an individual.
[0036] While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Accordingly, the foregoing description and drawings are by way of example only. | A goggle is disclosed that includes a frame having an opening with a top, a bottom, and opposite sides. A lens may be selectively removable from the opening even when the goggle is worn by an individual. To enable the removal of the lens, the lens may form a magnetic latch with at least one of the top, bottom, or opposite sides of the opening during insertion and removal. The frame may also include an overhang constructed and adapted to promote a pivoting movement of the magnetic latch and positioned over the magnetic latch. | Summarize the key points of the given patent document. | [
"BACKGROUND [0001] Goggles are used in any number of applications ranging from sports such as skiing and snowboarding to protective eye wear for use in a lab or even a military situation.",
"While each of type of goggle has different design considerations and performance requirements, those requirements may change during use.",
"For example, a snowboarding goggle that may be appropriate for use during a bright day may be too dark when a storm blows in or as evening approaches.",
"Therefore, a single goggle with a single lens may not provide adequate performance for all of the different situations a user may find themselves in.",
"SUMMARY [0002] In one embodiment, a goggle may include a frame having an opening and a first lens disposed in the opening that may be selectively removed and replaced with a second lens while the goggle is worn.",
"The selective removal and retention of the lenses may be provided through the use of a magnetic latch including at least one pair of retaining magnets correspondingly located on the goggle frame and lens.",
"[0003] In another embodiment, a goggle may include a frame having an opening with a top, a bottom, and opposite sides.",
"A lens may be selectively removable from the opening.",
"Furthermore, the lens may form a magnetic latch with at least one of the top side, bottom side, left side, or right side of the opening during insertion and removal.",
"The frame may also include an overhang constructed and adapted to promote a pivoting movement of the magnetic latch and positioned over the magnetic latch.",
"[0004] In yet another embodiment, a goggle lens may include a lens and a first magnet coupled to the lens along a first side of the lens.",
"The first magnet may have a first magnetic field direction.",
"The lens may also include a second magnet coupled to the lens along a second side of the lens.",
"The second magnet may have a second field direction that is substantially orthogonal to the first field direction.",
"[0005] In one embodiment, a goggle may include a frame and a first magnet coupled to the frame along a first side of the frame.",
"The first magnet may have a first magnetic field direction.",
"The frame may also include a second magnet coupled to the frame along a second side of the frame.",
"The second magnet may have a second field direction that is substantially orthogonal to the first field direction.",
"[0006] In another embodiment, a goggle may include a frame and a lens.",
"In addition, a first magnet may be coupled to the lens along a first side of the lens with a first field direction.",
"The goggle may also include a second magnet coupled to the lens along a second side of the lens with a second field direction.",
"The second field direction may be substantially orthogonal to the first field direction when the second magnet is coupled to the lens.",
"[0007] In yet another embodiment, a goggle may include a frame having an opening with a first and second side.",
"The first side may include two lips extending along the first side and the second side may include a single lip extending along the second side.",
"The goggle may also include a lens selectively disposed within the opening.",
"Furthermore, the lens may be disposed between the two lips along the first side and it may be flush with the single lip along the second side.",
"[0008] In another embodiment, a method for replacing a goggle lens includes pivoting a lens about a pivot axis defined between a removable lens and a frame.",
"The edge opposite the pivot axis pivots up and out during removal and in and down during insertion relative to a person when in the fitted state.",
"[0009] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein.",
"In addition, all combinations of claimed subject matter are contemplated as being part of the inventive subject matter disclosed herein.",
"[0010] The foregoing and other aspects, embodiments, and features of the present teachings can be more fully understood from the following description in conjunction with the accompanying drawings.",
"BRIEF DESCRIPTION OF DRAWINGS [0011] The accompanying drawings are not intended to be drawn to scale.",
"In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral.",
"For purposes of clarity, not every component may be labeled in every drawing.",
"In the drawings: [0012] FIGS. 1A-1C present front views of the goggle as the lens is removed from the frame;",
"[0013] FIGS. 2A-2C present isometric views of the goggle as the lens is removed from the frame;",
"[0014] FIGS. 3A-3C present side views of the goggle as the lens is removed from the frame;",
"[0015] FIGS. 4 and 5 present front and rear views of the lens;",
"[0016] FIG. 6 presents a perspective view of the frame detailing the overhanging projection and associated magnet;",
"[0017] FIG. 7 presents a rear perspective view of the lens detailing the magnetic field directions of the attached magnets;",
"[0018] FIGS. 8 and 9 present a front and perspective view of the frame detailing the magnets disposed in the frame;",
"[0019] FIG. 10 presents a perspective view of the frame detailing the lips present along the periphery of the opening in the frame;",
"and [0020] FIG. 11 presents a bottom view of the frame.",
"DETAILED DESCRIPTION [0021] There are any number of instances where a person may want to change the performance of the lens in a goggle.",
"Some reasons to change lenses may include, but are not limited to, changing the tinting for different light conditions, reducing glare, reducing fogging, increasing ballistic/shatter resistance, and/or to use a lens with a different chemical resistance to name a few non-limiting examples.",
"Instead of providing a separate goggle for the different conditions a person may encounter it may be desirable to quickly and simply replace one lens with another with the desired performance characteristics.",
"In view of the above, the inventors have appreciated the need to provide a goggle that may have the lens quickly and easily removed from the frame and replaced with another lens while the goggle is still worn by the person.",
"More specifically, the inventors have recognized the advantages of providing a goggle with a magnetic latch with a corresponding overhang that permits the lens to be pivoted up and outwards to easily and smoothly remove the lens from the frame.",
"[0022] With regards to the disclosure discussed below, it should be understood that there are pairs of mating magnets present on the lens and frame in corresponding locations and orientations.",
"However, for simplicity's sake, magnets located on the frame and lens will be referred to with the same numeral.",
"It should be understood that a magnet present on one component labeled with an identifier will mate with a magnet, or another material attracted to the magnet, present on the other component labeled with the same identifier.",
"[0023] In one embodiment, the goggle 2 includes a frame 4 and lens 8 .",
"The frame may include an opening 6 with a top 6 a, a bottom 6 b, left side 6 c, and right side 6 d. The lens may be shaped and sized so that it fits within the opening.",
"The lens and frame may include corresponding retaining features such as pairs of magnets located along the periphery of the opening that may attract one another to retain the lens in place during use.",
"These magnet pairs may include corresponding pairs of retaining magnets 12 located along the lower edge of the lens and opening and retaining magnets pairs 14 located on the opposite side along the top edge of the lens and frame opening.",
"Another retaining magnet pair 16 may also be located along a lower edge of the lens and frame opening corresponding to a portion of a nose ridge.",
"In the current embodiment, the various magnets are neodymium magnets.",
"However, it should be understood that the magnets could be any type of magnet including, but not limited to, ceramic, Alnico, other rare earth magnets, and any other applicable magnet suitable for the design requirements of the specific goggle as would be apparent to one of skill in the art.",
"[0024] While the above noted retaining magnets and magnetic latch have been described with respect to mating pairs of magnets the current disclosure is not limited in this fashion.",
"For example, it may be desirable, in some embodiments, to provide a single magnet on the frame or lens with a corresponding material on the other component that is attracted to the magnet.",
"This material may include any magnetically susceptible material, such as iron, nickel, cobalt, magnetic alloys, and other applicable materials as would be apparent to one of skill in the art.",
"For purposes of this patent, magnetic material includes magnets, materials attracted to magnets, and materials with magnetic properties.",
"Therefore, the various magnetic latches, retaining features, and magnetic pairs disclosed herein may include various combinations of magnetic materials.",
"Depending on the application, it may be also be desirable for the materials to be corrosion resistant.",
"Therefore, the material may be a magnetic stainless steel, a ceramic based magnet, or any other corrosion resistant material with magnetic properties.",
"[0025] For aesthetic as well as functional purposes, the above noted retaining magnets may be disposed within an outer shell.",
"In some embodiments, the shell may completely encase the magnets.",
"In other embodiments, similar to those depicted in the figures, the shells may expose the mating surfaces of each pair.",
"In addition, the shell may be made from a number of materials including nylon, polyethylene, or other appropriate materials.",
"The shells may also be roughened, coated, knurled, or prepared in any other appropriate manner to facilitate removal of the lens from the frame.",
"In other instances the shells associated with the retaining magnets 12 coupled to the lens 8 may be wedge shaped as seen in FIGS. 4 and 5 .",
"It is believed that a wedge shape oriented towards the mating part on the frame may help guide the magnets and lens during insertion.",
"However, other guiding shapes are also envisioned.",
"The shell of the magnets associated with the frame may also include a dovetail, not depicted, that mates with a dovetailed receiving slot on the frame.",
"The magnets may be assembled with the frame by deforming the frame and inserting the dovetail portion of the shell and associated magnet into the slot in the frame.",
"In other embodiments, the coupling may be provided by a mechanical interference fit.",
"An adhesive may also be used in addition to, or in place of, the various mechanical couplings disclosed above.",
"[0026] To reduce the removal force of the lens and increase the accuracy of placement, it may be desirable to remove the lens through a pivoting motion about a placement guide.",
"By removing the lens in this manner the retaining force of the magnets may be overcome gradually rather than all at once.",
"For example, if the lens were to pivot upwards the retaining forces on the bottom would be overcome prior to those on the top.",
"Hence, the removal force may be decreased as compared to overcoming the retaining force of every magnet at once.",
"FIGS. 1A-3C generally illustrate the concept of pivoting the lens relative to the goggle frame from several different viewpoints in different states of assembly.",
"As best seen in FIGS. 3A-3C the lens may be pivoted upwards by pushing or prying retaining magnets 12 up and out from the frame.",
"This will disengage the retaining magnets from the bottom edge of the opening and the lens may pivot about the magnetic latch 18 .",
"[0027] To promote the desired pivoting motion and obtain easy repeatable placement of the lens in the opening in the frame, one or more pairs of magnets may act as a magnetic latch 18 between the frame and lens.",
"To further facilitate the desired pivoting motion of the lens during removal and insertion, the frame may include a projection 10 that overhangs the magnetic latch 18 .",
"The portion of the magnetic latch 18 present on the lens may be positioned underneath the overhanging projection during insertion and use.",
"In some embodiments, the overhanging projection may act as a physical guide for placement of the lens and may further promote pivoting of the lens during insertion and removal.",
"As depicted in FIG. 6 , in some embodiments the overhanging projection 10 may include an angled surface 20 adjacent to the magnetic latch 18 .",
"The angled surface may facilitate the pivoting motion of the lens during insertion and removal by providing a pivot point for the lens to rotate about until the two magnets disengage gradually using the mechanical advantage provided by pivoting the magnet about its edge and onto the angled surface.",
"The angled surface may also act as a ramp intended to guide the portion of the magnetic latch on the lens smoothly towards the corresponding portion of the magnetic latch 18 disposed on the frame during insertion.",
"In a preferred embodiment, the magnets comprising the magnetic latch and the overhanging projection may be located along the top edge of the opening.",
"However, the current disclosure is not limited in this manner and the magnetic latch may be located along any side of the opening.",
"[0028] FIG. 7 illustrates the difference in the orientation of the magnetic field direction of the magnets disposed along the periphery of the lens 8 .",
"The first magnetic field direction is directed substantially upwards in the figure as depicted by arrows 20 and is associated with the magnetic latch 18 and the retaining magnets 14 disposed along the upper edge of the lens.",
"Without wishing to be bound by theory, while other magnetic field directions may be used, having the magnetic field direction associated with the magnetic latch oriented towards the pivot axis of the lens may reduce the torque applied by magnets 14 and 18 during lens removal.",
"A reduced torque may result in less force being applied to pivot the lens which may help avoid damage to the lens and provide a more controlled feel to removing the lens without the need to pull the magnetic latch apart.",
"Pivoting of the magnetic latch with minimal torque is further facilitated by angled surface 20 discussed above acting as a pivot point to avoid prematurely pulling the magnetic latch apart.",
"[0029] The second magnetic field direction is associated with retaining magnets 12 and 16 disposed along the lower edge of the lens and is depicted by the arrows 24 .",
"As shown in FIG. 7 , the second magnetic field direction is substantially orthogonal to the first magnetic field direction.",
"In certain embodiments, the first and second magnetic fields may be oriented between approximately 45 to 90 degrees relative to one another.",
"While other orientations are possible, in one embodiment, the second magnetic field direction may also be substantially orthogonal to the pivot axis, e.g. inwards towards a person's face resisting pivoting of the lens about the magnetic latch 18 .",
"Without wishing to be bound by theory, orienting the second magnetic field direction orthogonally towards the pivot axis may provide a larger torque to retain the lens within the frame for a given size magnet.",
"[0030] While only the magnetic field directions associated with the magnets on the lens have been shown, the portions of magnet pairs 12 , 14 , 16 , and 18 located on the frame will have corresponding magnetic field directions that are parallel and opposite to the magnetic field directions depicted with respect to the magnets on the lens shown in FIG. 7 .",
"Therefore, the magnetic field directions associated with the magnets along the top of the frame opening, i.e. the magnet latch 18 and retaining magnets 14 , will be substantially orthogonal to the magnetic field directions associated with retaining magnets 12 and 16 located along the bottom of the frame opening.",
"The locations of the above noted magnets on the frame is shown in FIGS. 8 and 9 .",
"[0031] Lenses for a goggle are generally disposed between interior 26 and exterior lips 28 running along the periphery of the opening in the frame to both retain the lens and seal the goggle.",
"In some embodiments, the exterior lip may be flush with an exterior surface of the frame and the interior lip may be recessed from the exterior surface of the goggle.",
"The seal is usually created by pressing the lens between the two lips.",
"However, to provide easy removal of a lens it may be desirable to have at least one side of the opening that does not have an exterior lip.",
"This may permit the lens to easily pivot upwards from at least one edge without being retained by an exterior lip 28 .",
"Therefore, in a preferred embodiment, at least one side of the opening may only have an interior lip 26 and it may be located on the side of the frame opposite the location of the magnetic latch.",
"In the embodiment presented in FIG. 10 , this corresponds to the bottom side of the frame which only has an interior lip 28 .",
"Both top, left, and right edges of the frame include both interior and exterior lips 26 and 28 .",
"Since a seal may not be made by pressing the lens between two lips, since only one lip is present along the bottom edge, it may be advantageous to create a seal by holding the lens flush against the interior lip.",
"In one embodiment the retaining magnets 12 and 16 may be mounted to the lens and frame in such a way as to compress a flat surface of the lens against the interior lip to create a seal.",
"[0032] In another embodiment, due to the magnets located along the edge corresponding to the magnetic latch providing an upwards, instead of inwards force, the lens may not be as strongly retained as it is along the opposite edge.",
"Therefore, it may be desirable to provide additional retention force for the lens along the edge corresponding to the location of the magnetic latch by providing both interior and exterior lips along this edge.",
"This is clearly shown in FIG. 10 where the top edge of the opening corresponding to the magnetic latch has both interior and exterior lips 26 and 28 .",
"While the interior and exterior lips are shown to include several pieces it is possible that each lip could be a single continuous piece, or there could be a plurality of lips spanning the edge, as the current disclosure is not limited in this fashion.",
"[0033] Although in the embodiments described above the goggle includes a single lens, the goggle may have two or more lenses arranged front to back (as with lenses having an insulating space between lenses to reduce fogging), side to side (as in typical spectacle-type goggles having one lens positioned in front of each eye) and/or other arrangements.",
"Moreover, the frame need not have the particular shape shown in the figures, but instead may have any suitable shape, such as that found in safety glasses, welding goggles, and so on.",
"That is, the frame may accommodate a single unitary lens, or separate lenses, and may have any suitable size, shape or other configuration.",
"The frame also need not include a face gasket or wrap-around shape that closely conforms to the wearer's face, but instead may be formed much like ordinary spectacles.",
"In addition, while the embodiments detailed above describe lenses disposed within an opening of a goggle frame the current disclosure is not limited in this manner.",
"In some embodiments, the lens may be disposed against an exterior edge of the frame such that the lens is placed around the front face of the frame.",
"Alternatively, the lens may simply lie flush against the front face of the frame such that the edges of the frame and lens substantially align with one another.",
"It is also possible an embodiment could contain a combination of the above noted lens and frame arrangements such that different edges of the lens could overlie a frame edge, align with a frame edge, or be disposed within an opening of the frame as the current disclosure is meant to include any of these variations.",
"[0034] The corresponding portions of the retaining magnets and magnetic latch may be mounted to the lens and frame in any suitable way.",
"In this embodiment, the frame and lens may create interference fits with the shells of the retaining magnets and magnetic latch.",
"However, the lens and/or frame may have any suitable features, materials or devices to mount the retaining magnets and magnetic latch.",
"For example, the retaining magnets and magnetic latch may be connected to the frame and/or lens using tabs, holes, pins, locking devices, slots, fasteners, adhesive, friction or snap fit, interference fit, etc.",
"[0035] The goggle may be held in place on a wearer's head in any suitable way.",
"For example, a head support may include an elastic strap.",
"However, the head support may include other features, such as tension adjustment buckles, earstems that extend from the frame to engage the sides and/or ears of a wearer, snaps, clips, hook-and-loop fasteners or other devices to secure the frames to a helmet or other headgear, and so on.",
"In addition to the above, in some embodiments the frame may include adjustable arms located at the sides of the frame that the head support may be attached to.",
"The adjustable arms may allow a user to adjust the fit of the goggle.",
"While several types of head supports have been discussed above, the current disclosure is not limited in this fashion.",
"Instead, the currently disclosed goggle with replaceable lens may be used with any type of head support that allows the goggle to be retained on the head of an individual.",
"[0036] While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples.",
"On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art.",
"Accordingly, the foregoing description and drawings are by way of example only."
] |
STATEMENT REGARDING FEDERALLY FUNDED RESEARCH
The invention was made with support from the National Institutes of Health under NIH Grant No. AI-13874. The Government has certain rights in the invention.
FIELD OF THE INVENTION
The invention relates generally to the field of immunosuppressive drugs and screening assays for their identification. More specifically, the invention relates to a screening assay for use in identifying agents which suppress, selectively or non-selectively, the synthesis or activity of antibodies of the immunoglobulin E isotype (IgE).
HISTORY OF THE RELATED ART
IgE antibodies mediate aspects of the mammalian immune response to antigens which contribute toward the onset of an allergic attack. In susceptible individuals, IgE can induce a hypersensitive phenotype involving the excessive and rapid release of mediators such as histamine, slow-reacting substance of anaphylaxis and eosinophilic chemotactic factor leading, in the extreme, to potentially fatal conditions such as anaphylaxis.
Control of the IgE mediated immune response is therefore an important goal of allergy therapy, especially in immunotherapies directed to the induction of antigen tolerance through repeated antigen challenge of the host immune system. For the purposes of allergy therapy, the challenge is to suppress the host immune system in a manner which dampens the activity of IgE while retaining the protective and otherwise beneficial effects of all of the host other immune response to particular antigens. Thus, immunosuppressive agents which selectively target IgE mediated immune responses are potentially potent weapons in the arsenal against allergic disease.
SUMMARY OF THE INVENTION
The invention provides an screening assay for use in identifying agents which have potential for pharmaceutical use as suppressors of IgE mediated, antigen-specific immune responses to antigens. For use in the assay, an animal which hyper responds to antigen by producing exaggerated levels of IgE is prepared or otherwise obtained. Initial sensitization of the animal to antigen is made within a specific, time-limited window of sensitivity defined by the invention. The animal thereafter maintains exaggerated IgE responsiveness to the sensitizing antigen, despite its return to an otherwise normal IgE phenotype.
Identification of potential IgE suppressors is performed in the animal by treating it with the candidate suppressor with or following primary immunization. A decline in antigen-specific IgE levels following treatment indicates that the candidate possesses suppressive activity. The scope of useful information provided by the assay can be expanded through measurement and comparison of other indicia of IgE immune responsiveness in the animal, such as levels of markers of the Th2 immunophenotype in which IgE production is normally induced.
To these ends, in one aspect of the invention, the animal platform for the screening assay is a non-human mammal whose IgE-mediated allergic system correlates with the IgE-mediated allergic systems of humans.
In another aspect of the invention, the non-human mammal is a rodent.
In another aspect of the invention, the rodent is a mouse.
In another aspect of the invention, the animal platform is rendered hyper responsive to antigen through low dose irradiation.
In another aspect of the invention, successful induction of an IgE hyperresponsive phenotype in the animal platform for the screening assay is confirmed through ablation of such responsiveness with CD23 + B cells delivered to the animal during the window of sensitivity defined by the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows data demonstrating allergic breakthrough in the context of the IgE-mediated immune response of SJL/J(H-2 s ) mice irradiated and immunized as described herein.
FIG. 2 shows data demonstrating the exclusion of antigens other than the primary immunogen from the exaggerated IgE responses of the mice described in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
I. Advantages Offered by the Invention
The invention consists of a practical application of the “allergic breakthrough” hypothesis for acquisition of IgE mediated allergy in mammals. According to the allergic breakthrough hypothesis, animals who have not previously exhibited an IgE-mediated allergic phenotype will do so on contact with antigen if the native dampening mechanism which controls their IgE antibody production is overcome under circumstances favoring acquisition of allergy.
With respect to such circumstances, a remarkable and surprising discovery leading to the invention was the realization that the allergic breakthrough phenomenon is dependent upon the timing of initial sensitization of an animal to an antigen in relation to the loss of regulatory control over IgE production in the animal. In particular, for allergic breakthrough to occur, such initial sensitization must take place within a day of the loss of regulatory control—a short and fairly rigid window of sensitivity whose existence could not have been predicted from simple observation of IgE responses to antigen.
More specifically, if the animal's sensitization to antigen takes place beyond the window of sensitivity defined by the invention, the animal will not acquire the exaggerated IgE responsiveness which characterizes allergic breakthrough. However, if sensitization occurs before closure of the window of sensitivity, not only will enhancement of the IgE response to the antigen occur, but it will be retained even after the animal returns to an otherwise normal level of IgE responsiveness to other antigens. Thus, the invention provides the parameters by which allergic breakthrough can be induced and exploited as a tool for identification of antigen-specific IgE suppressors.
For use in evaluating IgE selective suppressors, the invention further provides means of inducing exaggerated IgE responsiveness in an animal while the animal's other immune functions remain relatively unaffected. In this respect, the invention provides an in vivo environment in which the immune response can be induced, measured and targeted for IgE and antigen selective suppression.
II. Methods for Performance of Screening Assay
A. Animal Platforms
The animal utilized as a platform for the screening assay can be any animal whose IgE mediated immune system is susceptible to disruption by environmental influences such as sublethal radiation and certain toxins. Among such animals, those whose IgE mediated allergic systems correlate well with the human system are the better choices for use in the screening assay of the invention. The animal chosen may, but need not, be immunologically naive with respect to the immunizing antigen selected for study.
Mice offer a cost-effective, easily obtained model which correlates well with the human IgE mediated immune response at the physiological and molecular levels (see, c.g., Katz, Prog.Allergy , 32:105-160, 1982; and, Richards and Katz, J.Immunol ., 158:263-272, 1997). Any species of mouse can be utilized effectively in the screening assay, but those which are known to be low IgE responders are especially useful in that measurement of increases and declines of IgE levels is simplified by the low background levels of IgE usually produced in the animals. Mice of the SJL/J, C57BL/6(H-2 b ) and DBA/2 strains (with an IgE responsiveness at or below 80 PCA titer of 80) are examples of low IgE responder animals, and can be purchased commercially through sources such as Jackson Labs (based in Maine) and Charles River Labs (based in Massachusetts).
Those of ordinary skill in the art will be familiar with, or can readily ascertain, the identity of additional suitable animal models of human IgE-mediated allergy, including low IgE responder animals. The susceptibility of such animals to IgE immune modulation, if not known, can be determined through treatment of the animal with an IgE immune enhancer and measurement of the effect of the enhancer on the animal through conventional assay measurements of its IgE immune response (see, e.g., with respect to specific animals, Katz, Prog.Allergy , 32:105-160, 1982 [rodents]; Chen, et al., Int.Arch.Allergy Immunol ., 116:269-277, 1998 [murine model of anaphylaxis]; Ohta, et al., J.Allergy Clin.Immunol ., 7:212-223, 1983 [antigen-stimulated human B cells]; Vriesendorp, et al., Transplantation , 39:583-588, 1985 [susceptibility of dogs to IgE immune response modulation by sublethal irradiation]; Dombrowicz, et al., J.Immunol ., 15:1645-1651, 1996 [transgenic animal models of the human IgE immune system]).
B. Preparation of Animal Platform for Screening Assay
Certain environmental influences (“IgE enhancers”), such as sublethal irradiation and toxins such as ricin (castor bean lectin), have significant stimulatory effects on IgE responses to antigen. For use in developing exaggerated IgE responsiveness in the animal platform of the invention, sublethal irradiation is a convenient choice whose physiological effect is well-characterized (for example, low-dose irradiation has been used therapeutically in humans and experimentally in lower animals).
While exposure to high levels of radiation tends to have an overall immunosuppressive effect on mammals, the invention provides the discovery that exposure to discrete and relatively low doses of radiation coupled with antigen immunization will greatly enhance IgE responsiveness to antigen if irradiation and immunization occur within the correct temporal relationship; i.e., immunization should follow within about 24 hours of irradiation. The same temporal limitation applies to other IgE enhancers as well, indicating that the optimal sensitivity of activated IgE producing B cells to antigen sensitization lies within a 24 hour window which opens upon disruption of the animal's IgE dampening mechanisms.
Diurnal variations also play a role in optimization of IgE producer cell sensitivity to nonantigen stimulation. The sensitivity of IgE producer B cells to IgE enhancers such as irradiation is greatest in mice when accompanied by low levels of endogenous corticosteroids occurring at particular times of the day. For example, in SJL/J mice, IgE enhancement through whole-body irradiation is greater during the early afternoon (12:00 p.m. to 4:00 p.m.), when circulating levels of corticosteroids are at a natural low, than at other times of the day (for more details in regard to diurnal variations in mice and the effect on IgE responsiveness, see, e.g., Bargatze and Katz, J. Immunol ., 125:2306-2310, 1980). Thus, the time of day that the IgE enhancer is administered to an animal can effect the magnitude of the enhancement in IgE levels obtained, while the temporal relationship between the administration of the enhancer and antigen determines whether enhanced IgE levels are obtained at all.
To these ends, the animal to be utilized in the screening assay of the invention is treated with an IgE enhancer, then immunized within a day. Where the IgE enhancer is whole-body irradiation, the dose administered will necessarily be sublethal and should also be sub therapeutic. The optimal level may vary from species to species, but will generally fall below 700 rads, and desirably will fall within the range of 150-400 rads. Those of ordinary skill in the art will be familiar with, or can readily ascertain, suitable protocols for administration of sublethal, whole-body irradiation or other IgE enhancers, an example of which is provided elsewhere below.
C. Immunization of Animals
The immunogen chosen will vary with the clinical interests and goals of the practitioner, and may be comprised of an allergen, Th2 stimulatory infectious agent, immunogenic epitope, allergen extract or polynucleotide encoding an immunogenic (for convenience, the population of immunogenic substances which may be utilized in the invention will be referred to herein as “antigens”, unless context otherwise requires, but it will be understood that the immunization steps of the invention are not limited to delivery of antigens per se). Common allergens responsible for a relatively high incidence of IgE-related allergic events in humans include the IgE reactive major dust mite allergens Der pI and Der pII (Chua, et al., J.Exp.Med ., 167:175-182, 1988; and, Chua, et al., Int.Arch.Allergy Appl. Immunol ., 91:124-129, 1990); T cell epitope peptides of the Der pII allergen (Joost van Neerven, et al., J.Immunol ., 151:2326-2335, 1993); the highly abundant Antigen E (Amb aI) ragweed pollen allergen (Rafnar, et al., J.Biol.Chem ., 266:1229-1236, 1991); phospholipase A 2 (bee venom) allergen; the Fel dI major domestic cat allergen (Rogers, et al., Mol.Immunol ., 30:559-568, 1993); and, food allergens, notably the peanut and tree nut allergens. Model antigens accepted in the art as such, including ovalbumin (OVA), keyhole limpet hemocyanin (KLH) and conjugates thereof (e.g., with 2-dinitrophenyl [2-DNP]), are also well suited for use in invention.
Those of ordinary skill in the art will be entirely familiar with acceptable means of immunizing animals including, without limitation, means for immunization by intravascular, subcutaneous, intramuscular, intraperitoneal, nasal, topical and opthalmic routes of administration. Extensive protocols for immunizing animals for use in the invention are therefore not provided here.
Briefly, the antigen may be delivered in carrier (e.g., sterile saline), with or without an adjuvant, such as alum. The animal is sensitized to the antigen within a day, and desirably within 6-10 hours, of treatment of the animal with an IgE enhancer. Primary immunization with an immunologically related antigen (described further below) is made at a point in time after treatment of the animal with the IgE enhancer; conveniently, primary immunization will occur at about a week post-sensitization. Primary immunization may be followed by further immunizations with the same or immunologically related antigens to permit evaluation of the effect of the candidate IgE suppressor on the animal's response to subsequent antigen challenge.
It will be appreciated that the initial sensitizing antigen must share immunological activity with the antigen utilized in subsequent immunizations to permit evaluation of the animal's response of immunization and treatment following sensitization. In particular, to permit processing of antigen in later immunizations in a manner equivalent to processing of the antigen on initial sensitization, the antigens utilized in each immunizing step should share at least immunogenic epitopes (e.g., sensitization can be with whole antigen, followed by an immunogenic extract or fragment of the same, or vice-versa, so long as immunogenicity of the immunogens delivered in each step is comparable). Such antigens are those referred to herein as being “immunologically related”.
Where immune responses to more than one antigen are to be evaluated in the screening assay, the second antigen may be delivered in the initial sensitization step and on primary immunization, or only during the latter step, but if not delivered during the sensitization step, must be conjugated to the sensitizing antigen or otherwise delivered in a manner which permits both antigens to be processed by the animal's immune cells in similar fashion. An example of this approach is described in Example I below, where sensitization of an animal to KLH is followed by primary immunization with a KLH-DNP (2-dinitrophenyl) conjugate.
In the example provided, the KLH molecule in the conjugate delivered in the primary immunization step is “immunologically related” to the sensitizing KLH antigen. Because the DNP molecule is conjugated to the KLH molecule, it will be processed by the animal in a manner similar to the processing of the KLH molecule even though DNP is antigenically different from KLH. Thus, although the animal was not sensitized to DNP during the window of sensitivity, it will be “seen” by the animal's cells as immunologically related to KLH as both molecules are processed together as a consequence of their delivery as a conjugate—a single immunogenic moiety. As such, in this example, the exaggerated IgE response achieved in the primary immunization step will be specific to both KLH and DNP. However, if DNP is delivered independently of KLH in the primary immunization step, it will not be seen by the animal as immunologically related to the KLH sensitizing antigen, and the exaggerated IgE response will be directed only to KLH. In this manner, multiple antigens may be delivered to the animal, and evaluated accordingly, in the primary immunization step of the inventive screening assay.
Those of skill in the art will be familiar with, or can readily ascertain, methods for delivery of multiple immunogens to an animal as a single immunogenic moiety (e.g., by conjugation or co-delivery in a liposome), or can obtain suitable compositions for use in this regard from commercial sources.
D. Performance of the Screening Assay of the Invention
Following initial sensitization to antigen of an animal prepared for use in the screening assay as described above, the primed animal is treated (more than 24 hours after its exposure to an IgE enhancer) with a candidate IgE suppressor or, for use as a control, with vehicle. Primary immunization with the sensitizing antigen is desirably made with, but may be made at a time before, delivery of the candidate IgE suppressor.
At set time points before and after primary immunization (as well as before treatment with the IgE enhancer, if possible), an immune sample is taken from the animal and analyzed for antigen-specific and total levels of IgE. Depending on the antigen and its route of administration to the animal, the immune sample may consist of fluids such as serum, bronchoalevolar lavage and mucosal swabs. IgE levels are determined by conventional assays, many of which are commercially available in the art and will be familiar to those of ordinary skill in the art. An example of such an assay is provided in the Examples elsewhere below.
Other aspects of the IgE mediated immune response may also be examined in the assay. In this respect, those of ordinary skill in the art will understand that IgE antibodies are principally produced in the context of a “Th2 phenotype”; i.e., an immune phenotype associated with the extracellular exposure of a host to antigen and characterized by the activation of class 2 helper T lymphocytes. Th2 responses include the allergy-associated IgE antibody class; soluble protein antigens tend to stimulate relatively strong Th2 responses. In contrast, Th1 responses are induced by antigen binding to macrophages and dendritic cells.
IgG, antibodies are serological markers for a Th2 type immune response, whereas IgG 2a antibodies are indicative of a Th1 type immune response. The Th2 immune phenotype is further characterized by the release of certain cytokines; e.g., IL-4, while the Th1 immune phenotype tends to be accompanied by the release of cytokines such as IL-12 and/or an increase in IFN (α, β or γ) levels). Because the helper T lymphocyte system negatively reciprocates between the Th2 and Th1 classes of Th cells, a rise in levels of Th1 cytokines (e.g., IL-12 and IFN α, β or γ) and/or of IgG 2a antibodies correlates to suppression of the Th2 phenotype and, consequently, of a decline in the animal's ability to mount an IgE-mediated immune response.
Thus, the screening assay of the invention may also be applied to obtaining, circumstantial evidence of IgE suppression by a candidate compound gleaned from determining the class of helper T lymphocyte-mediated immune phenotype present before and after primary immunization and treatment with the candidate IgE suppressor. In particular, declines in Th2 cytokine and IgG 1 antibody levels and increases in Th1 cytokine and IgG 2a antibody levels are indicia of probable Th2 phenotype induction/IgE suppression; the reverse profiles are indicative of Th2 phenotype induction/IgE stimulation.
Comparative measurements of antibody isotypes other than IgE (pre- and post-primary immunization), as well as other antigen-sensitive immune components (cytokines, effectors, eosinophil infiltrate levels and the like) will provide information as to the relative sensitivity of the candidate IgE suppressor; i.e., as to whether it affects only IgE production/activity or whether other aspects of the immune system are also affected (desirably or not). In the murine animal platform of the invention utilizing low IgE responder animals, however, the assay can be expected to have a high degree of specificity for the IgE immune system; e.g., effects on total IgG responses can be expected to be meager.
All of these immune components can be detected and measured by conventional assays, many of which are commercially available to the art and will be familiar to those of ordinary skill in the art. Example of such assays are provided in the Examples elsewhere below and include an ELISA for the IgG 1 and IgG 2a isotypes using subclass-specific antibodies; an ELISA for antigen-specific and total IgE (Coligan, “ Current Protocols In Immunology ”, Unit 7.12.4, Vol. 1, Wiley & Sons, 1994); a sensitive (0.4 ng of IgE/ml) solid phase radioimmunoassay (RAST) modification of the IgE ELISA (substituting purified polyclonal goat antibodies specific for mouse ε chains for antibodies specific for human Fab); and, an anti-CD3 antibody (Pharmingen, La Jolla, Calif.) based splenocyte assay in which supernatants are assayed for cytokine levels (e.g., IL-4, IL-10 and IL-12) levels using a commercial kit, and interferon (e.g., INFγ) levels are assayed with an anti-INFγ murine antibody assay (see, e.g., Coligan, “ Current Protocols in Immunology ”, Unit 6.9.5., Vol. 1, Wiley & Sons, 1994).
Those of ordinary skill in the art will also recognize that an abbreviated protocol for the screening assay of the invention can be devised to test the activity of IgE enhancers. In particular, with measurement of IgE levels following treatment of an animal with a putative IgE enhancer and its priming with antigen, the failure of an animal which should develop an IgE hyperresponsive phenotype to do so is evidence that the putative IgE enhancer does not possess that activity, at least in the animal utilized in the assay.
Although not limited by any theory as to how IgE enhancement occurs in the animals utilized by the screening assay to evaluate IgE suppression, it appears that IgE enhancers such as low dose irradiation temporarily limit IgE binding by CD23 + (FccRII) B cells. Binding of IgE by B cells through the CD23 receptor regulates their differentiation and controls the onset of the IgE-mediated allergic phenotype. Thus, disruption of IgE binding by CD23 + B cells allows IgE-mediated responses to antigen to proceed unabated by CD23 + B cell regulation.
This probable explanation for the biological effect of IgE enhancers on host B cells suggests that the screening assay of the invention will be of particular use in evaluating agents which overcome the radiation-mediated perturbation of IgE binding by CD23 + B cells (such as ex vivo preparations of such cells). In addition, transplanted CD23 + B cells, or any other agent known to have IgE suppressive activity (e.g., isolated or synthetic CD23 + peptides including the IgE binding domain, or anti-IgE antibodies) can be used to verify the viability of the animal platform in that such cells can ablate IgE production and activity if administered during the window of sensitivity.
Examples illustrating the practice of the invention are set forth below. The examples are not intended to, and do not, limit the scope of the invention, which is defined by the appended claims.
EXAMPLE I
IRRADIATION-ENHANCED In Vivo IgE ANTIBODY RESPONSES
As proof of the principle that exaggerated IgE levels can be produced in an antigen-specific and time-specific manner, two groups of low IgE responder SJL/J (2-H s ) mice were prepared as follows: Group I was irradiated at 250 rads shortly before priming immunization with 2 μg of KLH in alum hydrogen peroxide (Pierce Chemical; a Th2 stimulatory adjuvant). The second group received the priming dose of KLH in alum, but was not irradiated. Seven days later (day 0), each group received 2 μg of DNP-KLH conjugate in alum and antigen-specific IgE levels were measured by ELISA in serum samples drawn from each mouse. Secondary antigen challenge was made on day 60 using the same antigen and dose given for primary immunization on day 0. Antigen-specific IgE were again measured at days 7, 14, 21, 60, 75, 120, 150 and 210.
Results are shown in FIG. 1, where IgE levels are represented as PCA titers. Anti-antigen IgE responses induced in the irradiated animals through irradiation-concomitant priming followed by primary immunization a week later were more than 1000 times the magnitude of IgE levels produced in the non-irradiated animals, and nearly 5000 times the magnitude following secondary immunization, indicating that the antigen-specific IgE responsiveness in the irradiated animals was not only induced, but maintained at allergic levels over time and on subsequent antigen challenge.
To determine the antigen-specificity of the exaggerated IgE response of the irradiated animals, two additional groups of animals were prepared and immunized as described above through day 0, except that irradiation was applied to the treatment group at 350 rads. On day 18, one group of the irradiated and untreated mice were secondarily immunized with the primary immunogen (2 μg DNP-KLH in alum), while a second group of irradiated and untreated mice received a different antigen—10 μg of OVA in alum. IgE responses to the DNP-KLH antigen were determined prior to and after primary immunization as well as at secondary immunization; anti-OVA IgE were also measured on days 28 and 35.
Results are shown in FIG. 2, where IgE levels are represented as PCA titers. Significantly, there was no detectable difference in the anti-OVA IgE produced in the irradiated and untreated mouse sets, even though there were dramatic differences in the anti-DNP IgE produced in irradiated versus untreated mouse groups (comparable to the responses shown in FIG. 1 ). Thus, the exaggerated antigen responsiveness in the IgE compartment of the irradiated mice was not retained with respect to antigens other than the primary immunogen following priming and allergic breakthrough.
With application of an active IgE suppressor at or near primary immunization, antigen-specific IgE can be expected to fall toward normal levels in the animal. For example, in low IgE responder mice, complete ablation of the exaggerated IgE response by an IgE suppressor would return the antigen-specific IgE levels to a magnitude comparable to that achieved in unirradiated mice and irradiated mice immunized outside of the window of sensitivity (data not shown).
The invention having been fully described, modifications and extensions of it may become apparent to those of ordinary skill in the art. All such modifications and extensions are intended to fall within the scope of the claimed invention. | The invention provides an IgE and antigen-specific screening assay for use in identifying agents which suppress the IgE mediated immune response to antigen. The assay is performed in vivo in animals which hyper respond to antigen by producing exaggerated levels of IgE. The animals are sensitized to an antigen during a specific window of sensitivity which closes a day after the animal has been treated to produce the IgE hyper responsive phenotype. The screening assay is performed in the animals by treating them with a candidate IgE suppressor agent in conjunction with further immunization made after closure of the window of sensitivity defined by the invention. Positive results (indicating that the candidate agent has IgE suppressive activity) are obtained in the assay through measurement of a decline in antigen-specific IgE in the animal following its treatment with the candidate agent. The screening assay may also be utilized to measure other components of the immune response to antigen, including IgG 1 and IgG 2a antibody production. | Briefly outline the background technology and the problem the invention aims to solve. | [
"STATEMENT REGARDING FEDERALLY FUNDED RESEARCH The invention was made with support from the National Institutes of Health under NIH Grant No. AI-13874.",
"The Government has certain rights in the invention.",
"FIELD OF THE INVENTION The invention relates generally to the field of immunosuppressive drugs and screening assays for their identification.",
"More specifically, the invention relates to a screening assay for use in identifying agents which suppress, selectively or non-selectively, the synthesis or activity of antibodies of the immunoglobulin E isotype (IgE).",
"HISTORY OF THE RELATED ART IgE antibodies mediate aspects of the mammalian immune response to antigens which contribute toward the onset of an allergic attack.",
"In susceptible individuals, IgE can induce a hypersensitive phenotype involving the excessive and rapid release of mediators such as histamine, slow-reacting substance of anaphylaxis and eosinophilic chemotactic factor leading, in the extreme, to potentially fatal conditions such as anaphylaxis.",
"Control of the IgE mediated immune response is therefore an important goal of allergy therapy, especially in immunotherapies directed to the induction of antigen tolerance through repeated antigen challenge of the host immune system.",
"For the purposes of allergy therapy, the challenge is to suppress the host immune system in a manner which dampens the activity of IgE while retaining the protective and otherwise beneficial effects of all of the host other immune response to particular antigens.",
"Thus, immunosuppressive agents which selectively target IgE mediated immune responses are potentially potent weapons in the arsenal against allergic disease.",
"SUMMARY OF THE INVENTION The invention provides an screening assay for use in identifying agents which have potential for pharmaceutical use as suppressors of IgE mediated, antigen-specific immune responses to antigens.",
"For use in the assay, an animal which hyper responds to antigen by producing exaggerated levels of IgE is prepared or otherwise obtained.",
"Initial sensitization of the animal to antigen is made within a specific, time-limited window of sensitivity defined by the invention.",
"The animal thereafter maintains exaggerated IgE responsiveness to the sensitizing antigen, despite its return to an otherwise normal IgE phenotype.",
"Identification of potential IgE suppressors is performed in the animal by treating it with the candidate suppressor with or following primary immunization.",
"A decline in antigen-specific IgE levels following treatment indicates that the candidate possesses suppressive activity.",
"The scope of useful information provided by the assay can be expanded through measurement and comparison of other indicia of IgE immune responsiveness in the animal, such as levels of markers of the Th2 immunophenotype in which IgE production is normally induced.",
"To these ends, in one aspect of the invention, the animal platform for the screening assay is a non-human mammal whose IgE-mediated allergic system correlates with the IgE-mediated allergic systems of humans.",
"In another aspect of the invention, the non-human mammal is a rodent.",
"In another aspect of the invention, the rodent is a mouse.",
"In another aspect of the invention, the animal platform is rendered hyper responsive to antigen through low dose irradiation.",
"In another aspect of the invention, successful induction of an IgE hyperresponsive phenotype in the animal platform for the screening assay is confirmed through ablation of such responsiveness with CD23 + B cells delivered to the animal during the window of sensitivity defined by the invention.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows data demonstrating allergic breakthrough in the context of the IgE-mediated immune response of SJL/J(H-2 s ) mice irradiated and immunized as described herein.",
"FIG. 2 shows data demonstrating the exclusion of antigens other than the primary immunogen from the exaggerated IgE responses of the mice described in FIG. 1 .",
"DETAILED DESCRIPTION OF THE INVENTION I. Advantages Offered by the Invention The invention consists of a practical application of the “allergic breakthrough”",
"hypothesis for acquisition of IgE mediated allergy in mammals.",
"According to the allergic breakthrough hypothesis, animals who have not previously exhibited an IgE-mediated allergic phenotype will do so on contact with antigen if the native dampening mechanism which controls their IgE antibody production is overcome under circumstances favoring acquisition of allergy.",
"With respect to such circumstances, a remarkable and surprising discovery leading to the invention was the realization that the allergic breakthrough phenomenon is dependent upon the timing of initial sensitization of an animal to an antigen in relation to the loss of regulatory control over IgE production in the animal.",
"In particular, for allergic breakthrough to occur, such initial sensitization must take place within a day of the loss of regulatory control—a short and fairly rigid window of sensitivity whose existence could not have been predicted from simple observation of IgE responses to antigen.",
"More specifically, if the animal's sensitization to antigen takes place beyond the window of sensitivity defined by the invention, the animal will not acquire the exaggerated IgE responsiveness which characterizes allergic breakthrough.",
"However, if sensitization occurs before closure of the window of sensitivity, not only will enhancement of the IgE response to the antigen occur, but it will be retained even after the animal returns to an otherwise normal level of IgE responsiveness to other antigens.",
"Thus, the invention provides the parameters by which allergic breakthrough can be induced and exploited as a tool for identification of antigen-specific IgE suppressors.",
"For use in evaluating IgE selective suppressors, the invention further provides means of inducing exaggerated IgE responsiveness in an animal while the animal's other immune functions remain relatively unaffected.",
"In this respect, the invention provides an in vivo environment in which the immune response can be induced, measured and targeted for IgE and antigen selective suppression.",
"II.",
"Methods for Performance of Screening Assay A. Animal Platforms The animal utilized as a platform for the screening assay can be any animal whose IgE mediated immune system is susceptible to disruption by environmental influences such as sublethal radiation and certain toxins.",
"Among such animals, those whose IgE mediated allergic systems correlate well with the human system are the better choices for use in the screening assay of the invention.",
"The animal chosen may, but need not, be immunologically naive with respect to the immunizing antigen selected for study.",
"Mice offer a cost-effective, easily obtained model which correlates well with the human IgE mediated immune response at the physiological and molecular levels (see, c.g., Katz, Prog.",
"Allergy , 32:105-160, 1982;",
"and, Richards and Katz, J.Immunol .",
", 158:263-272, 1997).",
"Any species of mouse can be utilized effectively in the screening assay, but those which are known to be low IgE responders are especially useful in that measurement of increases and declines of IgE levels is simplified by the low background levels of IgE usually produced in the animals.",
"Mice of the SJL/J, C57BL/6(H-2 b ) and DBA/2 strains (with an IgE responsiveness at or below 80 PCA titer of 80) are examples of low IgE responder animals, and can be purchased commercially through sources such as Jackson Labs (based in Maine) and Charles River Labs (based in Massachusetts).",
"Those of ordinary skill in the art will be familiar with, or can readily ascertain, the identity of additional suitable animal models of human IgE-mediated allergy, including low IgE responder animals.",
"The susceptibility of such animals to IgE immune modulation, if not known, can be determined through treatment of the animal with an IgE immune enhancer and measurement of the effect of the enhancer on the animal through conventional assay measurements of its IgE immune response (see, e.g., with respect to specific animals, Katz, Prog.",
"Allergy , 32:105-160, 1982 [rodents];",
"Chen, et al.",
", Int.",
"Arch.",
"Allergy Immunol .",
", 116:269-277, 1998 [murine model of anaphylaxis];",
"Ohta, et al.",
", J.Allergy Clin.",
"Immunol .",
", 7:212-223, 1983 [antigen-stimulated human B cells];",
"Vriesendorp, et al.",
", Transplantation , 39:583-588, 1985 [susceptibility of dogs to IgE immune response modulation by sublethal irradiation];",
"Dombrowicz, et al.",
", J.Immunol .",
", 15:1645-1651, 1996 [transgenic animal models of the human IgE immune system]).",
"B. Preparation of Animal Platform for Screening Assay Certain environmental influences (“IgE enhancers”), such as sublethal irradiation and toxins such as ricin (castor bean lectin), have significant stimulatory effects on IgE responses to antigen.",
"For use in developing exaggerated IgE responsiveness in the animal platform of the invention, sublethal irradiation is a convenient choice whose physiological effect is well-characterized (for example, low-dose irradiation has been used therapeutically in humans and experimentally in lower animals).",
"While exposure to high levels of radiation tends to have an overall immunosuppressive effect on mammals, the invention provides the discovery that exposure to discrete and relatively low doses of radiation coupled with antigen immunization will greatly enhance IgE responsiveness to antigen if irradiation and immunization occur within the correct temporal relationship;",
"i.e., immunization should follow within about 24 hours of irradiation.",
"The same temporal limitation applies to other IgE enhancers as well, indicating that the optimal sensitivity of activated IgE producing B cells to antigen sensitization lies within a 24 hour window which opens upon disruption of the animal's IgE dampening mechanisms.",
"Diurnal variations also play a role in optimization of IgE producer cell sensitivity to nonantigen stimulation.",
"The sensitivity of IgE producer B cells to IgE enhancers such as irradiation is greatest in mice when accompanied by low levels of endogenous corticosteroids occurring at particular times of the day.",
"For example, in SJL/J mice, IgE enhancement through whole-body irradiation is greater during the early afternoon (12:00 p.m. to 4:00 p.m.), when circulating levels of corticosteroids are at a natural low, than at other times of the day (for more details in regard to diurnal variations in mice and the effect on IgE responsiveness, see, e.g., Bargatze and Katz, J. Immunol .",
", 125:2306-2310, 1980).",
"Thus, the time of day that the IgE enhancer is administered to an animal can effect the magnitude of the enhancement in IgE levels obtained, while the temporal relationship between the administration of the enhancer and antigen determines whether enhanced IgE levels are obtained at all.",
"To these ends, the animal to be utilized in the screening assay of the invention is treated with an IgE enhancer, then immunized within a day.",
"Where the IgE enhancer is whole-body irradiation, the dose administered will necessarily be sublethal and should also be sub therapeutic.",
"The optimal level may vary from species to species, but will generally fall below 700 rads, and desirably will fall within the range of 150-400 rads.",
"Those of ordinary skill in the art will be familiar with, or can readily ascertain, suitable protocols for administration of sublethal, whole-body irradiation or other IgE enhancers, an example of which is provided elsewhere below.",
"C. Immunization of Animals The immunogen chosen will vary with the clinical interests and goals of the practitioner, and may be comprised of an allergen, Th2 stimulatory infectious agent, immunogenic epitope, allergen extract or polynucleotide encoding an immunogenic (for convenience, the population of immunogenic substances which may be utilized in the invention will be referred to herein as “antigens”, unless context otherwise requires, but it will be understood that the immunization steps of the invention are not limited to delivery of antigens per se).",
"Common allergens responsible for a relatively high incidence of IgE-related allergic events in humans include the IgE reactive major dust mite allergens Der pI and Der pII (Chua, et al.",
", J.Exp.",
"Med .",
", 167:175-182, 1988;",
"and, Chua, et al.",
", Int.",
"Arch.",
"Allergy Appl.",
"Immunol .",
", 91:124-129, 1990);",
"T cell epitope peptides of the Der pII allergen (Joost van Neerven, et al.",
", J.Immunol .",
", 151:2326-2335, 1993);",
"the highly abundant Antigen E (Amb aI) ragweed pollen allergen (Rafnar, et al.",
", J.Biol.",
"Chem .",
", 266:1229-1236, 1991);",
"phospholipase A 2 (bee venom) allergen;",
"the Fel dI major domestic cat allergen (Rogers, et al.",
", Mol.",
"Immunol .",
", 30:559-568, 1993);",
"and, food allergens, notably the peanut and tree nut allergens.",
"Model antigens accepted in the art as such, including ovalbumin (OVA), keyhole limpet hemocyanin (KLH) and conjugates thereof (e.g., with 2-dinitrophenyl [2-DNP]), are also well suited for use in invention.",
"Those of ordinary skill in the art will be entirely familiar with acceptable means of immunizing animals including, without limitation, means for immunization by intravascular, subcutaneous, intramuscular, intraperitoneal, nasal, topical and opthalmic routes of administration.",
"Extensive protocols for immunizing animals for use in the invention are therefore not provided here.",
"Briefly, the antigen may be delivered in carrier (e.g., sterile saline), with or without an adjuvant, such as alum.",
"The animal is sensitized to the antigen within a day, and desirably within 6-10 hours, of treatment of the animal with an IgE enhancer.",
"Primary immunization with an immunologically related antigen (described further below) is made at a point in time after treatment of the animal with the IgE enhancer;",
"conveniently, primary immunization will occur at about a week post-sensitization.",
"Primary immunization may be followed by further immunizations with the same or immunologically related antigens to permit evaluation of the effect of the candidate IgE suppressor on the animal's response to subsequent antigen challenge.",
"It will be appreciated that the initial sensitizing antigen must share immunological activity with the antigen utilized in subsequent immunizations to permit evaluation of the animal's response of immunization and treatment following sensitization.",
"In particular, to permit processing of antigen in later immunizations in a manner equivalent to processing of the antigen on initial sensitization, the antigens utilized in each immunizing step should share at least immunogenic epitopes (e.g., sensitization can be with whole antigen, followed by an immunogenic extract or fragment of the same, or vice-versa, so long as immunogenicity of the immunogens delivered in each step is comparable).",
"Such antigens are those referred to herein as being “immunologically related.”",
"Where immune responses to more than one antigen are to be evaluated in the screening assay, the second antigen may be delivered in the initial sensitization step and on primary immunization, or only during the latter step, but if not delivered during the sensitization step, must be conjugated to the sensitizing antigen or otherwise delivered in a manner which permits both antigens to be processed by the animal's immune cells in similar fashion.",
"An example of this approach is described in Example I below, where sensitization of an animal to KLH is followed by primary immunization with a KLH-DNP (2-dinitrophenyl) conjugate.",
"In the example provided, the KLH molecule in the conjugate delivered in the primary immunization step is “immunologically related”",
"to the sensitizing KLH antigen.",
"Because the DNP molecule is conjugated to the KLH molecule, it will be processed by the animal in a manner similar to the processing of the KLH molecule even though DNP is antigenically different from KLH.",
"Thus, although the animal was not sensitized to DNP during the window of sensitivity, it will be “seen”",
"by the animal's cells as immunologically related to KLH as both molecules are processed together as a consequence of their delivery as a conjugate—a single immunogenic moiety.",
"As such, in this example, the exaggerated IgE response achieved in the primary immunization step will be specific to both KLH and DNP.",
"However, if DNP is delivered independently of KLH in the primary immunization step, it will not be seen by the animal as immunologically related to the KLH sensitizing antigen, and the exaggerated IgE response will be directed only to KLH.",
"In this manner, multiple antigens may be delivered to the animal, and evaluated accordingly, in the primary immunization step of the inventive screening assay.",
"Those of skill in the art will be familiar with, or can readily ascertain, methods for delivery of multiple immunogens to an animal as a single immunogenic moiety (e.g., by conjugation or co-delivery in a liposome), or can obtain suitable compositions for use in this regard from commercial sources.",
"D. Performance of the Screening Assay of the Invention Following initial sensitization to antigen of an animal prepared for use in the screening assay as described above, the primed animal is treated (more than 24 hours after its exposure to an IgE enhancer) with a candidate IgE suppressor or, for use as a control, with vehicle.",
"Primary immunization with the sensitizing antigen is desirably made with, but may be made at a time before, delivery of the candidate IgE suppressor.",
"At set time points before and after primary immunization (as well as before treatment with the IgE enhancer, if possible), an immune sample is taken from the animal and analyzed for antigen-specific and total levels of IgE.",
"Depending on the antigen and its route of administration to the animal, the immune sample may consist of fluids such as serum, bronchoalevolar lavage and mucosal swabs.",
"IgE levels are determined by conventional assays, many of which are commercially available in the art and will be familiar to those of ordinary skill in the art.",
"An example of such an assay is provided in the Examples elsewhere below.",
"Other aspects of the IgE mediated immune response may also be examined in the assay.",
"In this respect, those of ordinary skill in the art will understand that IgE antibodies are principally produced in the context of a “Th2 phenotype”;",
"i.e., an immune phenotype associated with the extracellular exposure of a host to antigen and characterized by the activation of class 2 helper T lymphocytes.",
"Th2 responses include the allergy-associated IgE antibody class;",
"soluble protein antigens tend to stimulate relatively strong Th2 responses.",
"In contrast, Th1 responses are induced by antigen binding to macrophages and dendritic cells.",
"IgG, antibodies are serological markers for a Th2 type immune response, whereas IgG 2a antibodies are indicative of a Th1 type immune response.",
"The Th2 immune phenotype is further characterized by the release of certain cytokines;",
"e.g., IL-4, while the Th1 immune phenotype tends to be accompanied by the release of cytokines such as IL-12 and/or an increase in IFN (α, β or γ) levels).",
"Because the helper T lymphocyte system negatively reciprocates between the Th2 and Th1 classes of Th cells, a rise in levels of Th1 cytokines (e.g., IL-12 and IFN α, β or γ) and/or of IgG 2a antibodies correlates to suppression of the Th2 phenotype and, consequently, of a decline in the animal's ability to mount an IgE-mediated immune response.",
"Thus, the screening assay of the invention may also be applied to obtaining, circumstantial evidence of IgE suppression by a candidate compound gleaned from determining the class of helper T lymphocyte-mediated immune phenotype present before and after primary immunization and treatment with the candidate IgE suppressor.",
"In particular, declines in Th2 cytokine and IgG 1 antibody levels and increases in Th1 cytokine and IgG 2a antibody levels are indicia of probable Th2 phenotype induction/IgE suppression;",
"the reverse profiles are indicative of Th2 phenotype induction/IgE stimulation.",
"Comparative measurements of antibody isotypes other than IgE (pre- and post-primary immunization), as well as other antigen-sensitive immune components (cytokines, effectors, eosinophil infiltrate levels and the like) will provide information as to the relative sensitivity of the candidate IgE suppressor;",
"i.e., as to whether it affects only IgE production/activity or whether other aspects of the immune system are also affected (desirably or not).",
"In the murine animal platform of the invention utilizing low IgE responder animals, however, the assay can be expected to have a high degree of specificity for the IgE immune system;",
"e.g., effects on total IgG responses can be expected to be meager.",
"All of these immune components can be detected and measured by conventional assays, many of which are commercially available to the art and will be familiar to those of ordinary skill in the art.",
"Example of such assays are provided in the Examples elsewhere below and include an ELISA for the IgG 1 and IgG 2a isotypes using subclass-specific antibodies;",
"an ELISA for antigen-specific and total IgE (Coligan, “ Current Protocols In Immunology ”, Unit 7.12.4, Vol. 1, Wiley &",
"Sons, 1994);",
"a sensitive (0.4 ng of IgE/ml) solid phase radioimmunoassay (RAST) modification of the IgE ELISA (substituting purified polyclonal goat antibodies specific for mouse ε chains for antibodies specific for human Fab);",
"and, an anti-CD3 antibody (Pharmingen, La Jolla, Calif.) based splenocyte assay in which supernatants are assayed for cytokine levels (e.g., IL-4, IL-10 and IL-12) levels using a commercial kit, and interferon (e.g., INFγ) levels are assayed with an anti-INFγ murine antibody assay (see, e.g., Coligan, “ Current Protocols in Immunology ”, Unit 6.9[.",
"].5.",
", Vol. 1, Wiley &",
"Sons, 1994).",
"Those of ordinary skill in the art will also recognize that an abbreviated protocol for the screening assay of the invention can be devised to test the activity of IgE enhancers.",
"In particular, with measurement of IgE levels following treatment of an animal with a putative IgE enhancer and its priming with antigen, the failure of an animal which should develop an IgE hyperresponsive phenotype to do so is evidence that the putative IgE enhancer does not possess that activity, at least in the animal utilized in the assay.",
"Although not limited by any theory as to how IgE enhancement occurs in the animals utilized by the screening assay to evaluate IgE suppression, it appears that IgE enhancers such as low dose irradiation temporarily limit IgE binding by CD23 + (FccRII) B cells.",
"Binding of IgE by B cells through the CD23 receptor regulates their differentiation and controls the onset of the IgE-mediated allergic phenotype.",
"Thus, disruption of IgE binding by CD23 + B cells allows IgE-mediated responses to antigen to proceed unabated by CD23 + B cell regulation.",
"This probable explanation for the biological effect of IgE enhancers on host B cells suggests that the screening assay of the invention will be of particular use in evaluating agents which overcome the radiation-mediated perturbation of IgE binding by CD23 + B cells (such as ex vivo preparations of such cells).",
"In addition, transplanted CD23 + B cells, or any other agent known to have IgE suppressive activity (e.g., isolated or synthetic CD23 + peptides including the IgE binding domain, or anti-IgE antibodies) can be used to verify the viability of the animal platform in that such cells can ablate IgE production and activity if administered during the window of sensitivity.",
"Examples illustrating the practice of the invention are set forth below.",
"The examples are not intended to, and do not, limit the scope of the invention, which is defined by the appended claims.",
"EXAMPLE I IRRADIATION-ENHANCED In Vivo IgE ANTIBODY RESPONSES As proof of the principle that exaggerated IgE levels can be produced in an antigen-specific and time-specific manner, two groups of low IgE responder SJL/J (2-H s ) mice were prepared as follows: Group I was irradiated at 250 rads shortly before priming immunization with 2 μg of KLH in alum hydrogen peroxide (Pierce Chemical;",
"a Th2 stimulatory adjuvant).",
"The second group received the priming dose of KLH in alum, but was not irradiated.",
"Seven days later (day 0), each group received 2 μg of DNP-KLH conjugate in alum and antigen-specific IgE levels were measured by ELISA in serum samples drawn from each mouse.",
"Secondary antigen challenge was made on day 60 using the same antigen and dose given for primary immunization on day 0.",
"Antigen-specific IgE were again measured at days 7, 14, 21, 60, 75, 120, 150 and 210.",
"Results are shown in FIG. 1, where IgE levels are represented as PCA titers.",
"Anti-antigen IgE responses induced in the irradiated animals through irradiation-concomitant priming followed by primary immunization a week later were more than 1000 times the magnitude of IgE levels produced in the non-irradiated animals, and nearly 5000 times the magnitude following secondary immunization, indicating that the antigen-specific IgE responsiveness in the irradiated animals was not only induced, but maintained at allergic levels over time and on subsequent antigen challenge.",
"To determine the antigen-specificity of the exaggerated IgE response of the irradiated animals, two additional groups of animals were prepared and immunized as described above through day 0, except that irradiation was applied to the treatment group at 350 rads.",
"On day 18, one group of the irradiated and untreated mice were secondarily immunized with the primary immunogen (2 μg DNP-KLH in alum), while a second group of irradiated and untreated mice received a different antigen—10 μg of OVA in alum.",
"IgE responses to the DNP-KLH antigen were determined prior to and after primary immunization as well as at secondary immunization;",
"anti-OVA IgE were also measured on days 28 and 35.",
"Results are shown in FIG. 2, where IgE levels are represented as PCA titers.",
"Significantly, there was no detectable difference in the anti-OVA IgE produced in the irradiated and untreated mouse sets, even though there were dramatic differences in the anti-DNP IgE produced in irradiated versus untreated mouse groups (comparable to the responses shown in FIG. 1 ).",
"Thus, the exaggerated antigen responsiveness in the IgE compartment of the irradiated mice was not retained with respect to antigens other than the primary immunogen following priming and allergic breakthrough.",
"With application of an active IgE suppressor at or near primary immunization, antigen-specific IgE can be expected to fall toward normal levels in the animal.",
"For example, in low IgE responder mice, complete ablation of the exaggerated IgE response by an IgE suppressor would return the antigen-specific IgE levels to a magnitude comparable to that achieved in unirradiated mice and irradiated mice immunized outside of the window of sensitivity (data not shown).",
"The invention having been fully described, modifications and extensions of it may become apparent to those of ordinary skill in the art.",
"All such modifications and extensions are intended to fall within the scope of the claimed invention."
] |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. application Ser. No. 09/539,856 filed Mar. 31, 2000; the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention generally relates to a patch for mounting an electronic monitoring device to the inside surface of a pneumatic tire. More particularly, the present invention relates to a patch having an electronic monitoring device encapsulated directly to the patch so that it may be mounted to a tire with the patch.
[0004] 2. Background Information
[0005] Monitoring the internal conditions of a pneumatic tire while the tire is in use on a vehicle is becoming increasingly desired in the art. One problem with this technology is protecting the relatively sensitive electronic monitoring device in the relatively harsh environment inside a tire. Another problem in the art is that the inner surface of a tire does not have surfaces where monitoring devices may be easily mounted in a secure manner.
[0006] Protecting monitoring devices against harsh tire conditions has been accomplished in the past by encapsulating the monitoring device in an encapsulation or potting material. The potting material is poured over the monitoring device and fills the voids around the elements of the monitoring device. The material hardens and forms a protective block having a high modulus of elasticity around the elements of the monitoring device. The monitoring device is protected in this manner from the flexing and shock forces experienced in a pneumatic tire.
[0007] Rubber patches are also known in the art to mount monitoring devices to the inner surface of a tire. The potted monitoring device has been connected to the patch with adhesive and the patch was then adhered to the innerliner of the tire. Other methods of mounting monitoring devices inside tires include forming a pocket in the tire and placing the monitoring device in the pocket. Other methods have placed a rubber patch over the top of the monitoring device to hold the monitoring device against the tire sidewall.
[0008] One problem with these mounting solutions is the relatively high number of steps required to mount the monitoring device to the tire. Another problem is the number of times the monitoring device must be handled prior to mounting inside the tire. More importantly, the users of the monitoring devices desire stronger connections between the monitoring device and the tire.
[0009] Another problem in the art occurs when the antenna is mounted in a different substraight than the monitoring device. In these situations, a connection must be formed between the monitoring device and the antenna. An example of this situation is shown in patent application Ser. No. 09/301,781 filed Apr. 29, 1999, which is owned by the Assignee of the present application. In this situation, a pair of connectors are used to form the direct physical connection between the antenna and the monitoring device. The problem that has occurred is that the adhesive used to bond the monitoring device to the patch is forced around the connectors sometimes flowing into the connectors. The art desires a solution to this problem by providing a method of connecting the encapsulated monitoring device to a patch while not fouling the connectors.
SUMMARY OF THE INVENTION
[0010] In view of the foregoing, the present invention provides a mounted electronic monitoring device ready for mounting to the inside of the tire. The invention solves the problems in the art by directly potting the monitoring device to a rubber attachment patch to form an assembly.
[0011] The assembly of the present invention includes a rubber patch having a first surface and a second surface. An electronic monitoring device is positioned adjacent the first surface of the patch with an encapsulation material surrounding at least a portion of the electronic monitoring device. The encapsulation material bonds with the patch to connect the encapsulated monitoring device to the patch.
[0012] Another aspect of the invention preferably provides placing the connecting elements used to electrically connect the monitoring device to an antenna embedded within the patch in a location where the connecting elements are surrounded by the encapsulation material.
[0013] Another aspect of the invention provides a method for creating the assembly wherein the number of handling steps and fabricating steps are minimized.
[0014] The method of the present invention includes the steps of providing a patch having a first surface and a second surface, providing an electronic monitoring device adjacent the first surface of the patch, and encapsulating the electronic monitoring device directly to the first surface of the patch.
[0015] An advantage of the invention is that the patch provides a secure mounting platform for the monitoring device that can be readily attached to the innerliner of a pneumatic tire.
[0016] Another advantage of the invention is that the connection between the encapsulated monitoring device and the attachment patch does not rely on the strength of an adhesive to connect two separately formed elements.
[0017] Another advantage of the invention is that the assembly protects the connections between the antenna and the monitoring device.
[0018] Another advantage of the invention is that the connections between the monitoring device and the antenna do not become fouled by adhesive because the antenna and monitoring device are connected before the encapsulation material is poured into the mold.
[0019] The foregoing advantages, construction, and operation of the present invention will become more readily apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The preferred embodiments of the invention, illustrative of the best mode in which applicant contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended Claims.
[0021] [0021]FIG. 1 is a sectional view of a pneumatic tire with an encapsulated monitoring device mounted to the innerliner of the tire with an attachment patch;
[0022] [0022]FIG. 2 is a perspective view of the attachment patch with a potting frame assembled and placed on the upper surface of the attachment patch to surround the connectors for the antenna;
[0023] [0023]FIG. 3 is a top plan view of FIG. 2;
[0024] [0024]FIG. 4 is a sectional side view of the attachment patch and the potting frame with the electronic monitoring device positioned within the potting frame and the potting material being poured into the potting frame;
[0025] [0025]FIG. 4A is a view similar to FIG. 4 showing an alternative embodiment of the invention where the potting frame is held against the attachment patch with pressure;
[0026] [0026]FIG. 5 is a view similar to FIG. 4 showing the potting frame substantially filled with the potting material; and
[0027] [0027]FIG. 6 is a view similar to FIG. 4 showing one embodiment of the final product.
[0028] Similar numbers refer to similar parts throughout the specification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] An assembly used to mount an electronic monitoring device to the inside surface of a pneumatic tire is indicated generally by the numeral 10 in the drawings. Assembly 10 preferably mounts the electronic monitoring device to the innerliner 12 of a pneumatic tire 14 so that the electronic monitoring device may monitor at least one engineering condition of tire 14 .
[0030] Assembly 10 generally includes an attachment patch 20 and an encapsulated monitoring device 22 . Attachment patch 20 is used to connect encapsulated monitoring device 22 to innerliner 12 so that the monitoring device may perform its measurements. Attachment patch 20 includes a first side 24 configured to receive encapsulated monitoring device 22 and a second side 26 configured to attach to tire 14 . Attachment patch 20 is preferably fabricated from rubber. The rubber material is preferably vulcanized at a pre-selected temperature and a time sufficient to vulcanize the patch. The patch may be fabricated from a rubber selected from the group consisting of Ethylene Propylene Diene Monomer (EPDM) rubber, butyl rubber, natural rubber, neoprene, and mixtures thereof. One preferred embodiment is a mixture of chlorobutyl rubber and natural rubber. Another preferred embodiment is bromobutyl rubber. Another embodiment is a mixture of Styrene-Butadiene rubber (SBR) natural rubber. Typically, patches made from these rubber compositions may be cured by heating to a temperature of about 150 degrees Celsius and holding this temperature for about thirty minutes. The time and temperature may be modified as necessary to achieve sufficient curing of the patch for further manufacturing steps. The present invention also contemplates that patch 20 may be fabricated from a variety of other rubber mixtures known in the art. In addition to rubbers, patch 20 may be fabricated from other materials that may be adhered to tire 14 and accept encapsulated monitoring device 22 as described below. Thermoplastic Elastomers, Thermoplastic Urethanes or Thermoplastic Olefins may also be used to form attachment patch 20 .
[0031] In one embodiment of the present invention, patch 20 carries an antenna 30 used to send and receive signals from encapsulating monitoring device 22 . Antenna 30 includes connecting elements 32 that protrude outwardly from the outer perimeter of patch 20 . Connecting elements 32 may be the male or female portion of a pin and socket-type connector. Connecting elements 32 are used to allow a monitoring package 34 to be plugged into antenna 30 after antenna 30 is cured into to patch 20 . Antenna 30 may be connected to patch 20 in a variety of other ways other than being cured into patch 20 . For instance, antenna 30 may be mounted on an outer surface of patch 20 . Monitoring package 34 may include the various sensors, controllers, memory devices, and power supplies necessary to perform the monitoring, transmitting, and receiving functions desired in the art. Monitoring package 34 must be connected to antenna 30 so that it may communicate with a data gathering device position outside of tire 14 . Monitoring package 34 also includes connecting elements 36 that are configured to mate with connecting elements 32 to form a direct electrical connection between monitoring package 34 and antenna 30 .
[0032] In accordance with one of the objectives of the present invention, monitoring package 34 is encapsulated with an encapsulation material 40 directly to attachment patch 20 such that encapsulation material 40 is chemically and/or physically bonded to attachment patch 20 . In one embodiment of the invention, a frame 42 is fabricated and attached to first side 24 of attachment patch 20 by an adhesive 44 by applying adhesive 44 around frame 42 and ensuring a continuous bead of adhesive 44 around the perimeter. In one embodiment, a copper faced board having a thickness of 0.0345 inches is used to fabricate frame 42 by soldering the ends of four pieces together to form frame 42 . Another preferred material for forming frame 42 is glass-filled epoxy. In other embodiments, substantially any material may be used for frame 42 that will not interfere with a radio frequency signal if frame 42 remains connected to encapsulated monitoring device 22 as depicted in FIG. 5 and will not melt at the relatively high encapsulation or potting temperature. This temperature is typically 95-125 degrees Celsius.
[0033] In another embodiment of the invention, frame 42 is held against first side 24 of attachment patch 20 by applying pressure as indicated by the numeral 46 against frame 42 . Pressure 46 maintains the correct position of frame 42 and prevents encapsulation material 40 from leaking out from between frame 42 and attachment patch 20 .
[0034] Frame 42 is positioned on attachment patch 20 such that connecting elements 32 are disposed within frame 42 . The position of connecting elements 32 with respect to frame 42 is referred to as the connection location. It is an important aspect of the present invention to provide strength around the connection location so that the connections between monitoring package 34 and antenna 30 do not become loose with extended use of patch 10 .
[0035] Depending on the material used to fabricate frame 42 , frame 42 may need to be sandblasted and degreased with solvent to clean the surface prior to performing the encapsulation steps of the present invention. For instance, the copper-faced board discussed above is preferably sandblasted and solvent washed to clean the surface. In addition, first side 24 of attachment patch 20 is preferably cleaned and primed with a 3% 1, 3, 5- T ri c hloro-s- t riazine t rione (Trichloroisocyanuric acid) (TCTT) solutions in butyl actetate. Side 24 was then wiped with a piece of Rymplecloth to remove the excess solvent and surface dirt. Patch 20 was then allowed to dry thoroughly. Adhesive 44 used around frame 42 is preferably FUSOR®D 320 (five parts by weight)/ 310 B (two parts by weight). FUSOR® is available from Lord Corporation. Adhesive 44 is then cured in an oven at 80 degrees Celsius for thirty minutes.
[0036] Various other types of adhesives, frame materials, and surface preparations may be used without departing from the scope of the present invention. The specific materials and times described above are merely for the purpose of providing an exemplary embodiment of the invention and the best mode now known for performing the invention.
[0037] Monitoring package 34 is then positioned within frame 42 so that it is suspended within frame 42 adjacent first side 24 . A chimney 48 may be attached to a sensor (such as a pressure sensor or a temperature sensor) on monitoring package 34 so that it may communicate with the atmosphere surrounding encapsulated monitoring device 22 after encapsulation material 40 is cured. Chimney 48 provides an air passage 50 to monitoring package 34 .
[0038] After monitoring package 34 is positioned adjacent first side 24 and within frame 42 , encapsulation material 40 is introduced inside frame 42 to substantially surround monitoring package 34 and to fill substantially all voids around monitoring package 34 as depicted in FIG. 5. In the preferred embodiment of the present invention, encapsulation material 40 is a formulation including 100 gm STYCAST® 2651; 7 gm Catalyst 9; and 3 drops defoamer 88 . In another embodiment of the invention, encapsulation material 40 is a formulation including 110 gm STYCAST® 2651; 10 gm Phenyl Gycidyl Ether; 9.4 gm Catalyst 9; and 6 drops of defoamer 88 . These materials were mixed together at room temperature until thoroughly mixed. The formulation was degassed until foaming subsided. The formulation was then poured into frame 42 and allowed to cure in an oven at 55 degrees Celsius for thirty minutes. It was then post-cured at 80 degrees Celsius for thirty minutes. This process results in a strong encapsulated monitoring device 22 directly bonded to attachment patch 20 . Frame 42 may be left in position as depicted in FIG. 5 or removed as depicted in FIG. 6.
[0039] Various other encapsulation materials 40 will also function with the present invention. For instance, a variety of epoxies and urethanes that are pourable and cure to a rigid tough material having a high modulus of elasticity may be used. It is desired that encapsulation material 40 having a Young's modulus of at least 30,000 psi and which is capable of being molded around electronic monitoring package 34 . Preferably, encapsulation material 40 will have a Young's modulus at least 100,000 psi.
[0040] STYCAST®2651 is the preferred encapsulation material. Alternatively, high melting point polyurethanes and/or polyureas may be utilized. The polyurethanes are derived from polysiocyanates which generally have the formula R(NO) n where n is an integer of 2, 3 or 4 with approximately 2 being preferred. The “n” may, however, vary and often is not an integer because combinations of various polysiocyanates can be utilized. R is an aliphatic having from about 2 to about 20 carbon atoms or preferably an aromatic including an alkyl substituted aromatic having from about 6 to about 20 carbon atoms with from about 6 to about 15 carbon atoms being desired, or combinations thereof. Examples of suitable polysiocyanates include 1,6-diisocyanto hexane; 2,2,4- and/or 2,4,4-trimethylhexamethylene diisocyanate; p- and m-tetramethyl xylene diisocyanate; dicyclohexylmethane-4,4′-diisocyanate (Hydrogenated MDI); 4,4-methylene diphenyl isocyanate (MDI); p- and m-phenylene diisocyanate; 2,4-and/or 2,6-toluene diisocyanate (TDI); durene-1,4-diisocyanate; isophorone diisocyanate and isopropylene bis-(p-phenyl isocyanate). TDI is desirably utilized. The various diphenylmethane diisocyanates (MDI) and mixtures of MDI with polymeric MDI having an average isocyanate functionality of from about 2 to about 3.2 are preferred.
[0041] The preparation of the polyurethanes and/or polyureas are well known to the art and to the literature. For example, a short chain oligomer or polymer derived from polyester or polyether polyols generally having a molecular weight of from about 55 to about 1,000 and preferably from about 6 to about 200 are reacted with the above-noted diisocyanates to form a urethane prepolymer. Similarly, a short chain diamine can be utilized and reacted with the above-noted diisocyanates to form a urea prepolymer. Aromatic diisocyanates are generally utilized to yield high melting point urethane or urea prepolymers which also generally have a high modulus of elasticity. The resulting prepolymer is subsequently reacted with diols, diamine, diacids, or amino alcohols, and the like to cure the same and form a polyurethane or polyurea. Alternatively, the polyurethanes and/or polyureas are formed by reacting an existing prepolymer with the above-noted curing or chain extending agents.
[0042] The equivalent ratio of isocyanate groups (NCO) reacted with the hydroxyl groups (OH) or amine groups (NH 2 ) of the short chain compound is generally from about 0.90 to about 1.10, desirably from about 0.95 to about 1.05, and preferably from about 0.98 to about 1.02.
[0043] In general, thermoset epoxy resins are preferred. The epoxy resin or polymer is generally formed by the reaction of bisphenol A and epichlorohydrin. The preparation of epoxy resins is well known to the literature and to the art. Generally, epichlorohydrin is reacted with a variety of hydroxy, carboxy, or amino compounds to form monomers with two or more epoxied groups, and these monomers are then used in the reaction with bisphenol A. Examples of such compounds are the diglycidyl derivative of cyclohexane-1,2-dicarboxylic acid, the triglycidyl derivates of p-aminophenol and cyanuric acid, and the polyglycidyl derivative of phenolic prepolymers. Epoxidized diolefins can also be employed. Various co-reactants can be utilized to cure epoxy resins either through the epoxied or hydroxyl groups. Polyamines such as primary or secondary amines are a common curing agent such as aliphatic amines having a total of from about 2 to about 18 carbon atoms and desirably from about 4 to about 8 carbon atoms. Suitable compounds include diethylene triamine, triethylene tetraamine, tetraethylene pentaamine, 4,4′-diaminodiphenylmethane, and polyaminoamides. A combination of diethylene triamine and tetraethylene pentaamine is often desired. Aromatic amines can also be utilized such as those having a total of from 6 to 20 carbon atoms such as meta or paraphenylene diamine and the like. Other curing agents including polythiols, dicyandiamide (cyanoguanidine), diisocyanates, and phenolic prepolymers. Curing of epoxy resins can also be achieved by ring opening polymerization of the epoxied groups using either Lewis acids or Lewis bases.
[0044] Accordingly, the improved attachment patch for mounting an electronic monitoring device to the inside of a pneumatic tire apparatus is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
[0045] In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
[0046] Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
[0047] Having now described the features, discoveries, and principles of the invention, the manner in which the attachment patch for mounting an electronic monitoring device to the inside of a pneumatic tire is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended claims. | A patch and method for mounting an electronic monitoring device to the innerliner of a pneumatic tire is provided wherein the monitoring device is potted directly to an attachment patch. A frame is built on an attachment patch and the electronic monitoring device is disposed inside the frame. An encapsulation material is poured into the frame and cured to encapsulate the monitoring device directly against the patch. The patch may then be connected to the innerliner of a pneumatic tire. | Summarize the key points of the given document. | [
"CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a divisional of U.S. application Ser.",
"No. 09/539,856 filed Mar. 31, 2000;",
"the disclosures of which are incorporated herein by reference.",
"BACKGROUND OF THE INVENTION [0002] 1.",
"Technical Field [0003] The present invention generally relates to a patch for mounting an electronic monitoring device to the inside surface of a pneumatic tire.",
"More particularly, the present invention relates to a patch having an electronic monitoring device encapsulated directly to the patch so that it may be mounted to a tire with the patch.",
"[0004] 2.",
"Background Information [0005] Monitoring the internal conditions of a pneumatic tire while the tire is in use on a vehicle is becoming increasingly desired in the art.",
"One problem with this technology is protecting the relatively sensitive electronic monitoring device in the relatively harsh environment inside a tire.",
"Another problem in the art is that the inner surface of a tire does not have surfaces where monitoring devices may be easily mounted in a secure manner.",
"[0006] Protecting monitoring devices against harsh tire conditions has been accomplished in the past by encapsulating the monitoring device in an encapsulation or potting material.",
"The potting material is poured over the monitoring device and fills the voids around the elements of the monitoring device.",
"The material hardens and forms a protective block having a high modulus of elasticity around the elements of the monitoring device.",
"The monitoring device is protected in this manner from the flexing and shock forces experienced in a pneumatic tire.",
"[0007] Rubber patches are also known in the art to mount monitoring devices to the inner surface of a tire.",
"The potted monitoring device has been connected to the patch with adhesive and the patch was then adhered to the innerliner of the tire.",
"Other methods of mounting monitoring devices inside tires include forming a pocket in the tire and placing the monitoring device in the pocket.",
"Other methods have placed a rubber patch over the top of the monitoring device to hold the monitoring device against the tire sidewall.",
"[0008] One problem with these mounting solutions is the relatively high number of steps required to mount the monitoring device to the tire.",
"Another problem is the number of times the monitoring device must be handled prior to mounting inside the tire.",
"More importantly, the users of the monitoring devices desire stronger connections between the monitoring device and the tire.",
"[0009] Another problem in the art occurs when the antenna is mounted in a different substraight than the monitoring device.",
"In these situations, a connection must be formed between the monitoring device and the antenna.",
"An example of this situation is shown in patent application Ser.",
"No. 09/301,781 filed Apr. 29, 1999, which is owned by the Assignee of the present application.",
"In this situation, a pair of connectors are used to form the direct physical connection between the antenna and the monitoring device.",
"The problem that has occurred is that the adhesive used to bond the monitoring device to the patch is forced around the connectors sometimes flowing into the connectors.",
"The art desires a solution to this problem by providing a method of connecting the encapsulated monitoring device to a patch while not fouling the connectors.",
"SUMMARY OF THE INVENTION [0010] In view of the foregoing, the present invention provides a mounted electronic monitoring device ready for mounting to the inside of the tire.",
"The invention solves the problems in the art by directly potting the monitoring device to a rubber attachment patch to form an assembly.",
"[0011] The assembly of the present invention includes a rubber patch having a first surface and a second surface.",
"An electronic monitoring device is positioned adjacent the first surface of the patch with an encapsulation material surrounding at least a portion of the electronic monitoring device.",
"The encapsulation material bonds with the patch to connect the encapsulated monitoring device to the patch.",
"[0012] Another aspect of the invention preferably provides placing the connecting elements used to electrically connect the monitoring device to an antenna embedded within the patch in a location where the connecting elements are surrounded by the encapsulation material.",
"[0013] Another aspect of the invention provides a method for creating the assembly wherein the number of handling steps and fabricating steps are minimized.",
"[0014] The method of the present invention includes the steps of providing a patch having a first surface and a second surface, providing an electronic monitoring device adjacent the first surface of the patch, and encapsulating the electronic monitoring device directly to the first surface of the patch.",
"[0015] An advantage of the invention is that the patch provides a secure mounting platform for the monitoring device that can be readily attached to the innerliner of a pneumatic tire.",
"[0016] Another advantage of the invention is that the connection between the encapsulated monitoring device and the attachment patch does not rely on the strength of an adhesive to connect two separately formed elements.",
"[0017] Another advantage of the invention is that the assembly protects the connections between the antenna and the monitoring device.",
"[0018] Another advantage of the invention is that the connections between the monitoring device and the antenna do not become fouled by adhesive because the antenna and monitoring device are connected before the encapsulation material is poured into the mold.",
"[0019] The foregoing advantages, construction, and operation of the present invention will become more readily apparent from the following description and accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0020] The preferred embodiments of the invention, illustrative of the best mode in which applicant contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended Claims.",
"[0021] [0021 ]FIG. 1 is a sectional view of a pneumatic tire with an encapsulated monitoring device mounted to the innerliner of the tire with an attachment patch;",
"[0022] [0022 ]FIG. 2 is a perspective view of the attachment patch with a potting frame assembled and placed on the upper surface of the attachment patch to surround the connectors for the antenna;",
"[0023] [0023 ]FIG. 3 is a top plan view of FIG. 2;",
"[0024] [0024 ]FIG. 4 is a sectional side view of the attachment patch and the potting frame with the electronic monitoring device positioned within the potting frame and the potting material being poured into the potting frame;",
"[0025] [0025 ]FIG. 4A is a view similar to FIG. 4 showing an alternative embodiment of the invention where the potting frame is held against the attachment patch with pressure;",
"[0026] [0026 ]FIG. 5 is a view similar to FIG. 4 showing the potting frame substantially filled with the potting material;",
"and [0027] [0027 ]FIG. 6 is a view similar to FIG. 4 showing one embodiment of the final product.",
"[0028] Similar numbers refer to similar parts throughout the specification.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS [0029] An assembly used to mount an electronic monitoring device to the inside surface of a pneumatic tire is indicated generally by the numeral 10 in the drawings.",
"Assembly 10 preferably mounts the electronic monitoring device to the innerliner 12 of a pneumatic tire 14 so that the electronic monitoring device may monitor at least one engineering condition of tire 14 .",
"[0030] Assembly 10 generally includes an attachment patch 20 and an encapsulated monitoring device 22 .",
"Attachment patch 20 is used to connect encapsulated monitoring device 22 to innerliner 12 so that the monitoring device may perform its measurements.",
"Attachment patch 20 includes a first side 24 configured to receive encapsulated monitoring device 22 and a second side 26 configured to attach to tire 14 .",
"Attachment patch 20 is preferably fabricated from rubber.",
"The rubber material is preferably vulcanized at a pre-selected temperature and a time sufficient to vulcanize the patch.",
"The patch may be fabricated from a rubber selected from the group consisting of Ethylene Propylene Diene Monomer (EPDM) rubber, butyl rubber, natural rubber, neoprene, and mixtures thereof.",
"One preferred embodiment is a mixture of chlorobutyl rubber and natural rubber.",
"Another preferred embodiment is bromobutyl rubber.",
"Another embodiment is a mixture of Styrene-Butadiene rubber (SBR) natural rubber.",
"Typically, patches made from these rubber compositions may be cured by heating to a temperature of about 150 degrees Celsius and holding this temperature for about thirty minutes.",
"The time and temperature may be modified as necessary to achieve sufficient curing of the patch for further manufacturing steps.",
"The present invention also contemplates that patch 20 may be fabricated from a variety of other rubber mixtures known in the art.",
"In addition to rubbers, patch 20 may be fabricated from other materials that may be adhered to tire 14 and accept encapsulated monitoring device 22 as described below.",
"Thermoplastic Elastomers, Thermoplastic Urethanes or Thermoplastic Olefins may also be used to form attachment patch 20 .",
"[0031] In one embodiment of the present invention, patch 20 carries an antenna 30 used to send and receive signals from encapsulating monitoring device 22 .",
"Antenna 30 includes connecting elements 32 that protrude outwardly from the outer perimeter of patch 20 .",
"Connecting elements 32 may be the male or female portion of a pin and socket-type connector.",
"Connecting elements 32 are used to allow a monitoring package 34 to be plugged into antenna 30 after antenna 30 is cured into to patch 20 .",
"Antenna 30 may be connected to patch 20 in a variety of other ways other than being cured into patch 20 .",
"For instance, antenna 30 may be mounted on an outer surface of patch 20 .",
"Monitoring package 34 may include the various sensors, controllers, memory devices, and power supplies necessary to perform the monitoring, transmitting, and receiving functions desired in the art.",
"Monitoring package 34 must be connected to antenna 30 so that it may communicate with a data gathering device position outside of tire 14 .",
"Monitoring package 34 also includes connecting elements 36 that are configured to mate with connecting elements 32 to form a direct electrical connection between monitoring package 34 and antenna 30 .",
"[0032] In accordance with one of the objectives of the present invention, monitoring package 34 is encapsulated with an encapsulation material 40 directly to attachment patch 20 such that encapsulation material 40 is chemically and/or physically bonded to attachment patch 20 .",
"In one embodiment of the invention, a frame 42 is fabricated and attached to first side 24 of attachment patch 20 by an adhesive 44 by applying adhesive 44 around frame 42 and ensuring a continuous bead of adhesive 44 around the perimeter.",
"In one embodiment, a copper faced board having a thickness of 0.0345 inches is used to fabricate frame 42 by soldering the ends of four pieces together to form frame 42 .",
"Another preferred material for forming frame 42 is glass-filled epoxy.",
"In other embodiments, substantially any material may be used for frame 42 that will not interfere with a radio frequency signal if frame 42 remains connected to encapsulated monitoring device 22 as depicted in FIG. 5 and will not melt at the relatively high encapsulation or potting temperature.",
"This temperature is typically 95-125 degrees Celsius.",
"[0033] In another embodiment of the invention, frame 42 is held against first side 24 of attachment patch 20 by applying pressure as indicated by the numeral 46 against frame 42 .",
"Pressure 46 maintains the correct position of frame 42 and prevents encapsulation material 40 from leaking out from between frame 42 and attachment patch 20 .",
"[0034] Frame 42 is positioned on attachment patch 20 such that connecting elements 32 are disposed within frame 42 .",
"The position of connecting elements 32 with respect to frame 42 is referred to as the connection location.",
"It is an important aspect of the present invention to provide strength around the connection location so that the connections between monitoring package 34 and antenna 30 do not become loose with extended use of patch 10 .",
"[0035] Depending on the material used to fabricate frame 42 , frame 42 may need to be sandblasted and degreased with solvent to clean the surface prior to performing the encapsulation steps of the present invention.",
"For instance, the copper-faced board discussed above is preferably sandblasted and solvent washed to clean the surface.",
"In addition, first side 24 of attachment patch 20 is preferably cleaned and primed with a 3% 1, 3, 5- T ri c hloro-s- t riazine t rione (Trichloroisocyanuric acid) (TCTT) solutions in butyl actetate.",
"Side 24 was then wiped with a piece of Rymplecloth to remove the excess solvent and surface dirt.",
"Patch 20 was then allowed to dry thoroughly.",
"Adhesive 44 used around frame 42 is preferably FUSOR®D 320 (five parts by weight)/ 310 B (two parts by weight).",
"FUSOR® is available from Lord Corporation.",
"Adhesive 44 is then cured in an oven at 80 degrees Celsius for thirty minutes.",
"[0036] Various other types of adhesives, frame materials, and surface preparations may be used without departing from the scope of the present invention.",
"The specific materials and times described above are merely for the purpose of providing an exemplary embodiment of the invention and the best mode now known for performing the invention.",
"[0037] Monitoring package 34 is then positioned within frame 42 so that it is suspended within frame 42 adjacent first side 24 .",
"A chimney 48 may be attached to a sensor (such as a pressure sensor or a temperature sensor) on monitoring package 34 so that it may communicate with the atmosphere surrounding encapsulated monitoring device 22 after encapsulation material 40 is cured.",
"Chimney 48 provides an air passage 50 to monitoring package 34 .",
"[0038] After monitoring package 34 is positioned adjacent first side 24 and within frame 42 , encapsulation material 40 is introduced inside frame 42 to substantially surround monitoring package 34 and to fill substantially all voids around monitoring package 34 as depicted in FIG. 5. In the preferred embodiment of the present invention, encapsulation material 40 is a formulation including 100 gm STYCAST® 2651;",
"7 gm Catalyst 9;",
"and 3 drops defoamer 88 .",
"In another embodiment of the invention, encapsulation material 40 is a formulation including 110 gm STYCAST® 2651;",
"10 gm Phenyl Gycidyl Ether;",
"9.4 gm Catalyst 9;",
"and 6 drops of defoamer 88 .",
"These materials were mixed together at room temperature until thoroughly mixed.",
"The formulation was degassed until foaming subsided.",
"The formulation was then poured into frame 42 and allowed to cure in an oven at 55 degrees Celsius for thirty minutes.",
"It was then post-cured at 80 degrees Celsius for thirty minutes.",
"This process results in a strong encapsulated monitoring device 22 directly bonded to attachment patch 20 .",
"Frame 42 may be left in position as depicted in FIG. 5 or removed as depicted in FIG. 6. [0039] Various other encapsulation materials 40 will also function with the present invention.",
"For instance, a variety of epoxies and urethanes that are pourable and cure to a rigid tough material having a high modulus of elasticity may be used.",
"It is desired that encapsulation material 40 having a Young's modulus of at least 30,000 psi and which is capable of being molded around electronic monitoring package 34 .",
"Preferably, encapsulation material 40 will have a Young's modulus at least 100,000 psi.",
"[0040] STYCAST®2651 is the preferred encapsulation material.",
"Alternatively, high melting point polyurethanes and/or polyureas may be utilized.",
"The polyurethanes are derived from polysiocyanates which generally have the formula R(NO) n where n is an integer of 2, 3 or 4 with approximately 2 being preferred.",
"The “n”",
"may, however, vary and often is not an integer because combinations of various polysiocyanates can be utilized.",
"R is an aliphatic having from about 2 to about 20 carbon atoms or preferably an aromatic including an alkyl substituted aromatic having from about 6 to about 20 carbon atoms with from about 6 to about 15 carbon atoms being desired, or combinations thereof.",
"Examples of suitable polysiocyanates include 1,6-diisocyanto hexane;",
"2,2,4- and/or 2,4,4-trimethylhexamethylene diisocyanate;",
"p- and m-tetramethyl xylene diisocyanate;",
"dicyclohexylmethane-4,4′-diisocyanate (Hydrogenated MDI);",
"4,4-methylene diphenyl isocyanate (MDI);",
"p- and m-phenylene diisocyanate;",
"2,4-and/or 2,6-toluene diisocyanate (TDI);",
"durene-1,4-diisocyanate;",
"isophorone diisocyanate and isopropylene bis-(p-phenyl isocyanate).",
"TDI is desirably utilized.",
"The various diphenylmethane diisocyanates (MDI) and mixtures of MDI with polymeric MDI having an average isocyanate functionality of from about 2 to about 3.2 are preferred.",
"[0041] The preparation of the polyurethanes and/or polyureas are well known to the art and to the literature.",
"For example, a short chain oligomer or polymer derived from polyester or polyether polyols generally having a molecular weight of from about 55 to about 1,000 and preferably from about 6 to about 200 are reacted with the above-noted diisocyanates to form a urethane prepolymer.",
"Similarly, a short chain diamine can be utilized and reacted with the above-noted diisocyanates to form a urea prepolymer.",
"Aromatic diisocyanates are generally utilized to yield high melting point urethane or urea prepolymers which also generally have a high modulus of elasticity.",
"The resulting prepolymer is subsequently reacted with diols, diamine, diacids, or amino alcohols, and the like to cure the same and form a polyurethane or polyurea.",
"Alternatively, the polyurethanes and/or polyureas are formed by reacting an existing prepolymer with the above-noted curing or chain extending agents.",
"[0042] The equivalent ratio of isocyanate groups (NCO) reacted with the hydroxyl groups (OH) or amine groups (NH 2 ) of the short chain compound is generally from about 0.90 to about 1.10, desirably from about 0.95 to about 1.05, and preferably from about 0.98 to about 1.02.",
"[0043] In general, thermoset epoxy resins are preferred.",
"The epoxy resin or polymer is generally formed by the reaction of bisphenol A and epichlorohydrin.",
"The preparation of epoxy resins is well known to the literature and to the art.",
"Generally, epichlorohydrin is reacted with a variety of hydroxy, carboxy, or amino compounds to form monomers with two or more epoxied groups, and these monomers are then used in the reaction with bisphenol A. Examples of such compounds are the diglycidyl derivative of cyclohexane-1,2-dicarboxylic acid, the triglycidyl derivates of p-aminophenol and cyanuric acid, and the polyglycidyl derivative of phenolic prepolymers.",
"Epoxidized diolefins can also be employed.",
"Various co-reactants can be utilized to cure epoxy resins either through the epoxied or hydroxyl groups.",
"Polyamines such as primary or secondary amines are a common curing agent such as aliphatic amines having a total of from about 2 to about 18 carbon atoms and desirably from about 4 to about 8 carbon atoms.",
"Suitable compounds include diethylene triamine, triethylene tetraamine, tetraethylene pentaamine, 4,4′-diaminodiphenylmethane, and polyaminoamides.",
"A combination of diethylene triamine and tetraethylene pentaamine is often desired.",
"Aromatic amines can also be utilized such as those having a total of from 6 to 20 carbon atoms such as meta or paraphenylene diamine and the like.",
"Other curing agents including polythiols, dicyandiamide (cyanoguanidine), diisocyanates, and phenolic prepolymers.",
"Curing of epoxy resins can also be achieved by ring opening polymerization of the epoxied groups using either Lewis acids or Lewis bases.",
"[0044] Accordingly, the improved attachment patch for mounting an electronic monitoring device to the inside of a pneumatic tire apparatus is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.",
"[0045] In the foregoing description, certain terms have been used for brevity, clearness, and understanding;",
"but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.",
"[0046] Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.",
"[0047] Having now described the features, discoveries, and principles of the invention, the manner in which the attachment patch for mounting an electronic monitoring device to the inside of a pneumatic tire is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained;",
"the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended claims."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus and method for use in the setting, or reduction, of a fractured distal radius.
2. Background Information
The fracture of the distal radius is one of the most common human fractures, occurring in as many as 350,000 people per year in the United States alone. The application of an extension force and lateral depression for reducing a fracture of the distal radius is well known, having been described in the 1901 edition of Gray's Anatomy in the following manner, “The treatment consists in flexing the forearm, and making a powerful extension from the wrist and elbow, depressing at the same time the radial side of the hand, and retaining the parts in that position by well-padded pistol-shaped splints.”
Conventional methods for reducing a fractured distal radius require that the physician or surgeon must be helped by an assistant during the process. Two or more people are required to apply the extension force to the hand into a configuration providing an additional extension force at the site of the fracture, and to further manipulate any bone fragments or separated sections into position. What is needed is a convenient fixture for applying such forces during the process of setting this type of fracture, so that a physician or surgeon can reduce the fracture without requiring the help of an assistant.
U.S. Pat. No. 6,123,705 describes a support fixture for setting a fractured distal radius includes a housing having a strap for fastening the fixture to the patient's forearm, a sliding section, sliding within the housing as a screw is rotated, and a pivoting section extending from a distal end of the sliding section. The sliding section also includes a structure for supporting the patient's wrist. The distal end of the pivoting section includes a pair of fingertraps. Two of the patient's fingers are held in the fingertraps, while an extension force is applied between his forearm and hand through the rotation of the screw, and while his hand is twisted by adjusting the angle of the pivoting section to increase the gap between fractured sections of bone, causing reduction of the fracture to occur.
U.S. Pat. No. 5,074,291 describes a hand traction surgical table having an adjustable surgical table frame. An arm board having an upper surface and a lower surface is mounted on the surgical table frame, thereby providing an operating surface for surgical procedures on the wrist and forearm. A pulley is mounted on the surgical table frame, and a reduction force applying cable is mounted through the pulley. A finger retention device is mounted at a first end of a cable and a force applicator is mounted at a second end of the cable so that a predetermined reduction force can be applied to the patient's hand.
U.S. Pat. No. 5,006,120 shows the use of a device including a weight, a pulley, and fingertraps to hold a patient's arm extended, reducing a distal fracture of the radius during an operation installing, with a number of screws and blades extending into the bone, a plate spanning a fracture of the distal radius. What is needed, is a convenient means to support the wrist, from below and from a side, in a manner that the angle of the wrist can be controlled during the setting of such a fracture, and, for example, during the installation of a plate spanning a fracture of the distal radius.
A number of other patents, such as U.S. Pat. Nos. 4,554,915, 5,545,162, 5,741,251, and 6,197,027 describe external fixation frames which are used, for example, for immobilizing bone segments adjacent a fracture or joint. Again, what is needed is a convenient means to support the wrist in a manner that the angle of the wrist can be controlled during the installation of an external fixation frame.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a support fixture for setting a fractured distal radius of a forearm. The support fixture includes a central mounting structure, a pair of support brackets a clamping member, and a central support bracket. The pair of support plates extends along a first plane in opposite directions from the central mounting structure and pivotable on the central mounting structure in the first plane relative to one another. The clamping member is engageable to hold the support plates in a fixed relationship with one another. The central support bracket extends from the central mounting structure spaced apart from the support plates and is movable perpendicular to the first plane along the central mounting structure.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a support fixture built in accordance with the present invention;
FIG. 2 is a vertical cross-sectional elevation of the support fixture of FIG. 1 , taken through a central mounting structure therein;
FIG. 3 is a bottom plan view of a support plate within the support fixture of FIG. 1 ;
FIG. 4 is a vertical cross-sectional elevation of the support plate of FIG. 3 , taken as indicated by section lines IV—IV therein; and
FIG. 5 is a perspective view of the support fixture of FIG. 1 in use to set a fracture of a distal radius.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a perspective view of a support fixture 10 built in accordance with the present invention. The support fixture 10 includes a first support plate 12 , a second support plate 14 , a central support bracket 16 , and a central mounting structure 18 mounting the support plates 12 , 14 to pivot relative to one another and further mounting the central support bracket 16 to move in or opposite the direction of arrow 20 , perpendicular to a plane in which the support plates 12 , 14 extend.
FIG. 2 is vertical cross-sectional elevation of the support fixture 10 , taken through the central mounting structure 18 to show the arrangement thereof. The central mounting structure 18 includes a clamping member 22 having a threaded surface 24 engaging a threaded hole 26 within the first support plate 12 . The clamping member 22 additionally includes a bearing surface 28 , axially aligned with the threaded surface 24 to extend through a clearance hole 30 in the second support plate 14 , and a knob 32 used to rotate the clamping member 22 . When the threaded surface 24 is loosely held (i.e., not tightened) within the threaded hole 26 of the first support plate 12 , the second support 12 pivots on the bearing surface 28 , relative to the first support plate 12 within the plane in which the support plates 12 , 14 extend. Threads from the threaded hole 26 may extend around some or all of the bearing surface 28 . When the threaded surface 24 is tightened within the threaded hole 26 , a shoulder 34 of the clamping member 22 holds the lower surface 36 of the upper support plate 14 against the adjacent upper surface 38 of the support plate 12 , preventing rotation of these plates 12 , 14 relative to each other.
The central mounting structure 18 also includes a bracket screw member 40 , rotatably mounted on pivot shaft portion 42 of the clamping member 22 . The bracket screw member 40 includes an externally threaded surfaces 44 engaging a threaded hole 46 within the central support bracket 16 , so that rotation of the bracket screw member 40 relative to the central support bracket 16 moves the central support bracket 16 , relative to the bracket screw member 40 , in or opposite the direction of arrow 20 , perpendicular to the plane in which the support plates 12 , 14 extend.
Each of the support plates 12 , 14 has an upper surface 48 for supporting either the hand or forearm of the patient. The central support bracket 16 has a support surface 50 for supporting the wrist of the patient as it is elevated above the lower surfaces of the hand and forearm and a wall 52 extending outward from the support surface 50 to restrain rotation of the central support bracket 16 as bracket screw member 40 is rotated by means of a knob 54 to move the central support bracket 16 in or opposite the direction of arrow 20 .
FIG. 3 is a fragmentary bottom plan view of the second support plate 14 , showing a pattern of radially-extending ridges 56 and grooves 58 on the lower surface 36 of this plate 14 around the clearance hole 28 .
FIG. 4 is a fragmentary vertical cross-sectional view of the second support plate 14 , taken as indicated by section lines IV—IV in FIG. 3 , showing adjacent ridges 56 and grooves 58 .
Referring to FIGS. 2–4 , the lower surface 36 of the second support plate 14 and the upper surface 38 of the first support plate 12 each include similar, mating patterns of ridges 56 and grooves 58 , which extend below and above the adjacent flat area 60 of the lower surface 36 . When these surfaces 36 and 38 are held together by tightening the threaded surface 24 of the clamping member 22 within the threaded hole 26 of the first support plate 12 , the ridges 56 and grooves 58 form matching serrations that prevent pivoting movement of the support plates 12 , 14 relative to one another. That is, the engagement of ridges 56 of the second support plate 14 within grooves 58 of the first support plate 12 , together with the engagement of ridges 56 of the first support plate 12 within grooves 58 of the second support plate 14 . On the other hand, when the surfaces 36 and 38 are allowed to move apart by loosening the threaded surface 24 of the clamping member 22 within the threaded hole 26 of first support plate 12 , the ridges 56 of the first support plate 12 can move past the ridges 56 of the second support plate 14 , so that the support plates 12 , 14 may be pivoted relative to one another. The surfaces 36 , 38 additionally include recessed annular grooves 62 to accommodate misalignment between the patterns of ridges 56 and grooves 58 on the first and second support plates 12 , 14 .
The lower surface 36 of the second support plate 14 preferably includes a waffle pattern of cavities 64 extending upward to webs 66 extending along the upper surface 48 of this plate 14 . Preferably, the lower surface 68 of the first support plate 12 additionally includes a similar pattern of cavities 60 . These cavities 60 , reduce the amount of plastic resin needed to produce parts having sufficient stiffness and simplify the process of molding parts with suitable stiffness.
The process for setting, or reducing a fractured distal radius in accordance with the present invention will now be discussed in reference to FIG. 5 , which is a perspective view of the support fixture 10 as used to perform this process with the forearm 70 and hand 72 of the patient each being fastened to the support plates 12 , 14 of the support fixture 1 by means of a web 74 , and with the wrist 76 disposed adjacent to the central support bracket 18 . For example, each of the webs 74 may be a strip of self-adherent bandage sold under the registered trademark MEDI-RIP by Hartmann-Conco of Rock Hill, S.C. Such a material clings to itself when wrapped tightly more than once around the forearm 70 or hand 72 . Alternately, the webs 74 may each be formed as part of the apparatus 10 , with two parts of a textile web being joined by loop and hook closure pads sold under the registered trademark VELCRO. The forearm 70 and hand 72 are oriented on the apparatus 10 so that the central mounting structure 18 is disposed laterally outward from the forearm 70 , with the hand being attached to either the first support structure 12 , as shown in FIG. 5 , or the second support structure 14 , to place the central mounting structure 18 outside the forearm 70 , regardless of whether the right or left forearm is being treated.
After the forearm 70 and hand 72 are fastened to the apparatus 10 by means of the webs 74 , a process of manipulation of the apparatus 10 to set the fracture is begun, preferably to be carried out with the aid of fluoroscopic visualization of the fracture area to determine when a desirable relationship among the fractured bone structures has been attained. The various elements of the apparatus 10 are preferably composed of materials, such as thermoplastic resins, that are transparent to the radiation used for fluoroscopic visualization.
This process of manipulation of the apparatus 10 begins with manually adjusting the angular relationship the first and second support plates with the clamping member loosened to permit relative pivoting movement of these plates. First, the support plates 12 , 14 are manually pivoted relative to one another so that the hand 72 is pivoted laterally outward, in the direction of arrow 78 . When the desired relationship of the bones in the fracture area has been attained in this way, preferably as verified by fluoroscopic visualization, the support plates 12 , 14 are locked together by tightening the clamping member 22 by rotating the knob 32 . Then, the central support bracket 16 is moved away from the lower support plates 12 , 14 by rotating the knob 54 to turn the bracket screw member 40 . When the central support 16 has moved the wrist 76 so that the bones adjacent the fracture are moved into a desirable position, again preferably as verified through fluoroscopic visualization, this manipulation process is determined to have been completed.
At this point, the position of bones adjacent the fracture may by further maintained by attaching an external fixation device, such as the device described in U.S. Pat. No. 6,197,027, the disclosure of which is incorporated herein by reference, so that various pins extend into these bones. Alternate fixation means, including the attachment internal of screws and plates to hold the bones together, as well known to those skilled in the art, may alternately be employed. Portions of the webs 74 may be cut away to clear surgical sites, or two or more straps may be used in place of a web, so that access to surgical sites will not be impaired.
While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. | A support fixture for setting a fractured distal radius includes a pair of lower support plates extending in opposite directions and a central support bracket movable away from the support plates. The support plates are pivotable relative to one another. To set a fractured distal radius, the forearm of the patient is attached to one of the support plates and his hand is attached to the other of the support plates. Then, the support plates are pivoted and clamped to achieve a desired positioning of bones adjacent to the fracture. Next, the central support bracket is moved away from the support plates, moving the patient's wrist until another desired positioning of these bones is achieved. | Summarize the key points of the given document. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to an apparatus and method for use in the setting, or reduction, of a fractured distal radius.",
"Background Information The fracture of the distal radius is one of the most common human fractures, occurring in as many as 350,000 people per year in the United States alone.",
"The application of an extension force and lateral depression for reducing a fracture of the distal radius is well known, having been described in the 1901 edition of Gray's Anatomy in the following manner, “The treatment consists in flexing the forearm, and making a powerful extension from the wrist and elbow, depressing at the same time the radial side of the hand, and retaining the parts in that position by well-padded pistol-shaped splints.”",
"Conventional methods for reducing a fractured distal radius require that the physician or surgeon must be helped by an assistant during the process.",
"Two or more people are required to apply the extension force to the hand into a configuration providing an additional extension force at the site of the fracture, and to further manipulate any bone fragments or separated sections into position.",
"What is needed is a convenient fixture for applying such forces during the process of setting this type of fracture, so that a physician or surgeon can reduce the fracture without requiring the help of an assistant.",
"U.S. Pat. No. 6,123,705 describes a support fixture for setting a fractured distal radius includes a housing having a strap for fastening the fixture to the patient's forearm, a sliding section, sliding within the housing as a screw is rotated, and a pivoting section extending from a distal end of the sliding section.",
"The sliding section also includes a structure for supporting the patient's wrist.",
"The distal end of the pivoting section includes a pair of fingertraps.",
"Two of the patient's fingers are held in the fingertraps, while an extension force is applied between his forearm and hand through the rotation of the screw, and while his hand is twisted by adjusting the angle of the pivoting section to increase the gap between fractured sections of bone, causing reduction of the fracture to occur.",
"U.S. Pat. No. 5,074,291 describes a hand traction surgical table having an adjustable surgical table frame.",
"An arm board having an upper surface and a lower surface is mounted on the surgical table frame, thereby providing an operating surface for surgical procedures on the wrist and forearm.",
"A pulley is mounted on the surgical table frame, and a reduction force applying cable is mounted through the pulley.",
"A finger retention device is mounted at a first end of a cable and a force applicator is mounted at a second end of the cable so that a predetermined reduction force can be applied to the patient's hand.",
"U.S. Pat. No. 5,006,120 shows the use of a device including a weight, a pulley, and fingertraps to hold a patient's arm extended, reducing a distal fracture of the radius during an operation installing, with a number of screws and blades extending into the bone, a plate spanning a fracture of the distal radius.",
"What is needed, is a convenient means to support the wrist, from below and from a side, in a manner that the angle of the wrist can be controlled during the setting of such a fracture, and, for example, during the installation of a plate spanning a fracture of the distal radius.",
"A number of other patents, such as U.S. Pat. Nos. 4,554,915, 5,545,162, 5,741,251, and 6,197,027 describe external fixation frames which are used, for example, for immobilizing bone segments adjacent a fracture or joint.",
"Again, what is needed is a convenient means to support the wrist in a manner that the angle of the wrist can be controlled during the installation of an external fixation frame.",
"SUMMARY OF THE INVENTION According to a first aspect of the invention, there is provided a support fixture for setting a fractured distal radius of a forearm.",
"The support fixture includes a central mounting structure, a pair of support brackets a clamping member, and a central support bracket.",
"The pair of support plates extends along a first plane in opposite directions from the central mounting structure and pivotable on the central mounting structure in the first plane relative to one another.",
"The clamping member is engageable to hold the support plates in a fixed relationship with one another.",
"The central support bracket extends from the central mounting structure spaced apart from the support plates and is movable perpendicular to the first plane along the central mounting structure.",
"BRIEF DESCRIPTION OF THE FIGURES FIG. 1 is a perspective view of a support fixture built in accordance with the present invention;",
"FIG. 2 is a vertical cross-sectional elevation of the support fixture of FIG. 1 , taken through a central mounting structure therein;",
"FIG. 3 is a bottom plan view of a support plate within the support fixture of FIG. 1 ;",
"FIG. 4 is a vertical cross-sectional elevation of the support plate of FIG. 3 , taken as indicated by section lines IV—IV therein;",
"and FIG. 5 is a perspective view of the support fixture of FIG. 1 in use to set a fracture of a distal radius.",
"DETAILED DESCRIPTION OF THE INVENTION FIG. 1 is a perspective view of a support fixture 10 built in accordance with the present invention.",
"The support fixture 10 includes a first support plate 12 , a second support plate 14 , a central support bracket 16 , and a central mounting structure 18 mounting the support plates 12 , 14 to pivot relative to one another and further mounting the central support bracket 16 to move in or opposite the direction of arrow 20 , perpendicular to a plane in which the support plates 12 , 14 extend.",
"FIG. 2 is vertical cross-sectional elevation of the support fixture 10 , taken through the central mounting structure 18 to show the arrangement thereof.",
"The central mounting structure 18 includes a clamping member 22 having a threaded surface 24 engaging a threaded hole 26 within the first support plate 12 .",
"The clamping member 22 additionally includes a bearing surface 28 , axially aligned with the threaded surface 24 to extend through a clearance hole 30 in the second support plate 14 , and a knob 32 used to rotate the clamping member 22 .",
"When the threaded surface 24 is loosely held (i.e., not tightened) within the threaded hole 26 of the first support plate 12 , the second support 12 pivots on the bearing surface 28 , relative to the first support plate 12 within the plane in which the support plates 12 , 14 extend.",
"Threads from the threaded hole 26 may extend around some or all of the bearing surface 28 .",
"When the threaded surface 24 is tightened within the threaded hole 26 , a shoulder 34 of the clamping member 22 holds the lower surface 36 of the upper support plate 14 against the adjacent upper surface 38 of the support plate 12 , preventing rotation of these plates 12 , 14 relative to each other.",
"The central mounting structure 18 also includes a bracket screw member 40 , rotatably mounted on pivot shaft portion 42 of the clamping member 22 .",
"The bracket screw member 40 includes an externally threaded surfaces 44 engaging a threaded hole 46 within the central support bracket 16 , so that rotation of the bracket screw member 40 relative to the central support bracket 16 moves the central support bracket 16 , relative to the bracket screw member 40 , in or opposite the direction of arrow 20 , perpendicular to the plane in which the support plates 12 , 14 extend.",
"Each of the support plates 12 , 14 has an upper surface 48 for supporting either the hand or forearm of the patient.",
"The central support bracket 16 has a support surface 50 for supporting the wrist of the patient as it is elevated above the lower surfaces of the hand and forearm and a wall 52 extending outward from the support surface 50 to restrain rotation of the central support bracket 16 as bracket screw member 40 is rotated by means of a knob 54 to move the central support bracket 16 in or opposite the direction of arrow 20 .",
"FIG. 3 is a fragmentary bottom plan view of the second support plate 14 , showing a pattern of radially-extending ridges 56 and grooves 58 on the lower surface 36 of this plate 14 around the clearance hole 28 .",
"FIG. 4 is a fragmentary vertical cross-sectional view of the second support plate 14 , taken as indicated by section lines IV—IV in FIG. 3 , showing adjacent ridges 56 and grooves 58 .",
"Referring to FIGS. 2–4 , the lower surface 36 of the second support plate 14 and the upper surface 38 of the first support plate 12 each include similar, mating patterns of ridges 56 and grooves 58 , which extend below and above the adjacent flat area 60 of the lower surface 36 .",
"When these surfaces 36 and 38 are held together by tightening the threaded surface 24 of the clamping member 22 within the threaded hole 26 of the first support plate 12 , the ridges 56 and grooves 58 form matching serrations that prevent pivoting movement of the support plates 12 , 14 relative to one another.",
"That is, the engagement of ridges 56 of the second support plate 14 within grooves 58 of the first support plate 12 , together with the engagement of ridges 56 of the first support plate 12 within grooves 58 of the second support plate 14 .",
"On the other hand, when the surfaces 36 and 38 are allowed to move apart by loosening the threaded surface 24 of the clamping member 22 within the threaded hole 26 of first support plate 12 , the ridges 56 of the first support plate 12 can move past the ridges 56 of the second support plate 14 , so that the support plates 12 , 14 may be pivoted relative to one another.",
"The surfaces 36 , 38 additionally include recessed annular grooves 62 to accommodate misalignment between the patterns of ridges 56 and grooves 58 on the first and second support plates 12 , 14 .",
"The lower surface 36 of the second support plate 14 preferably includes a waffle pattern of cavities 64 extending upward to webs 66 extending along the upper surface 48 of this plate 14 .",
"Preferably, the lower surface 68 of the first support plate 12 additionally includes a similar pattern of cavities 60 .",
"These cavities 60 , reduce the amount of plastic resin needed to produce parts having sufficient stiffness and simplify the process of molding parts with suitable stiffness.",
"The process for setting, or reducing a fractured distal radius in accordance with the present invention will now be discussed in reference to FIG. 5 , which is a perspective view of the support fixture 10 as used to perform this process with the forearm 70 and hand 72 of the patient each being fastened to the support plates 12 , 14 of the support fixture 1 by means of a web 74 , and with the wrist 76 disposed adjacent to the central support bracket 18 .",
"For example, each of the webs 74 may be a strip of self-adherent bandage sold under the registered trademark MEDI-RIP by Hartmann-Conco of Rock Hill, S.C. Such a material clings to itself when wrapped tightly more than once around the forearm 70 or hand 72 .",
"Alternately, the webs 74 may each be formed as part of the apparatus 10 , with two parts of a textile web being joined by loop and hook closure pads sold under the registered trademark VELCRO.",
"The forearm 70 and hand 72 are oriented on the apparatus 10 so that the central mounting structure 18 is disposed laterally outward from the forearm 70 , with the hand being attached to either the first support structure 12 , as shown in FIG. 5 , or the second support structure 14 , to place the central mounting structure 18 outside the forearm 70 , regardless of whether the right or left forearm is being treated.",
"After the forearm 70 and hand 72 are fastened to the apparatus 10 by means of the webs 74 , a process of manipulation of the apparatus 10 to set the fracture is begun, preferably to be carried out with the aid of fluoroscopic visualization of the fracture area to determine when a desirable relationship among the fractured bone structures has been attained.",
"The various elements of the apparatus 10 are preferably composed of materials, such as thermoplastic resins, that are transparent to the radiation used for fluoroscopic visualization.",
"This process of manipulation of the apparatus 10 begins with manually adjusting the angular relationship the first and second support plates with the clamping member loosened to permit relative pivoting movement of these plates.",
"First, the support plates 12 , 14 are manually pivoted relative to one another so that the hand 72 is pivoted laterally outward, in the direction of arrow 78 .",
"When the desired relationship of the bones in the fracture area has been attained in this way, preferably as verified by fluoroscopic visualization, the support plates 12 , 14 are locked together by tightening the clamping member 22 by rotating the knob 32 .",
"Then, the central support bracket 16 is moved away from the lower support plates 12 , 14 by rotating the knob 54 to turn the bracket screw member 40 .",
"When the central support 16 has moved the wrist 76 so that the bones adjacent the fracture are moved into a desirable position, again preferably as verified through fluoroscopic visualization, this manipulation process is determined to have been completed.",
"At this point, the position of bones adjacent the fracture may by further maintained by attaching an external fixation device, such as the device described in U.S. Pat. No. 6,197,027, the disclosure of which is incorporated herein by reference, so that various pins extend into these bones.",
"Alternate fixation means, including the attachment internal of screws and plates to hold the bones together, as well known to those skilled in the art, may alternately be employed.",
"Portions of the webs 74 may be cut away to clear surgical sites, or two or more straps may be used in place of a web, so that access to surgical sites will not be impaired.",
"While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention."
] |
This is a division of application Ser. No. 448,748 filed Mar. 6, 1974, now U.S. Pat. No. 3,994,910.
BACKGROUND OF THE INVENTION
Since its discovery almost a quarter of a century ago, phenylbutazone (4-n-butyl-1,2-diphenyl-3,5-pyrazolidinedione) has dominated the field of non-steroid anti-inflammatory drugs despite the fact that it has several serious toxic effects of which ulcerogenesis and fluid retention are probably the most frequent.
The most probable reason for the continued success of phenylbutazone is that none of the numerous modifications of its structure nor the even more numerous attempts to design novel structures with anti-inflammatory activity have resulted in a truly successful separation of desired pharmacological activity and undesired toxicity.
SUMMARY OF THE INVENTION
This invention relates to a process for preparing derivatives of 1,2-diphenyl-3,5-dioxo-4-n-butyl-pyrazolidine having the formula: ##STR2## in which R is represented by a basic compound namely: either 2-amino-4-methyl-pyridine or 2-amino-2-thiazoline, having the respective formulae: ##STR3##
It has been found that the compounds of Formula I are a clear improvement over phenylbutazone in that they have increased therapeutic activities but reduced or decreased toxicity.
As will be more fully discussed hereinafter, the therapeutic compounds of the present invention have a number of additional advantages over phenylbutazone. For example, smaller doses of the new therapeutic compounds as compared with phenylbutazone can be used with comparable and superior effectiveness. The therapeutic compounds of the present invention have fewer and less severe side effects.
In equimolar reaction with 1,2-diphenyl-3,5-dioxo-4-n-butyl-pyrazolidine, these compounds form stable crystalline combinations with an interesting therapeutic action as antiinflammatories, analgesics and analeptics.
Pharmacological testing of these compounds led to results to be described hereinafter and reflected in the compound formed by the equimolar combination of 1,2-diphenyl-3,5-dioxo-4-n-butyl-pyrazolidine-2-amino-2-thiazoline, referred to hereinafter as LAS-11871. The equimolar combination of phenylbutazone salt with 2-amino-4-methylpyridine is hereinafter referred to as LAS 6671.
The doses of compounds referred to are in mg of salt and not in mg equivalents of phenylbutazone content (i.e., the comparison has been made on a weight for weight basis and not equimolar) since it was considered that this would be more demonstrative of the potential value of the compound. Equimolar comparisons can be made by taking into account the respective molecular weights of LAS 11871 (410.54) and phenylbutazone (308.4) from which it is evident that 100 mg. of LAS 11871 contains the equivalent of 75 mg of phenylbutazone.
DETAILED DESCRIPTION OF THE INVENTION
The properties and advantages of the therapeutic compounds of the present invention will be discussed below as to some of their therapeutic activities, their toxicity effects and their chemical functions and synthesis.
PHARMACOLOGY
LAS 11871 and 6671 were compared in a preliminary screening test with phenylbutazone and a commercially available piperazine salt of phenylbutazone and they had definite advantages over each of these two products (see Table I below).
TABLE I
This shows the effects of LAS- 11871 in various screening tests as compared with phenylbutazone and a piperazine salt thereof.
______________________________________ Desired Effects Toxic EffectsCompound CE AA AP UG TX______________________________________LAS 11871 ++ +++ +++ ++ +LAS 6671 ++ + ++ ++ +Phenylbutazone ++ ++ ++ ++ ++Piperazine saltof Phenylbutazone + + + + +______________________________________ CE = Inhibition of carrageenin-induced oedema in rat's paw. AA = Inhibition of contortions induced by acetic acid in mice. AP = Inhibition of yeast-induced pyrexia in rats. UG = Intensity of ulceration produced in the rat stomach. TX = Acute toxicity in mice.
More detailed studies confirmed these preliminary results and clearly showed that LAS 11871, although more active as an analgesic and anti-inflammatory agent than phenylbutazone, produces fewer gastric lesions and is less toxic than phenylbutazone (see Tables 2, 3, 4, 5 and 6 below).
TABLE 2
This shows the effect of various doses of phenylbutazone and LAS 11871 on carrageenin-induced oedema in the rat's paw.
______________________________________Compound per os Volume of paw % Inhibition1 h before No. of (ml) standard ± standardcarrageenin animals error error______________________________________Control 46 0.9663 ± 0.0564 0.00 ± 5.80Phenylbutazone 200 12 0.2458 ± 0.0454** 74.60 ± 4.70100 18 0.3139 ± 0.0224** 67.50 ± 2.30 50 22 0.6886 ± 0.0699* 28.70 ± 7.24 25 22 0.6545 ± 0.0545**LAS 11871 200 11 0.1545 ± 0.0384** 84.00 ± 3.97100 18 0.2667 ± 0.0428** 72.40 ± 4.43 50 22 0.6182 ± 0.0683* 36.01 ± 7.06 25 22 0.7864 ± 0.0632 18.60 ± 6.54______________________________________
Volume of paws measured 3 hours after injection of carrageenin *P <0.05, >0.001; **P <0.001 for the differences from the control using Student's "t" test.
TABLE 3__________________________________________________________________________Effects of various doses of phenyl butazone and LAS 11871on granuloma induced in rats by implantation of cotton balls.__________________________________________________________________________ Percentage No. of Dry granuloma ± inhibitionmg/Kg/day of compound granulomas Weight of wet standard error Wet Dryper os (animals) granuloma (mg) granuloma granuloma__________________________________________________________________________Control 40 (20) 454.20 ± 11.74 77.34 ± 0.33 0.00 ± 2.60 0.00 ± 0.40Phenylbutazone 200 20 (10) 353.40 ± 13.14** 49.96 ± 4.25** 22.20 ± 2.80 35.40 ± 5.50100 20 (10) 424.50 ± 13.47 71.23 ± 5.18 6.50 ± 2.90 7.90 ± 6.70 50 20 (10) 434.75 ± 18.36 83.94 ± 8.22 4.30 ± 4.10 8.50 ± 10.6LAS 11871 200 20 (10) 361.21 ± 12.84** 48.29 ± 1.98** 20.50 ± 2.80 37.60 ± 2.50100 20 (10) 369.69 ± 16.68** 61.95 ± 4.74* 18.60 ± 3.70 19.90 ± 6.10 50 20 (10) 388.59 ± 8.74** 61.82 ± 3.16** 14.40 ± 1.90 20.00 ± 4.10__________________________________________________________________________ The figures refer to the net weight of granuloma tissue obtained by subtracting the original weight of the cotton ball. *P <0.05, >0.001 **P <0.001 for the differences from the control using Student's "t" test.
TABLE 4______________________________________Effect of various doses of phenylbutazone and LAS 11871on cortortions induced by acetic acidinjected into the abdominal cavity of the mouse______________________________________mg/kg of compound No. ofper os 1 h before No. of contortions ± % inhibition ±acetic acid injection animals standard error standard error______________________________________Control 20 81.65 ± 5.73 0.00 ± 7.02Phenylbutazone 300 10 42.30 ± 6.75** 48.20 ± 8.27100 10 47.30 ± 6.70* 42.10 ± 8.20 30 10 59.00 ± 6.51* 27.70 ± 7.97LAS 11871 300 10 24.10 ± 3.74** 70.50 ± 4.60100 10 36.90 ± 6.34** 54.90 ± 7.76 30 10 44.20 ± 6.03** 45.90 ± 7.39______________________________________ *P <0.05, >0.001 **P >0.001 for the differences from the control using Student's "t" test.
TABLE 5
Ulcerogenic activity of LAS 11871 on the stomach as compared with phenylbutazone
TABLE 5______________________________________Ulcerogenic activity of LAS 11871 on the stomach as comparedwith phenylbutazone______________________________________mg/kg of compound No. of ± standard error ofper os animals ulcerogenic indices______________________________________Control 40 0.17 ± 0.07Phenylbutazone 2×200 29 5.00 ± 0.562×100 30 4.33 ± 0.472× 50 30 0.73 ± 0.21LAS 2×200 29 3.65 ± 0.56*2×100 30 2.43 ± 0.41**2× 50 29 0.59 ± 0.19______________________________________ *P <0.1, >0.01 **P <0.01 for the differences between equivalent doses of phenylbutazone and LAS 11871 using Student's "t" test.
From Table 2 it is demonstrated that LAS 11871 is at least as active as phenylbutazone against inflammation and at doses of 50 mg/kg and above LAS 11871 was the more active compound.
Table 3 compares the activity of LAS 11871 and phenylbutazone against chronic inflammation. It is seen that although both products produced about the same degree of inhibition of granuloma tissue formation at high doses (200 mg/kg), at the lower dose levels (100 and 50 mg/kg) LAS 11871 continued to inhibit the granuloma tissue formation but phenylbutazone did not.
Table 4 demonstrates that LAS 11871 is more potent than phenylbutazone as an analgesic.
Although LAS 11871, in common with virtually all of the other non-steroid anti-inflammatory compounds, possesses a certain capacity to cause ulcerous lesions in the gastro-intestinal tract. However, as Table 5 illustrates, it is much less active in this respect than phenylbutazone.
______________________________________TOXICITYLD50 per os in the rat of LAS 11871Group Dose No. animals No. deaths % mortality______________________________________I 1000 mg/kg 10 1 10II 1210 mg/kg 12 3 25III 1470 mg/kg 10 5 50IV 1780 mg/kg 10 9 90V 2150 mg/kg 10 10 100LD50 = 1425 mg/kg (1250 - 1624)LD50 per os in the rat of phenylbutazoneGroup Dose No. animals No. deaths % mortality______________________________________I 464 mg/kg 9 1 11II 562 mg/kg 10 4 40III 681 mg/kg 10 8 80IV 825 mg/kg 10 8 80V 1000 mg/kg 10 9 90VI 1210 mg/kg 10 10 100LD50 = 620 (530 - 725)LD50 per os in the rat of 2-amino-thiazolineGroup Dose No. animals No. deaths % mortality______________________________________I 316 mg/kg 10 2 20II 383 mg/kg 10 4 40III 464 mg/kg 10 6 60IV 562 mg/kg 10 7 70V 681 mg/kg 10 9 90VI 825 mg/kg 10 9 90LD50 = 430 mg/kg (358 - 516)______________________________________
In general, the new therapeutic compounds can be used to treat the same disorders as phenylbutazone. As the above discussion illustrates, the therapeutic compounds of the present invention are less toxic and less ulcerogenic than phenylbutazone, and they have greater effectiveness in anti-inflammatory, analgesic, and antipyretic activity. These therapeutic compounds have been found effective in treating humans as well as animals. For example, LAS 11871 has been shown effective in the treatment of humans with reumatic diseases and LAS 11871 has been used to successfully treat polyarthritics at doses of 200 mg. two, or three times per day.
These new therapeutic compounds also have limited and reduced side effects. As noted earlier, they have no anti-diuretic effect and relatively low ulcerogenic potential. They are also relatively free of serious side effects on the central nervous system.
However, the compounds, much more than phenylbutazone, show marked inhibition of spontaneous motor activity. This activity is best described as a tranquilizing or muscle relaxant activity. Also, the compounds appear to have immunosuppressant activity.
______________________________________PHARMACEUTICAL FORMULATIONS - LAS 11871 capsules g______________________________________LAS 11871 0.200Colloidal silica 0.005LAS 11871 tabletsLAS 11871 0.250Hydroxypropyl cellulose 0.016Microcrystalline cellulose 0.100Carboxymethyl starch 0.012Colloidal silica 0.003Magnesium stearate 0.003LAS 11871 suppositoriesLAS 11871 0.300Stearine composition 1.240LAS 11871 suppositoriesLAS 11871 0.5000Ascorbyl palmitate 0.0025Stearine composition 1.9975Dose: from 200 to 1,500 mg/day______________________________________
CHEMISTRY AND SYNTHESIS
The reaction process for synthesising the therapeutic compounds of the present invention is carried into effect with the use of organic solvents such as methanol, ethanol, acetone, methyl ethyl acetone and dioxane in conditions which will be described in the following Examples.
EXAMPLE 1
Equimolar combination of 1,2-diphenyl-3,5-dioxo-4-n-butylpyrazolidine-2-amino-4-methyl-pyridine.
30.8 g (0.1 mol) of 1,2-diphenyl-3,5-dioxo-4-butyl-pyrazolidine are introduced with agitation into a 500 cc flask and mixed with 150 ml of acetone until complete dissolution. 10.8 g (0.1 mol) of 2-amino-4-methylpyridine which have previously been dissolved in 100 cc of acetone are then added and the mixture is boiled for 30 minutes. It is filtered cold, and 39 g of a product having a melting point of 121°-2° C are crystallized out.
EXAMPLE 2
Equimolar combination of 1,2-diphenyl-3,5-dioxo-4-n-butylpyrazolidine-2-amino-2-thiazoline.
Working is performed under the same conditions as in Example 1 but using ethyl alcohol as the solvent. 2.04 g (0.02 mol) of 2-amino-2-thiazoline are heated in ethanol with 6.16 g (0.02 mol) of 1,2-diphenyl-3,5-dioxo-4-n-butylpyrazolidine for 30 minutes; after cooling, the crystals which form are collected. The substance has a melting point of 161°-2° C. The yield is 86%. The final product was a white crystalline powder virtually insoluble in ether, sparingly soluble in water and soluble in hot ethanol. | The present invention concerns novel therapeutic compounds having the formula: ##STR1## wherein R is a basic compound comprising 2-amino-4-methylpyridine or 2-amino-2-thiazoline, and methods of making this compound. | Briefly describe the main idea outlined in the provided context. | [
"This is a division of application Ser.",
"No. 448,748 filed Mar. 6, 1974, now U.S. Pat. No. 3,994,910.",
"BACKGROUND OF THE INVENTION Since its discovery almost a quarter of a century ago, phenylbutazone (4-n-butyl-1,2-diphenyl-3,5-pyrazolidinedione) has dominated the field of non-steroid anti-inflammatory drugs despite the fact that it has several serious toxic effects of which ulcerogenesis and fluid retention are probably the most frequent.",
"The most probable reason for the continued success of phenylbutazone is that none of the numerous modifications of its structure nor the even more numerous attempts to design novel structures with anti-inflammatory activity have resulted in a truly successful separation of desired pharmacological activity and undesired toxicity.",
"SUMMARY OF THE INVENTION This invention relates to a process for preparing derivatives of 1,2-diphenyl-3,5-dioxo-4-n-butyl-pyrazolidine having the formula: ##STR2## in which R is represented by a basic compound namely: either 2-amino-4-methyl-pyridine or 2-amino-2-thiazoline, having the respective formulae: ##STR3## It has been found that the compounds of Formula I are a clear improvement over phenylbutazone in that they have increased therapeutic activities but reduced or decreased toxicity.",
"As will be more fully discussed hereinafter, the therapeutic compounds of the present invention have a number of additional advantages over phenylbutazone.",
"For example, smaller doses of the new therapeutic compounds as compared with phenylbutazone can be used with comparable and superior effectiveness.",
"The therapeutic compounds of the present invention have fewer and less severe side effects.",
"In equimolar reaction with 1,2-diphenyl-3,5-dioxo-4-n-butyl-pyrazolidine, these compounds form stable crystalline combinations with an interesting therapeutic action as antiinflammatories, analgesics and analeptics.",
"Pharmacological testing of these compounds led to results to be described hereinafter and reflected in the compound formed by the equimolar combination of 1,2-diphenyl-3,5-dioxo-4-n-butyl-pyrazolidine-2-amino-2-thiazoline, referred to hereinafter as LAS-11871.",
"The equimolar combination of phenylbutazone salt with 2-amino-4-methylpyridine is hereinafter referred to as LAS 6671.",
"The doses of compounds referred to are in mg of salt and not in mg equivalents of phenylbutazone content (i.e., the comparison has been made on a weight for weight basis and not equimolar) since it was considered that this would be more demonstrative of the potential value of the compound.",
"Equimolar comparisons can be made by taking into account the respective molecular weights of LAS 11871 (410.54) and phenylbutazone (308.4) from which it is evident that 100 mg.",
"of LAS 11871 contains the equivalent of 75 mg of phenylbutazone.",
"DETAILED DESCRIPTION OF THE INVENTION The properties and advantages of the therapeutic compounds of the present invention will be discussed below as to some of their therapeutic activities, their toxicity effects and their chemical functions and synthesis.",
"PHARMACOLOGY LAS 11871 and 6671 were compared in a preliminary screening test with phenylbutazone and a commercially available piperazine salt of phenylbutazone and they had definite advantages over each of these two products (see Table I below).",
"TABLE I This shows the effects of LAS- 11871 in various screening tests as compared with phenylbutazone and a piperazine salt thereof.",
"______________________________________ Desired Effects Toxic EffectsCompound CE AA AP UG TX______________________________________LAS 11871 ++ +++ +++ ++ +LAS 6671 ++ + ++ ++ +Phenylbutazone ++ ++ ++ ++ ++Piperazine saltof Phenylbutazone + + + + +______________________________________ CE = Inhibition of carrageenin-induced oedema in rat's paw.",
"AA = Inhibition of contortions induced by acetic acid in mice.",
"AP = Inhibition of yeast-induced pyrexia in rats.",
"UG = Intensity of ulceration produced in the rat stomach.",
"TX = Acute toxicity in mice.",
"More detailed studies confirmed these preliminary results and clearly showed that LAS 11871, although more active as an analgesic and anti-inflammatory agent than phenylbutazone, produces fewer gastric lesions and is less toxic than phenylbutazone (see Tables 2, 3, 4, 5 and 6 below).",
"TABLE 2 This shows the effect of various doses of phenylbutazone and LAS 11871 on carrageenin-induced oedema in the rat's paw.",
"______________________________________Compound per os Volume of paw % Inhibition1 h before No. of (ml) standard ± standardcarrageenin animals error error______________________________________Control 46 0.9663 ± 0.0564 0.00 ± 5.80Phenylbutazone 200 12 0.2458 ± 0.0454** 74.60 ± 4.70100 18 0.3139 ± 0.0224** 67.50 ± 2.30 50 22 0.6886 ± 0.0699* 28.70 ± 7.24 25 22 0.6545 ± 0.0545**LAS 11871 200 11 0.1545 ± 0.0384** 84.00 ± 3.97100 18 0.2667 ± 0.0428** 72.40 ± 4.43 50 22 0.6182 ± 0.0683* 36.01 ± 7.06 25 22 0.7864 ± 0.0632 18.60 ± 6.54______________________________________ Volume of paws measured 3 hours after injection of carrageenin *P <0.05, >0.001;",
"**P <0.001 for the differences from the control using Student's "t"",
"test.",
"TABLE 3__________________________________________________________________________Effects of various doses of phenyl butazone and LAS 11871on granuloma induced in rats by implantation of cotton balls.",
"__________________________________________________________________________ Percentage No. of Dry granuloma ± inhibitionmg/Kg/day of compound granulomas Weight of wet standard error Wet Dryper os (animals) granuloma (mg) granuloma granuloma__________________________________________________________________________Control 40 (20) 454.20 ± 11.74 77.34 ± 0.33 0.00 ± 2.60 0.00 ± 0.40Phenylbutazone 200 20 (10) 353.40 ± 13.14** 49.96 ± 4.25** 22.20 ± 2.80 35.40 ± 5.50100 20 (10) 424.50 ± 13.47 71.23 ± 5.18 6.50 ± 2.90 7.90 ± 6.70 50 20 (10) 434.75 ± 18.36 83.94 ± 8.22 4.30 ± 4.10 8.50 ± 10.6LAS 11871 200 20 (10) 361.21 ± 12.84** 48.29 ± 1.98** 20.50 ± 2.80 37.60 ± 2.50100 20 (10) 369.69 ± 16.68** 61.95 ± 4.74* 18.60 ± 3.70 19.90 ± 6.10 50 20 (10) 388.59 ± 8.74** 61.82 ± 3.16** 14.40 ± 1.90 20.00 ± 4.10__________________________________________________________________________ The figures refer to the net weight of granuloma tissue obtained by subtracting the original weight of the cotton ball.",
"*P <0.05, >0.001 **P <0.001 for the differences from the control using Student's "t"",
"test.",
"TABLE 4______________________________________Effect of various doses of phenylbutazone and LAS 11871on cortortions induced by acetic acidinjected into the abdominal cavity of the mouse______________________________________mg/kg of compound No. ofper os 1 h before No. of contortions ± % inhibition ±acetic acid injection animals standard error standard error______________________________________Control 20 81.65 ± 5.73 0.00 ± 7.02Phenylbutazone 300 10 42.30 ± 6.75** 48.20 ± 8.27100 10 47.30 ± 6.70* 42.10 ± 8.20 30 10 59.00 ± 6.51* 27.70 ± 7.97LAS 11871 300 10 24.10 ± 3.74** 70.50 ± 4.60100 10 36.90 ± 6.34** 54.90 ± 7.76 30 10 44.20 ± 6.03** 45.90 ± 7.39______________________________________ *P <0.05, >0.001 **P >0.001 for the differences from the control using Student's "t"",
"test.",
"TABLE 5 Ulcerogenic activity of LAS 11871 on the stomach as compared with phenylbutazone TABLE 5______________________________________Ulcerogenic activity of LAS 11871 on the stomach as comparedwith phenylbutazone______________________________________mg/kg of compound No. of ± standard error ofper os animals ulcerogenic indices______________________________________Control 40 0.17 ± 0.07Phenylbutazone 2×200 29 5.00 ± 0.562×100 30 4.33 ± 0.472× 50 30 0.73 ± 0.21LAS 2×200 29 3.65 ± 0.56*2×100 30 2.43 ± 0.41**2× 50 29 0.59 ± 0.19______________________________________ *P <0.1, >0.01 **P <0.01 for the differences between equivalent doses of phenylbutazone and LAS 11871 using Student's "t"",
"test.",
"From Table 2 it is demonstrated that LAS 11871 is at least as active as phenylbutazone against inflammation and at doses of 50 mg/kg and above LAS 11871 was the more active compound.",
"Table 3 compares the activity of LAS 11871 and phenylbutazone against chronic inflammation.",
"It is seen that although both products produced about the same degree of inhibition of granuloma tissue formation at high doses (200 mg/kg), at the lower dose levels (100 and 50 mg/kg) LAS 11871 continued to inhibit the granuloma tissue formation but phenylbutazone did not.",
"Table 4 demonstrates that LAS 11871 is more potent than phenylbutazone as an analgesic.",
"Although LAS 11871, in common with virtually all of the other non-steroid anti-inflammatory compounds, possesses a certain capacity to cause ulcerous lesions in the gastro-intestinal tract.",
"However, as Table 5 illustrates, it is much less active in this respect than phenylbutazone.",
"______________________________________TOXICITYLD50 per os in the rat of LAS 11871Group Dose No. animals No. deaths % mortality______________________________________I 1000 mg/kg 10 1 10II 1210 mg/kg 12 3 25III 1470 mg/kg 10 5 50IV 1780 mg/kg 10 9 90V 2150 mg/kg 10 10 100LD50 = 1425 mg/kg (1250 - 1624)LD50 per os in the rat of phenylbutazoneGroup Dose No. animals No. deaths % mortality______________________________________I 464 mg/kg 9 1 11II 562 mg/kg 10 4 40III 681 mg/kg 10 8 80IV 825 mg/kg 10 8 80V 1000 mg/kg 10 9 90VI 1210 mg/kg 10 10 100LD50 = 620 (530 - 725)LD50 per os in the rat of 2-amino-thiazolineGroup Dose No. animals No. deaths % mortality______________________________________I 316 mg/kg 10 2 20II 383 mg/kg 10 4 40III 464 mg/kg 10 6 60IV 562 mg/kg 10 7 70V 681 mg/kg 10 9 90VI 825 mg/kg 10 9 90LD50 = 430 mg/kg (358 - 516)______________________________________ In general, the new therapeutic compounds can be used to treat the same disorders as phenylbutazone.",
"As the above discussion illustrates, the therapeutic compounds of the present invention are less toxic and less ulcerogenic than phenylbutazone, and they have greater effectiveness in anti-inflammatory, analgesic, and antipyretic activity.",
"These therapeutic compounds have been found effective in treating humans as well as animals.",
"For example, LAS 11871 has been shown effective in the treatment of humans with reumatic diseases and LAS 11871 has been used to successfully treat polyarthritics at doses of 200 mg.",
"two, or three times per day.",
"These new therapeutic compounds also have limited and reduced side effects.",
"As noted earlier, they have no anti-diuretic effect and relatively low ulcerogenic potential.",
"They are also relatively free of serious side effects on the central nervous system.",
"However, the compounds, much more than phenylbutazone, show marked inhibition of spontaneous motor activity.",
"This activity is best described as a tranquilizing or muscle relaxant activity.",
"Also, the compounds appear to have immunosuppressant activity.",
"______________________________________PHARMACEUTICAL FORMULATIONS - LAS 11871 capsules g______________________________________LAS 11871 0.200Colloidal silica 0.005LAS 11871 tabletsLAS 11871 0.250Hydroxypropyl cellulose 0.016Microcrystalline cellulose 0.100Carboxymethyl starch 0.012Colloidal silica 0.003Magnesium stearate 0.003LAS 11871 suppositoriesLAS 11871 0.300Stearine composition 1.240LAS 11871 suppositoriesLAS 11871 0.5000Ascorbyl palmitate 0.0025Stearine composition 1.9975Dose: from 200 to 1,500 mg/day______________________________________ CHEMISTRY AND SYNTHESIS The reaction process for synthesising the therapeutic compounds of the present invention is carried into effect with the use of organic solvents such as methanol, ethanol, acetone, methyl ethyl acetone and dioxane in conditions which will be described in the following Examples.",
"EXAMPLE 1 Equimolar combination of 1,2-diphenyl-3,5-dioxo-4-n-butylpyrazolidine-2-amino-4-methyl-pyridine.",
"30.8 g (0.1 mol) of 1,2-diphenyl-3,5-dioxo-4-butyl-pyrazolidine are introduced with agitation into a 500 cc flask and mixed with 150 ml of acetone until complete dissolution.",
"10.8 g (0.1 mol) of 2-amino-4-methylpyridine which have previously been dissolved in 100 cc of acetone are then added and the mixture is boiled for 30 minutes.",
"It is filtered cold, and 39 g of a product having a melting point of 121°-2° C are crystallized out.",
"EXAMPLE 2 Equimolar combination of 1,2-diphenyl-3,5-dioxo-4-n-butylpyrazolidine-2-amino-2-thiazoline.",
"Working is performed under the same conditions as in Example 1 but using ethyl alcohol as the solvent.",
"2.04 g (0.02 mol) of 2-amino-2-thiazoline are heated in ethanol with 6.16 g (0.02 mol) of 1,2-diphenyl-3,5-dioxo-4-n-butylpyrazolidine for 30 minutes;",
"after cooling, the crystals which form are collected.",
"The substance has a melting point of 161°-2° C. The yield is 86%.",
"The final product was a white crystalline powder virtually insoluble in ether, sparingly soluble in water and soluble in hot ethanol."
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 62/190,478 titled “CONTROL PLATE IN A VALVE,” filed Jul. 9, 2015, and Provisional Application Ser. No. 62/292,526 titled “CONTROL PLATE IN A VALVE,” filed Feb. 8, 2016, each of which is incorporated by reference herein in its entirety for all purposes.
BACKGROUND
[0002] The present invention is related to a moveable portion of a fluid control valve that may be actively positioned, anywhere between an extreme open condition and an extreme closed condition, to adjust a flow of fluid passing therethrough. The invention is particularly useful in valves intended for proportional or modulating control of fluid delivery within industrial processes making semiconductor devices, pharmaceuticals, or fine chemicals, and many similar high-purity fluid delivery systems that simultaneously demand a leak-tight shut-off in the fully closed condition along with proportional control. Many combinations of metallic and elastomeric elements enhancing valve shut-off are known in the art.
SUMMARY
[0003] Applicant has invented uniquely manufacturable configurations of a moveable valve element suited for use with various sized valve orifices. The moveable disk-shaped element has a flat surface generally perpendicular to the valve axis of symmetry when closed and translates toward or away from an orifice surrounded by a narrow lip or orifice ridge. This combination of valve structures is sometimes referred to as being the jet & seat class of fluid pathway element combinations. In this disclosure the flat surfaced element (colloquially a seat) which closes against the narrow lip (colloquially a jet) surrounding the orifice is often referred to as a control plate. Enhanced leak tightness in the valve shut-off condition is provided by selectively incorporating into the control plate materials that are softer than the material comprising the lip or ridge surrounding the orifice. Control plate materials being softer than the orifice ridge-lip allows elastic deformation of the control plate surface as it presses against the orifice ridge-lip and thereby enhances the sealing effected between the control plate and the orifice ridge-lip. The disclosed arrangements can use welding or interference press-fit pieces to avoid problems associated with having threads within high purity fluid pathways.
[0004] One embodiment comprises a metallic seat housing having a small diameter central insert of polymer material held in place by a metallic retaining ring pressed into a gap between the outside diameter of the polymer insert and the inside diameter of a seat housing counterbore. Another embodiment comprises a ring of polymer material held in place by a metallic retaining ring pressed into a gap between the inside diameter of the polymer ring and the small internal diameter of a trepanned channel in the control plate, and a metallic retaining ring pressed into the gap between the outside diameter of the polymer ring and the large internal diameter of the trepanned channel in the control plate. Another embodiment comprises a small diameter central insert of a corrosion resistant Nickel alloy typically retained by welding to the larger control plate. Another embodiment comprises a control plate substantially made of a corrosion resistant Nickel alloy with a cover piece optionally made from another alloy.
[0005] In one aspect of the present disclosure, a valve control plate is provided that is configured to sealingly engage a fluid conduit opening surrounded by a planar orifice ridge. The valve control plate comprises a valve control plate body and a valve seat insert. The valve control plate body is formed from a first material having a first hardness, the valve control plate body having a first surface configured to face toward the fluid conduit opening. The valve control plate body has a recess defined in the first surface of the valve control plate body. The valve seat insert is formed from a second material having a second hardness that is less than the first hardness, the valve seat insert having a first surface configured to face toward the fluid conduit opening and sealingly engage the planar orifice ridge, the valve seat insert being received in the recess.
[0006] In some embodiments, the recess is one of a counterbore or a trepanned groove.
[0007] In some embodiments, a volume of the second material is smaller than a volume of the first material.
[0008] In some embodiments, the first material is a metal, the recess is a counterbore defined in the first surface of the valve control plate body, the second material is a polymer material, and the valve seat insert is retained in the counterbore by a retaining ring located at an outer periphery of the valve seat insert. In accordance with an exemplary embodiment, the valve seat insert may be configured to engage a planar orifice ridge having a diameter of 4 mm or less.
[0009] In some embodiments, the second material is a polymer material, the recess is a trepanned groove defined in the first surface of the valve control plate body, the valve seat insert is ring-shaped, and the first material is a metal. In some embodiments, the valve seat insert is retained in the trepanned groove by an inner retaining ring located at an inner periphery of the valve seat insert and an outer retaining ring located at an outer periphery of the valve seat insert. In other embodiments, the valve seat insert is retained in the trepanned groove by posts, columns, and/or bridges. In accordance with an exemplary embodiment, the valve seat insert may be configured to engage a planar orifice ridge having a diameter of 4 mm or greater.
[0010] In some embodiments, the first material is a first metal, the recess is a counterbore defined in the first surface of the control plate body, the second material is a second metal different from the first metal, and the valve seat insert is retained in the counterbore by welding the valve seat insert to the control plate body. In accordance with an exemplary embodiment, the valve seat insert may be configured to engage a planar orifice ridge having a diameter of 4 mm or less.
[0011] In some embodiments, a region of the first surface of the valve seat insert that sealingly engages the planar orifice ridge is planar.
[0012] In another aspect of the present disclosure, a valve bonnet for use with a control valve body is provided. The control valve body is formed from a first material having a first hardness and has a fluid conduit opening surrounded by a planar orifice ridge. The valve bonnet comprises a bonnet body, a valve diaphragm in sealing engagement with the bonnet body at an outer periphery of the valve diaphragm, a control shaft secured to the diaphragm, the control shaft having a shank projecting from the control shaft, and a valve control plate. The valve control plate is secured to the shank and at least a portion of the valve control plate is formed from a second material having a second hardness that is less than the first hardness, the at least a portion of the valve control plate being configured to sealingly engage the planar orifice ridge. In some embodiments, the at least a portion of the valve control plate is configured to engage a planar orifice ridge that is one of circular and non-circular. In some embodiments, the valve diaphragm is formed integrally with the bonnet body and the control shaft is integrally formed with the diaphragm. In other embodiments, the diaphragm is formed separately from the bonnet body and is welded to the bonnet body.
[0013] In some embodiments, the valve control plate further includes a valve control plate body having a trepanned groove defined in the valve control plate body, and the at least a portion of the valve control plate is a valve seat insert that fills the trepanned groove. In some embodiments, the valve seat insert is molded into the trepanned groove, and in some embodiments, the valve seat insert is retained in the trepanned groove by posts, columns, and/or bridges.
[0014] In another aspect of the present disclosure, a control valve is provided. The control valve comprises a valve body, a bonnet body secured to the valve body, a valve diaphragm, a control shaft, and a valve control plate. The valve body has a fluid inlet conduit terminating at a first fluid conduit opening, a fluid outlet conduit commencing at a second fluid conduit opening, and an orifice ridge formed from a first material having a first hardness and surrounding the first fluid conduit opening. The valve diaphragm is in sealing engagement with the bonnet body at an outer periphery of the valve diaphragm. The control shaft is secured to the diaphragm, and a shank projects from the control shaft. The valve control plate is secured to the shank and at least a portion of the valve control plate is formed from a second material having a second hardness that is less than the first hardness, the at least a portion of the valve control plate being configured to sealingly engage the orifice ridge.
[0015] In some embodiments, the orifice ridge is circular or non-circular.
[0016] In some embodiments, the valve control plate includes a valve control plate body having a trepanned groove defined in the valve control plate body, and the at least a portion of the valve control plate is a valve seat insert that fills the trepanned groove. In some embodiments, the valve seat insert is molded into the trepanned groove, and in some embodiments, the valve seat insert is retained in the trepanned groove by posts, columns, and/or bridges.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a cross-sectioned perspective view of a representative valve with a control plate having a polymer material insert and a small orifice ridge of maximal span.
[0018] FIG. 2 is a cross-sectioned perspective view of a representative valve with a control plate having a polymer material insert and a large orifice ridge of typical span.
[0019] FIG. 3 is a cross-sectioned perspective view of a representative valve with a control plate having a soft corrosion resistant alloy insert and a small orifice ridge of maximal span.
[0020] FIG. 4 is a cross-sectioned perspective view of a representative valve with a control plate having a soft corrosion resistant alloy body and a large orifice ridge of typical span.
[0021] FIG. 5 is a cross-sectioned perspective view of another representative valve with an alternate design soft corrosion resistant alloy control plate.
[0022] FIG. 6A is a cross-sectioned perspective view of another representative valve with an alternate design polymer insert control plate.
[0023] FIG. 6B is an enlarged perspective section view of the control plate illustrated in FIG. 6A to further illustrate construction of the polymer material insert.
[0024] FIG. 6C is a view of a molded polymer insert without the metal control plate body, to further illustrate the geometry of the polymer material insert.
[0025] FIG. 6D is an enlarged perspective section view of an alternate control plate for use in the valve illustrated in FIG. 6A to further illustrate construction of the polymer material insert.
[0026] FIG. 6E is a view of a molded polymer insert without the metal control plate body, to further illustrate the geometry of the polymer material insert
[0027] FIG. 6F is an enlarged perspective section view of another alternate control plate for use in the valve illustrated in FIG. 6A to further illustrate construction of the polymer material insert.
[0028] FIG. 6G is a view of a molded polymer insert without the metal control plate body, to further illustrate the geometry of the polymer material insert.
DETAILED DESCRIPTION
[0029] Embodiments of the present invention are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. Aspects of the present invention are capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phrasing and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The use of directional adjectives “inner”, “outer,” “upper,” “lower,” and like terms, are meant to assist with understanding relative relationships among design elements and should not be construed as meaning an absolute direction in space nor regarded as limiting. In the following design discussions fluid flow is typically described as proceeding from a first fluid conduit, through the controlling portion of the valve, and then through a second fluid conduit. Designers will of course appreciate the discussed direction is merely a matter of descriptive convenience, fluid flow may proceed in an opposite sequence, and should not be considered as limiting.
[0030] In most current high purity valve designs a diaphragm type of moveable sealing structure is the preferred approach. Using a diaphragm to contain a controlled fluid, while allowing easy motion of a moveable control element, has become standard practice. In many such valve designs the diaphragm serves as the moveable control element and valve shut-off is achieved by having the diaphragm itself press against a narrow ring of polymer material surrounding a fluid conduit opening. Designers making valves intended for proportional, or modulating, control of fluid delivery within industrial processes making semiconductor devices may find direct contacting type diaphragm valves have insufficiently gradual control curves. One type of known alternative design has a substantially flat control plate moving toward or away from a metallic lip or orifice ridge surrounding a fluid conduit opening. Complications may however arise when the diaphragm itself is not the element best suited to blocking fluid flow through the valve and shut-off sealing against a metallic structure can be problematic.
[0031] FIG. 1 illustrates a representative example of a proportional control valve 100 using diaphragm sealing and also having a control plate 140 which abuts an orifice ridge 118 surrounding a centrally located fluid conduit opening 112 . The proportional control valve 100 comprises a valve body 119 having a first fluid conduit 110 and a second fluid conduit 114 , each of which communicates fluid to or from a valve chamber 150 , and a valve bonnet (bonnet body) 169 sealed to the valve body 119 by a gasket 165 , the bonnet 169 having a diaphragm 167 allowing movement of the attached control plate 140 within the valve chamber 150 . The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 112 , in fluid communication with the first fluid conduit 110 and surrounded by the orifice ridge 118 , whereby at least a portion of the control plate 140 may be moved toward or away from the orifice ridge 118 to create a small clearance control gap (not shown) through which fluid may controllably flow. The controllable fluid flow may transit into the valve chamber 150 from whence it may exit through an offset fluid conduit opening 116 in fluid communication with the second fluid conduit 114 . In the present example valve 100 , an actuator (not shown) may apply a retracting force to a control shaft 182 to deflect the diaphragm 167 and thereby modulate the conductance through the valve by changing the control gap. In the present FIG. 1 illustration the valve 100 is completely closed in a no-flow condition so there is no control gap shown.
[0032] Achieving leak-free valve shut-off when the control plate 140 contacts the orifice ridge 118 may be difficult and moreover the criteria for what constitutes leak-free operation may differ among design applications. For example, not producing any gas bubbles when the valve outlet is submerged in water might be sufficient in one circumstance while having a helium gas leak rate less than 10 e-9 sccm/sec might be required for another situation. A valve design having a polymer material contact a metallic material upon closure is known to generally provide among the most leak-tight of shut-off arrangements. But polymer materials usually absorb moisture and consequently in high purity applications it is desirable to minimize the total amount of polymer material exposed to the controlled fluid. In the representative proportional control valve 100 this goal of reducing polymer content is achieved by creating a control plate 140 comprising a metallic control plate body 146 and an insert 130 of polymer material having a relatively small volume. The orifice ridge 118 may be considered as having a “maximal span” relative to the polymer insert 130 in that the orifice ridge engages the polymer insert adjacent an outer periphery of the insert.
[0033] A metallic control plate body 146 of the control plate 140 can be machined as a flat disk having a central thru-hole 142 with a counterbore 144 on the side intended to face the central fluid conduit opening 112 . The counterbore 144 will enable the metallic control plate body 146 to function as a seat housing whereby a polymer seat insert 130 may be retained therein to provide a more compliant sealing material of reduced volume. In manufacturing the illustrated valve design 100 the control plate body 146 is placed onto a shank 181 , projecting from the control shaft 182 and diaphragm 167 , which passes through the central thru-hole 142 . The shank 181 and control plate body 146 may be welded together at the central thru-hole 142 interface using electron beam, laser, TIG, or any equivalent welding process. Any resulting minor weld bead excess may be machined off to match the bottom of the counterbore 144 . The polymer material insert 130 may subsequently be placed into the counterbore 144 and held in place by inserting a metallic retaining ring 132 into a space around the outer periphery of the polymer material insert 130 within the outer diameter of the counterbore 144 . The complete assembly may then undergo final finishing for flatness (by lapping, for example) as needed for good valve function. This design approach is especially advantageous for valves having an orifice ridge of about 4 mm diameter or less.
[0034] The polymer material insert 130 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 118 .
[0035] FIG. 2 illustrates a representative example of a proportional control valve 200 using diaphragm sealing and also having a control plate 240 which abuts an orifice ridge 218 surrounding a central fluid conduit opening 212 . The proportional control valve 200 comprises a valve body 219 having a first fluid conduit 210 and a second fluid conduit 214 , each of which communicates fluid to or from a valve chamber 250 , and a valve bonnet 269 sealed to the valve body 219 by a gasket 265 , the bonnet 269 having a diaphragm 267 allowing movement of the attached control plate 240 within the valve chamber 250 . The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 212 , in fluid communication with the first fluid conduit 210 and surrounded by the orifice ridge 218 , whereby at least a portion of the control plate 240 may be moved toward or away from the orifice ridge 218 to create a small clearance control gap (not shown) through which fluid may controllably flow. The controllable fluid flow may transit into the valve chamber 250 from whence it may exit through an offset fluid conduit opening 216 in fluid communication with the second fluid conduit 214 . In the present example valve 200 , an actuator (not shown) may apply a retracting force to a control shaft 282 to deflect the diaphragm 267 and thereby modulate the conductance through the valve by changing the control gap. In the present FIG. 2 illustration the valve 200 is completely closed in a no-flow condition so there is no control gap shown.
[0036] In the representative proportional control valve 200 the goal of reducing polymer content is achieved by creating a control plate 240 comprising a metallic control plate body 246 and a ring-shaped insert 230 of polymer material having a relatively small volume. The orifice ridge 218 may be considered as having a “typical span” relative to the ring-shaped insert 230 in that the orifice ridge engages the insert adjacent a more central region of the insert 230 located between an inner periphery and an outer periphery of the insert. It should be appreciated that FIG. 2 is not drawn to scale, and that the volume of the polymer can be less than that illustrated in at least some embodiments. The metallic control plate body 246 of the control plate 240 can be machined as a flat disk having a central thru-hole 242 and a trepanned (i.e., ring-shaped) groove 245 on the side intended to face the central fluid conduit opening 212 . The trepanned groove 245 will enable the metallic control plate body 246 to function as a seat housing whereby a polymer material insert 230 may be retained therein to provide a more compliant sealing material of reduced volume. In manufacturing the illustrated valve design 200 the ring-shaped polymer material insert 230 may be placed into the trepanned groove 245 and held in place by inserting a metallic inner retaining ring 234 into a space around the inner diameter of the trepanned groove 245 within the inner diameter of the ring-shaped polymer insert 230 , and inserting a metallic outer retaining ring 236 into a space around the outer periphery of the ring-shaped polymer insert 230 within the outer diameter of the trepanned groove 245 . The control plate 240 is subsequently placed onto a shank 281 , projecting from the control shaft 282 and diaphragm 267 , which passes through the central thru-hole 242 . The shank 281 and control plate body 246 may be welded together at the central thru-hole 242 interface using electron beam, laser, TIG, or any equivalent welding process. Any resulting minor weld bead excess may be machined off the control plate 240 surface as well as any splatter on the ring-shaped polymer insert 230 . The complete assembly may then undergo final finishing for flatness (by lapping, for example) as needed for good valve function. This design approach is especially advantageous for valves having an orifice ridge maximal span greater than about 4 mm. It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure.
[0037] In addition to concerns discussed above regarding moisture absorption by polymer materials, it is also known that many gases will diffuse through polymers. Although the diffusion occurs at a very low rate it may amount to detectable quantities which are considered undesirable or even problematic. Additionally, in nuclear science applications a problematic diffusion of radioactive gas may also lead to a simultaneous destruction of the polymer material. A valve having metal to metal sealing is free of these concerns but it is difficult to achieve good shut-off performance in such designs. Moreover, cold welding between very clean valve metallic components can be a potential problem. One design approach is to make the valve of two dissimilar metallic materials to avoid cold welding and also provide dissimilar hardness to enhance shut-off. FIG. 3 , FIG. 4 , and FIG. 5 illustrate embodiments of a control plate for implementing a metal to metal valve design.
[0038] The polymer material insert 230 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 218 .
[0039] FIG. 3 illustrates a representative example of a proportional control valve 300 using diaphragm sealing and also having a control plate 340 which abuts an orifice ridge 318 surrounding a central fluid conduit opening 312 . The proportional control valve 300 comprises a valve body 319 having a first fluid conduit 310 and a second fluid conduit 314 , each of which communicates fluid to or from a valve chamber 350 , and a valve bonnet 369 sealed to the valve body 319 by a gasket 365 , the bonnet 369 having a diaphragm 367 allowing movement of the attached control plate 340 within the valve chamber 350 . The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 312 , in fluid communication with the first fluid conduit 310 and surrounded by the orifice ridge 318 , whereby at least a portion of the control plate 340 may be moved toward or away from the orifice ridge 318 to create a small clearance control gap (not shown) through which fluid may controllably flow. The controllable fluid flow may transit into the valve chamber 350 from whence it may exit through an offset fluid conduit opening 316 in fluid communication with the second fluid conduit 314 . In the present example valve 300 , an actuator (not shown) may apply a retracting force to a control shaft 382 to deflect the diaphragm 367 and thereby modulate the conductance through the valve by changing the control gap. In the present FIG. 3 illustration the valve 300 is completely closed in a no-flow condition so there is no control gap shown.
[0040] In the representative proportional control valve 300 enhancing shut-off performance is achieved by creating a control plate 340 comprising a metallic control plate body 346 and a metallic insert 330 of less hardness than the orifice ridge 318 . The orifice ridge 318 may be considered as having a “maximal span” relative to the metallic insert 330 in that the orifice ridge engages the metallic insert adjacent an outer periphery of the insert. The metallic control plate body 346 of the control plate 340 can be machined as a flat disk having a central thru-hole 342 with a counterbore 344 on the side intended to face the central fluid conduit opening 312 . The counterbore 344 will enable the metallic control plate body 346 to function as a seat housing whereby an annealed, or preferably fully annealed, corrosion resistant metallic alloy insert 330 may be retained therein to provide a more compliant sealing material. In manufacturing the illustrated valve design 300 the control plate body 346 is placed onto a shank 381 , projecting from the control shaft 382 and diaphragm 367 , which passes through the central thru-hole 342 .
[0041] The shank 381 and control plate body 346 may be welded together at the central thru-hole 342 interface using electron beam, laser, TIG, or any equivalent welding process. Any resulting minor weld bead excess may be machined off to match the bottom of the counterbore 344 . The annealed, or fully annealed, corrosion resistant metallic alloy insert 330 may subsequently be placed into the counterbore 344 and held in place by using electron beam, laser, TIG, or any equivalent welding process around the outer periphery of the insert 330 and the inner diameter of the counterbore 344 . Alternatively, an interference fit between the outer diameter of the metallic alloy insert 330 and the inner diameter of the counterbore 344 may be considered sufficient to retain the insert 330 . The complete assembly may then undergo final finishing for flatness (by lapping, or single point diamond turning, for example) as needed for good valve function. This design approach is especially advantageous for valves having an orifice ridge of about 4 mm diameter or less. In a typical application the orifice ridge 318 will be made of one alloy while the metallic alloy seat insert 330 will be made from a different alloy. One usual choice of materials is type 316 stainless for the orifice ridge 318 and a corrosion resistant nickel alloy (such as Hastelloy® C-22® available from Haynes International) for the insert 330 .
[0042] The metallic insert 330 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 318 .
[0043] FIG. 4 illustrates a representative example of a proportional control valve 400 using diaphragm sealing and also having a control plate 440 which abuts an orifice ridge 418 surrounding a central fluid conduit opening 412 . The proportional control valve 400 comprises a valve body 419 having a first fluid conduit 410 and a second fluid conduit 414 , each of which communicates fluid to or from a valve chamber 450 , and a valve bonnet 469 sealed to the valve body 419 by a gasket 465 , the bonnet 469 having a diaphragm 467 allowing movement of the attached control plate 440 within the valve chamber 450 . The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 412 , in fluid communication with the first fluid conduit 410 and surrounded by an orifice ridge 418 , whereby at least a portion of the control plate 440 may be moved toward or away from the orifice ridge 418 to create a small clearance control gap (not shown) through which fluid may controllably flow. The controllable fluid flow may transit into the valve chamber 450 from whence it may exit through an offset fluid conduit opening 416 in fluid communication with the second fluid conduit 414 . In the present example valve 400 , an actuator (not shown) may apply a retracting force to a control shaft 482 to deflect the diaphragm 467 and thereby modulate the conductance through the valve by changing the control gap. In the present FIG. 4 illustration the valve 400 is completely closed in a no-flow condition so there is no control gap shown.
[0044] In the representative proportional control valve 400 enhancing shut-off performance is achieved by creating a control plate 440 comprising a metallic control plate body 446 of less hardness than the orifice ridge 418 and a metallic cover piece 430 . The orifice ridge 418 may be considered as having a “typical span” relative to the control plate body 446 in that the orifice ridge engages the control plate body adjacent a more central region of the control plate body 446 located between an inner periphery and an outer periphery of the control plate body 446 . The metallic control plate body 446 of the control plate 440 can be machined from an annealed, or preferably fully annealed, corrosion resistant alloy as a flat disk having a central thru-hole 442 with a counterbore 444 on the side intended to face the central fluid conduit opening 412 . The counterbore 444 enables the attachment process by providing access to the moveable valve elements. In manufacturing the illustrated valve design 400 the control plate body 446 is placed onto a shank 481 , projecting from the control shaft 482 and diaphragm 467 , which passes through the central thru-hole 442 . The shank 481 and control plate body 446 may be welded together at the central thru-hole 442 interface using electron beam, laser, TIG, or any equivalent welding process. Any resulting minor weld bead excess may be machined off to match the bottom of the counterbore 444 . A suitable metallic cover piece 430 may subsequently be placed into the counterbore 444 and held in place by using electron beam, laser, TIG, or any equivalent welding process around the outer periphery of the cover piece 430 and the inner diameter of the counterbore 444 . Alternatively, an interference fit between the outer diameter of the metallic cover piece 430 and the inner diameter of the counterbore 444 may be considered sufficient to retain the cover piece 430 . The complete assembly may then undergo final finishing for flatness (by lapping, or single point diamond turning, for example) as needed for good valve function. This design approach is especially advantageous for valves having an orifice ridge maximal span greater than about 4 mm. It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure. In a typical application the orifice ridge 418 will be made of one alloy while the metallic control plate body 446 will be made from a different alloy. One usual choice of materials is type 316 stainless for the orifice ridge 418 and a corrosion resistant nickel alloy (such as Hastelloy® C-22® available from Haynes International) for the control plate body 446 . The metallic cover piece 430 may be made from the same material as either the orifice ridge 418 or the control plate 440 , or from yet another different alloy.
[0045] The cover piece 430 and the control plate body 446 are provided as separate components in FIG. 4 to allow for improved welding of the control plate 440 to the shank 481 . First, the control plate body 446 is welded to the shank 481 . Next the cover piece 430 is welded to the control plate body 446 . Then cover piece 430 and the control plate body 446 can undergo finishing for flatness (e.g. by lapping, or single point diamond turning, or another method).
[0046] In some embodiments, the structure of FIG. 4 could be provided without the cover piece 430 , because the cover piece 430 is not used to engage the orifice ridge 418 .
[0047] The term cover piece, as used herein, is used to describe an insert in which the insert itself is not used to sealingly engage the orifice ridge.
[0048] The control plate body 446 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 418 .
[0049] FIG. 5 illustrates a representative example of a proportional control valve 500 using diaphragm sealing and also having a control plate 540 which abuts an orifice ridge 518 surrounding a central fluid conduit opening 512 . The proportional control valve 500 comprises a valve body 519 having a first fluid conduit 510 and a second fluid conduit 514 , each of which communicates fluid to or from a valve chamber 550 , and a valve bonnet 569 sealed to the valve body 519 by a gasket 565 , the bonnet 569 having a diaphragm 567 allowing movement of the attached control plate 540 within the valve chamber 550 . The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 512 , in fluid communication with the first fluid conduit 510 and surrounded by an orifice ridge 518 , whereby at least a portion of the control plate 540 may be moved toward or away from the orifice ridge 518 to create a small clearance control gap (not shown) through which fluid may controllably flow. The controllable fluid flow may transit into the valve chamber 550 from whence it may exit through an offset fluid conduit opening 516 in fluid communication with the second fluid conduit 514 . In the present example valve 500 an actuator (not shown) may apply a retracting force to a control shaft 582 to deflect the diaphragm 567 and thereby modulate the conductance through the valve by changing the control gap. In the present FIG. 5 illustration the valve 500 is completely closed in a no-flow condition so there is no control gap shown.
[0050] The metallic control plate 540 can be machined from an annealed or preferably fully annealed corrosion resistant alloy, of less hardness than the orifice ridge, as a flat disk having a blind central counterbore 542 on the side intended to face the diaphragm 567 . In manufacturing the illustrated valve design 500 the control plate 540 may be press fit onto a shank 581 , projecting from the control shaft 582 and diaphragm 567 . Alternatively, the shank 581 and control plate 540 may be welded together using electron beam, laser, or any equivalently energetic welding process suitable to penetrate the thin central portion 530 of the control plate 540 and fuse it to the shank 581 . It should be noted that in the embodiment depicted in FIG. 5 , the shank 581 may extend deeper into the control plate 540 than, for example, the embodiments depicted in FIGS. 3 and 4 to aid in the welding process. The thin central portion 530 may further include a detent or other type of weld preparation (not shown) to reduce the amount of material in the central portion 530 of the control plate to minimize the amount of energy or time needed to weld the central portion 530 of the control plate 540 to the shank 581 . Any resulting minor weld bead excess may be machined off and the complete assembly may then undergo final finishing for flatness (by lapping, or single point diamond turning, for example, or another method) as needed for good valve function. This design approach is especially advantageous due to the lesser number of machined pieces and its suitability for use with a variety of orifice ridge sizes and shapes. It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure and an ensemble plurality of coplanar orifice ridges is also contemplated. In a typical application the orifice ridge 518 will be made of one alloy while the metallic control plate 540 will be made from a different alloy. One usual choice of materials is type 316 stainless for the orifice ridge 518 and a corrosion resistant nickel alloy (such as Hastelloy® C-22® available from Haynes International) for the control plate 540 .
[0051] The control plate 540 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 518
[0052] FIG. 6A and FIG. 6B illustrate a representative example of a proportional control valve 600 using diaphragm sealing and also having a control plate 640 which abuts an orifice ridge 618 surrounding an inner fluid conduit opening 612 . The proportional control valve 600 comprises a valve body 619 having a first fluid conduit 610 and a second fluid conduit 614 , each of which communicates fluid to or from a valve chamber 650 , and a valve bonnet 669 sealed to the valve body 619 by a gasket 665 , the bonnet 669 having a diaphragm 667 allowing movement of the attached control plate 640 within the valve chamber 650 . The manner of controlling fluid flow may be further understood by considering the inner fluid conduit opening 612 , in fluid communication with the first fluid conduit 610 and surrounded by the orifice ridge 618 , whereby at least a portion of the control plate 640 may be moved toward or away from the orifice ridge 618 to create a small clearance control gap (not shown) through which fluid may controllably flow. The controllable fluid flow may transit into the valve chamber 650 from whence it may exit through an outer fluid conduit opening 616 in fluid communication with the second fluid conduit 614 . In the present example valve 600 , an actuator (not shown) may apply a retracting force to a control shaft 682 to deflect the diaphragm 667 and thereby modulate the conductance through the valve by changing the control gap. In the present FIG. 6A illustration the valve 600 is completely closed in a no-flow condition so there is no control gap shown.
[0053] In the representative proportional control valve 600 the goal of reducing polymer content is achieved by creating a control plate 640 comprising a metallic control plate body 646 and a molded insert 630 of polymer material. As may be seen in FIG. 6B , the metallic control plate body 646 of the control plate 640 can be machined as a flat disk having a central thru-hole 642 and a plurality of concentric ring-shaped grooves 648 on the side intended to face the inner fluid conduit opening 612 . The grooves 648 enable the metallic control plate body 646 to function as a seat housing whereby a polymer material insert 630 may be retained therein, as will be further explained, to provide a more compliant sealing material of reduced volume. The remaining metal 649 between the concentric grooves 648 in the control plate body 646 provides meaningful reduction of the total volume of the molded insert 630 . Vent holes 644 , defined in the flat back side of the disk facing away from the inner fluid opening 612 , are made centered between the grooves 648 deep enough with sufficient diameter to intersect the bottoms of adjacent grooves 648 while leaving the majority of the remaining metal 649 intact. In manufacturing the illustrated control plate 640 the polymer material insert 630 may be formed by compression molding (e.g. starting with polychlorotrifluoroethene (PCTFE) powder and polymerizing under the effect of heat and pressure) directly into the control plate body 646 by known methods. During the molding process bridges 634 of polymer material will surround parts of the remaining metal 649 and fill the vent holes 644 . The polymer material bridges 634 surrounding the remaining metal 649 thus lock the molded polymer insert 630 into the metallic control plate body 646 . FIG. 6C shows a perspective view of a molded polymer insert 630 , with the metallic control plate body 646 not shown for the purpose of illustrating the geometry of the molded polymer insert 630 . The molded polymer insert 630 has a plurality of annular ridges 638 , that are complementary with the grooves 648 and which fill the grooves 648 that are defined in the control plate body 646 .
[0054] The control plate 640 comprising the metallic control plate body 646 including the molded polymer insert 630 may be attached to a shank 681 , projecting from the control shaft 682 and diaphragm 667 , by press fit into the central thru-hole 642 . Alternatively, prior to the above described molding, the control plate body 646 may first be placed onto the shank 681 and welded together at the central thru-hole 642 interface using electron beam, laser, TIG, or any equivalent welding process. Any resulting minor weld bead excess may be machined off the control plate body 646 surface before molding the insert 630 into the control plate body 646 . The process sequence choice will depend upon practitioners' preference in compression molding techniques. The complete assembly may then undergo final finishing for flatness (by lapping, for example) as needed for good valve function. This design approach is especially advantageous for use with valve bodies having a variety of orifice ridge sizes and shapes. It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure. Careful examination of the illustrated example of FIG. 6A will reveal the orifice ridge 618 is circular but placed off geometric center of the diaphragm 667 and control plate 640 to accommodate a correspondingly large non-circular outer fluid opening 617 because the orifice ridge is so large in diameter.
[0055] An alternate control plate 660 suitable for use in the representative proportional control valve 600 is illustrated in FIG. 6D . A metallic control plate body 676 of the control plate 660 can be machined as a flat disk having a central thru-hole 672 and a wide shallow ring-shaped groove 675 on the side intended to face the inner fluid conduit opening 612 . The groove 675 enables the metallic control plate body 676 to function as a seat housing whereby a polymer material insert 670 may be retained therein, as will be further explained, to provide a more compliant sealing material of reduced volume. A plurality of thru-holes 674 defined in the flat back side of the disk facing away from the inner fluid opening 612 penetrate the wide shallow ring-shaped groove 675 . In manufacturing the illustrated control plate 660 the polymer material insert 670 may be formed by compression molding (e.g. starting with PCTFE powder and polymerizing under the effect of heat and pressure) directly into the control plate body 676 by known methods. During the molding process a plurality of columns 673 of polymer material will fill the thru-holes 674 thereby frictionally locking the polymer material into the groove 675 defined in the metallic control plate body 676 . The geometry of the polymer material insert 670 that is formed by the molding process is shown in FIG. 6E , with the control plate body 676 not shown for illustration purposes. The control plate 660 comprising the metallic control plate body 676 including the molded polymer insert 670 may be attached to a shank 681 , projecting from the control shaft 682 and diaphragm 667 , by press fit into the central thru-hole 672 , or attached in another manner as previously described.
[0056] Another alternate control plate 680 suitable for use in the representative proportional control valve 600 is illustrated in FIG. 6F . A metallic control plate body 696 of the control plate 680 can be machined as a flat disk having a central thru-hole 692 , a wide shallow counterbore 695 , and a plurality of wedge-shaped (being approximately circular sectors) cavities 697 , 698 cut into the bottom of the counterbore 695 on the side intended to face the inner fluid conduit opening 612 . The counterbore 695 and plurality of cavities 697 , 698 enable the metallic control plate body 696 to function as a seat housing whereby a polymer material insert 690 may be retained therein, as will be further explained, to provide a more compliant sealing material of reduced volume. The metal between the between the plurality of wedge-shaped cavities 697 , 698 , in the wide shallow counterbore 695 of the control plate body 696 , form radial ribs 699 . Vent holes 691 , defined in the flat back side of the disk facing away from the inner fluid opening 612 , are made centered over the radial ribs 699 deep enough with sufficient diameter to intersect the bottoms of adjacent wedge-shaped cavities 697 , 698 while leaving the majority of the remaining metal rib 699 intact. A plurality of thru-holes 694 , also defined in the flat back side of the disk facing away from the inner fluid opening 612 , penetrate the bottom of each of the wedge-shaped cavities 697 , 698 . In manufacturing the illustrated valve design 600 the polymer material insert 690 may be formed by compression molding (e.g. starting with PCTFE powder and polymerizing under the effect of heat and pressure) directly into the control plate body 696 by known methods. During the molding process polymer material will fill the thru-holes 694 and surround the metal radial ribs 699 to fill the vent holes 691 . The molded polymer material forms bridges 689 to fill the vent holes and posts 693 to fill the thru-holes 694 . The molded polymer material also forms wedge portions of the insert 690 to fill respective wedge-shaped cavities 697 , 698 . The polymer material surrounding the metal ribs 699 thus lock the molded insert 690 into the metallic control plate body 696 . The geometry of the polymer material insert 690 that is formed by the molding process is shown in FIG. 6G , with the control plate body 696 not shown for illustration purposes. The control plate 680 comprising the metallic control plate body 696 including the molded polymer insert 690 may be attached to a shank 681 , projecting from the control shaft 682 and diaphragm 670 , by press fit into the central thru-hole 692 , or attached in another manner as previously described.
[0057] In each of FIGS. 6A-6G , the respective polymer material insert 630 , 670 , 690 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 618 .
[0058] It should be appreciated that the specific sizes of features shown in FIGS. 6A-6G may be varied and are not necessarily drawn to scale.
[0059] Referring again to FIG. 2 , the ring-shaped insert 230 could be molded in the control plate body 246 of the control plate 240 and secured within the control plate body 246 of the control plate 240 by retaining features such as the structure of FIGS. 6A-6G . That is, for example, the ring-shaped insert 230 could have columns that are positioned in thru-holes defined in the control plate body 246 , posts that are positioned in thru-holes defined in the control plate body 246 , and/or bridges that are positioned in vent holes defined in the control plate body in a manner similar to that described with respect to FIGS. 6A-6G .
[0060] The counterbores and grooves described above are examples of recesses that can be defined in a control plate body. In some embodiments, an insert can be secured in another type of recess that is defined in the control plate body.
[0061] In some embodiments, a retention mechanism is used to retain an insert in one or more counterbores and/or one or more grooves defined in a control plate body. Some examples of a retention mechanism include a retaining ring located at an outer periphery of the insert, an inner retaining ring located at an inner periphery of the insert and an outer retaining ring located at an outer periphery of the insert, a post, a column, a bridge, and a weld. Other retention mechanisms are possible. It should be appreciated that although embodiments of the present disclosure have been primarily described with respect to diaphragm sealed valves in which a control plate is disposed below and attached to or integrally formed with the diaphragm, aspects of the present disclosure may be readily adapted for use with other types of valves, such as bellows sealed valves similar to those described in U.S. Pat. No. 3,295,191. Moreover, although embodiments of the present disclosure have been described with respect to control valves in which an actuator is used to move an orifice ridge sealing surface of the control plate toward and away from an orifice ridge, this movement need not need not be uniform across the orifice ridge sealing surface of the control plate. For example, embodiments of the present disclosure may readily be used with a valve stroke amplification mechanism, such as disclosed in US Patent Publication No. US2016/0138730 A1, in which an amplifier disc may be used to effect a wedge shaped gap having a higher conductance than would otherwise be obtained.
[0062] Although the embodiments depicted in FIGS. 1-6A are all depicted as showing a valve bonnet body 169 , 269 , 369 , 469 , 569 , 669 in which the diaphragm 167 , 267 , 367 , 467 , 567 , 667 is integrally formed with the bonnet body, it should be appreciated that the present invention is not so limited. Indeed, embodiments of the present disclosure encompass diaphragms that are stamped, punched, or cut out of a piece of sheet metal that is later attached (for example, by welding) to a bonnet body, as well as those in which the diaphragm and bonnet body are integrally formed from a single block of starting material, as shown herein.
[0063] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the scope of the invention. Accordingly, the foregoing description and drawings are by way of example only. | A control plate for effecting superior shut-off in a proportional control valve comprises a moveable disk-shaped element that has a flat surface, generally perpendicular to the valve axis of symmetry when closed, and translates toward or away from an orifice surrounded by a narrow lip or orifice ridge. Enhanced leak tightness in the valve shut-off condition is achieved by selectively incorporating into the control plate materials that are softer than the material comprising the orifice ridge. | Summarize the key points of the given document. | [
"CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit under 35 U.S.C. §119(e) to U.S. Provisional Application Ser.",
"No. 62/190,478 titled “CONTROL PLATE IN A VALVE,” filed Jul. 9, 2015, and Provisional Application Ser.",
"No. 62/292,526 titled “CONTROL PLATE IN A VALVE,” filed Feb. 8, 2016, each of which is incorporated by reference herein in its entirety for all purposes.",
"BACKGROUND [0002] The present invention is related to a moveable portion of a fluid control valve that may be actively positioned, anywhere between an extreme open condition and an extreme closed condition, to adjust a flow of fluid passing therethrough.",
"The invention is particularly useful in valves intended for proportional or modulating control of fluid delivery within industrial processes making semiconductor devices, pharmaceuticals, or fine chemicals, and many similar high-purity fluid delivery systems that simultaneously demand a leak-tight shut-off in the fully closed condition along with proportional control.",
"Many combinations of metallic and elastomeric elements enhancing valve shut-off are known in the art.",
"SUMMARY [0003] Applicant has invented uniquely manufacturable configurations of a moveable valve element suited for use with various sized valve orifices.",
"The moveable disk-shaped element has a flat surface generally perpendicular to the valve axis of symmetry when closed and translates toward or away from an orifice surrounded by a narrow lip or orifice ridge.",
"This combination of valve structures is sometimes referred to as being the jet &",
"seat class of fluid pathway element combinations.",
"In this disclosure the flat surfaced element (colloquially a seat) which closes against the narrow lip (colloquially a jet) surrounding the orifice is often referred to as a control plate.",
"Enhanced leak tightness in the valve shut-off condition is provided by selectively incorporating into the control plate materials that are softer than the material comprising the lip or ridge surrounding the orifice.",
"Control plate materials being softer than the orifice ridge-lip allows elastic deformation of the control plate surface as it presses against the orifice ridge-lip and thereby enhances the sealing effected between the control plate and the orifice ridge-lip.",
"The disclosed arrangements can use welding or interference press-fit pieces to avoid problems associated with having threads within high purity fluid pathways.",
"[0004] One embodiment comprises a metallic seat housing having a small diameter central insert of polymer material held in place by a metallic retaining ring pressed into a gap between the outside diameter of the polymer insert and the inside diameter of a seat housing counterbore.",
"Another embodiment comprises a ring of polymer material held in place by a metallic retaining ring pressed into a gap between the inside diameter of the polymer ring and the small internal diameter of a trepanned channel in the control plate, and a metallic retaining ring pressed into the gap between the outside diameter of the polymer ring and the large internal diameter of the trepanned channel in the control plate.",
"Another embodiment comprises a small diameter central insert of a corrosion resistant Nickel alloy typically retained by welding to the larger control plate.",
"Another embodiment comprises a control plate substantially made of a corrosion resistant Nickel alloy with a cover piece optionally made from another alloy.",
"[0005] In one aspect of the present disclosure, a valve control plate is provided that is configured to sealingly engage a fluid conduit opening surrounded by a planar orifice ridge.",
"The valve control plate comprises a valve control plate body and a valve seat insert.",
"The valve control plate body is formed from a first material having a first hardness, the valve control plate body having a first surface configured to face toward the fluid conduit opening.",
"The valve control plate body has a recess defined in the first surface of the valve control plate body.",
"The valve seat insert is formed from a second material having a second hardness that is less than the first hardness, the valve seat insert having a first surface configured to face toward the fluid conduit opening and sealingly engage the planar orifice ridge, the valve seat insert being received in the recess.",
"[0006] In some embodiments, the recess is one of a counterbore or a trepanned groove.",
"[0007] In some embodiments, a volume of the second material is smaller than a volume of the first material.",
"[0008] In some embodiments, the first material is a metal, the recess is a counterbore defined in the first surface of the valve control plate body, the second material is a polymer material, and the valve seat insert is retained in the counterbore by a retaining ring located at an outer periphery of the valve seat insert.",
"In accordance with an exemplary embodiment, the valve seat insert may be configured to engage a planar orifice ridge having a diameter of 4 mm or less.",
"[0009] In some embodiments, the second material is a polymer material, the recess is a trepanned groove defined in the first surface of the valve control plate body, the valve seat insert is ring-shaped, and the first material is a metal.",
"In some embodiments, the valve seat insert is retained in the trepanned groove by an inner retaining ring located at an inner periphery of the valve seat insert and an outer retaining ring located at an outer periphery of the valve seat insert.",
"In other embodiments, the valve seat insert is retained in the trepanned groove by posts, columns, and/or bridges.",
"In accordance with an exemplary embodiment, the valve seat insert may be configured to engage a planar orifice ridge having a diameter of 4 mm or greater.",
"[0010] In some embodiments, the first material is a first metal, the recess is a counterbore defined in the first surface of the control plate body, the second material is a second metal different from the first metal, and the valve seat insert is retained in the counterbore by welding the valve seat insert to the control plate body.",
"In accordance with an exemplary embodiment, the valve seat insert may be configured to engage a planar orifice ridge having a diameter of 4 mm or less.",
"[0011] In some embodiments, a region of the first surface of the valve seat insert that sealingly engages the planar orifice ridge is planar.",
"[0012] In another aspect of the present disclosure, a valve bonnet for use with a control valve body is provided.",
"The control valve body is formed from a first material having a first hardness and has a fluid conduit opening surrounded by a planar orifice ridge.",
"The valve bonnet comprises a bonnet body, a valve diaphragm in sealing engagement with the bonnet body at an outer periphery of the valve diaphragm, a control shaft secured to the diaphragm, the control shaft having a shank projecting from the control shaft, and a valve control plate.",
"The valve control plate is secured to the shank and at least a portion of the valve control plate is formed from a second material having a second hardness that is less than the first hardness, the at least a portion of the valve control plate being configured to sealingly engage the planar orifice ridge.",
"In some embodiments, the at least a portion of the valve control plate is configured to engage a planar orifice ridge that is one of circular and non-circular.",
"In some embodiments, the valve diaphragm is formed integrally with the bonnet body and the control shaft is integrally formed with the diaphragm.",
"In other embodiments, the diaphragm is formed separately from the bonnet body and is welded to the bonnet body.",
"[0013] In some embodiments, the valve control plate further includes a valve control plate body having a trepanned groove defined in the valve control plate body, and the at least a portion of the valve control plate is a valve seat insert that fills the trepanned groove.",
"In some embodiments, the valve seat insert is molded into the trepanned groove, and in some embodiments, the valve seat insert is retained in the trepanned groove by posts, columns, and/or bridges.",
"[0014] In another aspect of the present disclosure, a control valve is provided.",
"The control valve comprises a valve body, a bonnet body secured to the valve body, a valve diaphragm, a control shaft, and a valve control plate.",
"The valve body has a fluid inlet conduit terminating at a first fluid conduit opening, a fluid outlet conduit commencing at a second fluid conduit opening, and an orifice ridge formed from a first material having a first hardness and surrounding the first fluid conduit opening.",
"The valve diaphragm is in sealing engagement with the bonnet body at an outer periphery of the valve diaphragm.",
"The control shaft is secured to the diaphragm, and a shank projects from the control shaft.",
"The valve control plate is secured to the shank and at least a portion of the valve control plate is formed from a second material having a second hardness that is less than the first hardness, the at least a portion of the valve control plate being configured to sealingly engage the orifice ridge.",
"[0015] In some embodiments, the orifice ridge is circular or non-circular.",
"[0016] In some embodiments, the valve control plate includes a valve control plate body having a trepanned groove defined in the valve control plate body, and the at least a portion of the valve control plate is a valve seat insert that fills the trepanned groove.",
"In some embodiments, the valve seat insert is molded into the trepanned groove, and in some embodiments, the valve seat insert is retained in the trepanned groove by posts, columns, and/or bridges.",
"BRIEF DESCRIPTION OF DRAWINGS [0017] FIG. 1 is a cross-sectioned perspective view of a representative valve with a control plate having a polymer material insert and a small orifice ridge of maximal span.",
"[0018] FIG. 2 is a cross-sectioned perspective view of a representative valve with a control plate having a polymer material insert and a large orifice ridge of typical span.",
"[0019] FIG. 3 is a cross-sectioned perspective view of a representative valve with a control plate having a soft corrosion resistant alloy insert and a small orifice ridge of maximal span.",
"[0020] FIG. 4 is a cross-sectioned perspective view of a representative valve with a control plate having a soft corrosion resistant alloy body and a large orifice ridge of typical span.",
"[0021] FIG. 5 is a cross-sectioned perspective view of another representative valve with an alternate design soft corrosion resistant alloy control plate.",
"[0022] FIG. 6A is a cross-sectioned perspective view of another representative valve with an alternate design polymer insert control plate.",
"[0023] FIG. 6B is an enlarged perspective section view of the control plate illustrated in FIG. 6A to further illustrate construction of the polymer material insert.",
"[0024] FIG. 6C is a view of a molded polymer insert without the metal control plate body, to further illustrate the geometry of the polymer material insert.",
"[0025] FIG. 6D is an enlarged perspective section view of an alternate control plate for use in the valve illustrated in FIG. 6A to further illustrate construction of the polymer material insert.",
"[0026] FIG. 6E is a view of a molded polymer insert without the metal control plate body, to further illustrate the geometry of the polymer material insert [0027] FIG. 6F is an enlarged perspective section view of another alternate control plate for use in the valve illustrated in FIG. 6A to further illustrate construction of the polymer material insert.",
"[0028] FIG. 6G is a view of a molded polymer insert without the metal control plate body, to further illustrate the geometry of the polymer material insert.",
"DETAILED DESCRIPTION [0029] Embodiments of the present invention are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings.",
"Aspects of the present invention are capable of other embodiments and of being practiced or of being carried out in various ways.",
"Also, the phrasing and terminology used herein is for the purpose of description and should not be regarded as limiting.",
"The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.",
"The use of directional adjectives “inner”, “outer,” “upper,” “lower,” and like terms, are meant to assist with understanding relative relationships among design elements and should not be construed as meaning an absolute direction in space nor regarded as limiting.",
"In the following design discussions fluid flow is typically described as proceeding from a first fluid conduit, through the controlling portion of the valve, and then through a second fluid conduit.",
"Designers will of course appreciate the discussed direction is merely a matter of descriptive convenience, fluid flow may proceed in an opposite sequence, and should not be considered as limiting.",
"[0030] In most current high purity valve designs a diaphragm type of moveable sealing structure is the preferred approach.",
"Using a diaphragm to contain a controlled fluid, while allowing easy motion of a moveable control element, has become standard practice.",
"In many such valve designs the diaphragm serves as the moveable control element and valve shut-off is achieved by having the diaphragm itself press against a narrow ring of polymer material surrounding a fluid conduit opening.",
"Designers making valves intended for proportional, or modulating, control of fluid delivery within industrial processes making semiconductor devices may find direct contacting type diaphragm valves have insufficiently gradual control curves.",
"One type of known alternative design has a substantially flat control plate moving toward or away from a metallic lip or orifice ridge surrounding a fluid conduit opening.",
"Complications may however arise when the diaphragm itself is not the element best suited to blocking fluid flow through the valve and shut-off sealing against a metallic structure can be problematic.",
"[0031] FIG. 1 illustrates a representative example of a proportional control valve 100 using diaphragm sealing and also having a control plate 140 which abuts an orifice ridge 118 surrounding a centrally located fluid conduit opening 112 .",
"The proportional control valve 100 comprises a valve body 119 having a first fluid conduit 110 and a second fluid conduit 114 , each of which communicates fluid to or from a valve chamber 150 , and a valve bonnet (bonnet body) 169 sealed to the valve body 119 by a gasket 165 , the bonnet 169 having a diaphragm 167 allowing movement of the attached control plate 140 within the valve chamber 150 .",
"The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 112 , in fluid communication with the first fluid conduit 110 and surrounded by the orifice ridge 118 , whereby at least a portion of the control plate 140 may be moved toward or away from the orifice ridge 118 to create a small clearance control gap (not shown) through which fluid may controllably flow.",
"The controllable fluid flow may transit into the valve chamber 150 from whence it may exit through an offset fluid conduit opening 116 in fluid communication with the second fluid conduit 114 .",
"In the present example valve 100 , an actuator (not shown) may apply a retracting force to a control shaft 182 to deflect the diaphragm 167 and thereby modulate the conductance through the valve by changing the control gap.",
"In the present FIG. 1 illustration the valve 100 is completely closed in a no-flow condition so there is no control gap shown.",
"[0032] Achieving leak-free valve shut-off when the control plate 140 contacts the orifice ridge 118 may be difficult and moreover the criteria for what constitutes leak-free operation may differ among design applications.",
"For example, not producing any gas bubbles when the valve outlet is submerged in water might be sufficient in one circumstance while having a helium gas leak rate less than 10 e-9 sccm/sec might be required for another situation.",
"A valve design having a polymer material contact a metallic material upon closure is known to generally provide among the most leak-tight of shut-off arrangements.",
"But polymer materials usually absorb moisture and consequently in high purity applications it is desirable to minimize the total amount of polymer material exposed to the controlled fluid.",
"In the representative proportional control valve 100 this goal of reducing polymer content is achieved by creating a control plate 140 comprising a metallic control plate body 146 and an insert 130 of polymer material having a relatively small volume.",
"The orifice ridge 118 may be considered as having a “maximal span”",
"relative to the polymer insert 130 in that the orifice ridge engages the polymer insert adjacent an outer periphery of the insert.",
"[0033] A metallic control plate body 146 of the control plate 140 can be machined as a flat disk having a central thru-hole 142 with a counterbore 144 on the side intended to face the central fluid conduit opening 112 .",
"The counterbore 144 will enable the metallic control plate body 146 to function as a seat housing whereby a polymer seat insert 130 may be retained therein to provide a more compliant sealing material of reduced volume.",
"In manufacturing the illustrated valve design 100 the control plate body 146 is placed onto a shank 181 , projecting from the control shaft 182 and diaphragm 167 , which passes through the central thru-hole 142 .",
"The shank 181 and control plate body 146 may be welded together at the central thru-hole 142 interface using electron beam, laser, TIG, or any equivalent welding process.",
"Any resulting minor weld bead excess may be machined off to match the bottom of the counterbore 144 .",
"The polymer material insert 130 may subsequently be placed into the counterbore 144 and held in place by inserting a metallic retaining ring 132 into a space around the outer periphery of the polymer material insert 130 within the outer diameter of the counterbore 144 .",
"The complete assembly may then undergo final finishing for flatness (by lapping, for example) as needed for good valve function.",
"This design approach is especially advantageous for valves having an orifice ridge of about 4 mm diameter or less.",
"[0034] The polymer material insert 130 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 118 .",
"[0035] FIG. 2 illustrates a representative example of a proportional control valve 200 using diaphragm sealing and also having a control plate 240 which abuts an orifice ridge 218 surrounding a central fluid conduit opening 212 .",
"The proportional control valve 200 comprises a valve body 219 having a first fluid conduit 210 and a second fluid conduit 214 , each of which communicates fluid to or from a valve chamber 250 , and a valve bonnet 269 sealed to the valve body 219 by a gasket 265 , the bonnet 269 having a diaphragm 267 allowing movement of the attached control plate 240 within the valve chamber 250 .",
"The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 212 , in fluid communication with the first fluid conduit 210 and surrounded by the orifice ridge 218 , whereby at least a portion of the control plate 240 may be moved toward or away from the orifice ridge 218 to create a small clearance control gap (not shown) through which fluid may controllably flow.",
"The controllable fluid flow may transit into the valve chamber 250 from whence it may exit through an offset fluid conduit opening 216 in fluid communication with the second fluid conduit 214 .",
"In the present example valve 200 , an actuator (not shown) may apply a retracting force to a control shaft 282 to deflect the diaphragm 267 and thereby modulate the conductance through the valve by changing the control gap.",
"In the present FIG. 2 illustration the valve 200 is completely closed in a no-flow condition so there is no control gap shown.",
"[0036] In the representative proportional control valve 200 the goal of reducing polymer content is achieved by creating a control plate 240 comprising a metallic control plate body 246 and a ring-shaped insert 230 of polymer material having a relatively small volume.",
"The orifice ridge 218 may be considered as having a “typical span”",
"relative to the ring-shaped insert 230 in that the orifice ridge engages the insert adjacent a more central region of the insert 230 located between an inner periphery and an outer periphery of the insert.",
"It should be appreciated that FIG. 2 is not drawn to scale, and that the volume of the polymer can be less than that illustrated in at least some embodiments.",
"The metallic control plate body 246 of the control plate 240 can be machined as a flat disk having a central thru-hole 242 and a trepanned (i.e., ring-shaped) groove 245 on the side intended to face the central fluid conduit opening 212 .",
"The trepanned groove 245 will enable the metallic control plate body 246 to function as a seat housing whereby a polymer material insert 230 may be retained therein to provide a more compliant sealing material of reduced volume.",
"In manufacturing the illustrated valve design 200 the ring-shaped polymer material insert 230 may be placed into the trepanned groove 245 and held in place by inserting a metallic inner retaining ring 234 into a space around the inner diameter of the trepanned groove 245 within the inner diameter of the ring-shaped polymer insert 230 , and inserting a metallic outer retaining ring 236 into a space around the outer periphery of the ring-shaped polymer insert 230 within the outer diameter of the trepanned groove 245 .",
"The control plate 240 is subsequently placed onto a shank 281 , projecting from the control shaft 282 and diaphragm 267 , which passes through the central thru-hole 242 .",
"The shank 281 and control plate body 246 may be welded together at the central thru-hole 242 interface using electron beam, laser, TIG, or any equivalent welding process.",
"Any resulting minor weld bead excess may be machined off the control plate 240 surface as well as any splatter on the ring-shaped polymer insert 230 .",
"The complete assembly may then undergo final finishing for flatness (by lapping, for example) as needed for good valve function.",
"This design approach is especially advantageous for valves having an orifice ridge maximal span greater than about 4 mm.",
"It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure.",
"[0037] In addition to concerns discussed above regarding moisture absorption by polymer materials, it is also known that many gases will diffuse through polymers.",
"Although the diffusion occurs at a very low rate it may amount to detectable quantities which are considered undesirable or even problematic.",
"Additionally, in nuclear science applications a problematic diffusion of radioactive gas may also lead to a simultaneous destruction of the polymer material.",
"A valve having metal to metal sealing is free of these concerns but it is difficult to achieve good shut-off performance in such designs.",
"Moreover, cold welding between very clean valve metallic components can be a potential problem.",
"One design approach is to make the valve of two dissimilar metallic materials to avoid cold welding and also provide dissimilar hardness to enhance shut-off.",
"FIG. 3 , FIG. 4 , and FIG. 5 illustrate embodiments of a control plate for implementing a metal to metal valve design.",
"[0038] The polymer material insert 230 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 218 .",
"[0039] FIG. 3 illustrates a representative example of a proportional control valve 300 using diaphragm sealing and also having a control plate 340 which abuts an orifice ridge 318 surrounding a central fluid conduit opening 312 .",
"The proportional control valve 300 comprises a valve body 319 having a first fluid conduit 310 and a second fluid conduit 314 , each of which communicates fluid to or from a valve chamber 350 , and a valve bonnet 369 sealed to the valve body 319 by a gasket 365 , the bonnet 369 having a diaphragm 367 allowing movement of the attached control plate 340 within the valve chamber 350 .",
"The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 312 , in fluid communication with the first fluid conduit 310 and surrounded by the orifice ridge 318 , whereby at least a portion of the control plate 340 may be moved toward or away from the orifice ridge 318 to create a small clearance control gap (not shown) through which fluid may controllably flow.",
"The controllable fluid flow may transit into the valve chamber 350 from whence it may exit through an offset fluid conduit opening 316 in fluid communication with the second fluid conduit 314 .",
"In the present example valve 300 , an actuator (not shown) may apply a retracting force to a control shaft 382 to deflect the diaphragm 367 and thereby modulate the conductance through the valve by changing the control gap.",
"In the present FIG. 3 illustration the valve 300 is completely closed in a no-flow condition so there is no control gap shown.",
"[0040] In the representative proportional control valve 300 enhancing shut-off performance is achieved by creating a control plate 340 comprising a metallic control plate body 346 and a metallic insert 330 of less hardness than the orifice ridge 318 .",
"The orifice ridge 318 may be considered as having a “maximal span”",
"relative to the metallic insert 330 in that the orifice ridge engages the metallic insert adjacent an outer periphery of the insert.",
"The metallic control plate body 346 of the control plate 340 can be machined as a flat disk having a central thru-hole 342 with a counterbore 344 on the side intended to face the central fluid conduit opening 312 .",
"The counterbore 344 will enable the metallic control plate body 346 to function as a seat housing whereby an annealed, or preferably fully annealed, corrosion resistant metallic alloy insert 330 may be retained therein to provide a more compliant sealing material.",
"In manufacturing the illustrated valve design 300 the control plate body 346 is placed onto a shank 381 , projecting from the control shaft 382 and diaphragm 367 , which passes through the central thru-hole 342 .",
"[0041] The shank 381 and control plate body 346 may be welded together at the central thru-hole 342 interface using electron beam, laser, TIG, or any equivalent welding process.",
"Any resulting minor weld bead excess may be machined off to match the bottom of the counterbore 344 .",
"The annealed, or fully annealed, corrosion resistant metallic alloy insert 330 may subsequently be placed into the counterbore 344 and held in place by using electron beam, laser, TIG, or any equivalent welding process around the outer periphery of the insert 330 and the inner diameter of the counterbore 344 .",
"Alternatively, an interference fit between the outer diameter of the metallic alloy insert 330 and the inner diameter of the counterbore 344 may be considered sufficient to retain the insert 330 .",
"The complete assembly may then undergo final finishing for flatness (by lapping, or single point diamond turning, for example) as needed for good valve function.",
"This design approach is especially advantageous for valves having an orifice ridge of about 4 mm diameter or less.",
"In a typical application the orifice ridge 318 will be made of one alloy while the metallic alloy seat insert 330 will be made from a different alloy.",
"One usual choice of materials is type 316 stainless for the orifice ridge 318 and a corrosion resistant nickel alloy (such as Hastelloy® C-22® available from Haynes International) for the insert 330 .",
"[0042] The metallic insert 330 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 318 .",
"[0043] FIG. 4 illustrates a representative example of a proportional control valve 400 using diaphragm sealing and also having a control plate 440 which abuts an orifice ridge 418 surrounding a central fluid conduit opening 412 .",
"The proportional control valve 400 comprises a valve body 419 having a first fluid conduit 410 and a second fluid conduit 414 , each of which communicates fluid to or from a valve chamber 450 , and a valve bonnet 469 sealed to the valve body 419 by a gasket 465 , the bonnet 469 having a diaphragm 467 allowing movement of the attached control plate 440 within the valve chamber 450 .",
"The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 412 , in fluid communication with the first fluid conduit 410 and surrounded by an orifice ridge 418 , whereby at least a portion of the control plate 440 may be moved toward or away from the orifice ridge 418 to create a small clearance control gap (not shown) through which fluid may controllably flow.",
"The controllable fluid flow may transit into the valve chamber 450 from whence it may exit through an offset fluid conduit opening 416 in fluid communication with the second fluid conduit 414 .",
"In the present example valve 400 , an actuator (not shown) may apply a retracting force to a control shaft 482 to deflect the diaphragm 467 and thereby modulate the conductance through the valve by changing the control gap.",
"In the present FIG. 4 illustration the valve 400 is completely closed in a no-flow condition so there is no control gap shown.",
"[0044] In the representative proportional control valve 400 enhancing shut-off performance is achieved by creating a control plate 440 comprising a metallic control plate body 446 of less hardness than the orifice ridge 418 and a metallic cover piece 430 .",
"The orifice ridge 418 may be considered as having a “typical span”",
"relative to the control plate body 446 in that the orifice ridge engages the control plate body adjacent a more central region of the control plate body 446 located between an inner periphery and an outer periphery of the control plate body 446 .",
"The metallic control plate body 446 of the control plate 440 can be machined from an annealed, or preferably fully annealed, corrosion resistant alloy as a flat disk having a central thru-hole 442 with a counterbore 444 on the side intended to face the central fluid conduit opening 412 .",
"The counterbore 444 enables the attachment process by providing access to the moveable valve elements.",
"In manufacturing the illustrated valve design 400 the control plate body 446 is placed onto a shank 481 , projecting from the control shaft 482 and diaphragm 467 , which passes through the central thru-hole 442 .",
"The shank 481 and control plate body 446 may be welded together at the central thru-hole 442 interface using electron beam, laser, TIG, or any equivalent welding process.",
"Any resulting minor weld bead excess may be machined off to match the bottom of the counterbore 444 .",
"A suitable metallic cover piece 430 may subsequently be placed into the counterbore 444 and held in place by using electron beam, laser, TIG, or any equivalent welding process around the outer periphery of the cover piece 430 and the inner diameter of the counterbore 444 .",
"Alternatively, an interference fit between the outer diameter of the metallic cover piece 430 and the inner diameter of the counterbore 444 may be considered sufficient to retain the cover piece 430 .",
"The complete assembly may then undergo final finishing for flatness (by lapping, or single point diamond turning, for example) as needed for good valve function.",
"This design approach is especially advantageous for valves having an orifice ridge maximal span greater than about 4 mm.",
"It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure.",
"In a typical application the orifice ridge 418 will be made of one alloy while the metallic control plate body 446 will be made from a different alloy.",
"One usual choice of materials is type 316 stainless for the orifice ridge 418 and a corrosion resistant nickel alloy (such as Hastelloy® C-22® available from Haynes International) for the control plate body 446 .",
"The metallic cover piece 430 may be made from the same material as either the orifice ridge 418 or the control plate 440 , or from yet another different alloy.",
"[0045] The cover piece 430 and the control plate body 446 are provided as separate components in FIG. 4 to allow for improved welding of the control plate 440 to the shank 481 .",
"First, the control plate body 446 is welded to the shank 481 .",
"Next the cover piece 430 is welded to the control plate body 446 .",
"Then cover piece 430 and the control plate body 446 can undergo finishing for flatness (e.g. by lapping, or single point diamond turning, or another method).",
"[0046] In some embodiments, the structure of FIG. 4 could be provided without the cover piece 430 , because the cover piece 430 is not used to engage the orifice ridge 418 .",
"[0047] The term cover piece, as used herein, is used to describe an insert in which the insert itself is not used to sealingly engage the orifice ridge.",
"[0048] The control plate body 446 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 418 .",
"[0049] FIG. 5 illustrates a representative example of a proportional control valve 500 using diaphragm sealing and also having a control plate 540 which abuts an orifice ridge 518 surrounding a central fluid conduit opening 512 .",
"The proportional control valve 500 comprises a valve body 519 having a first fluid conduit 510 and a second fluid conduit 514 , each of which communicates fluid to or from a valve chamber 550 , and a valve bonnet 569 sealed to the valve body 519 by a gasket 565 , the bonnet 569 having a diaphragm 567 allowing movement of the attached control plate 540 within the valve chamber 550 .",
"The manner of controlling fluid flow may be further understood by considering the fluid conduit opening 512 , in fluid communication with the first fluid conduit 510 and surrounded by an orifice ridge 518 , whereby at least a portion of the control plate 540 may be moved toward or away from the orifice ridge 518 to create a small clearance control gap (not shown) through which fluid may controllably flow.",
"The controllable fluid flow may transit into the valve chamber 550 from whence it may exit through an offset fluid conduit opening 516 in fluid communication with the second fluid conduit 514 .",
"In the present example valve 500 an actuator (not shown) may apply a retracting force to a control shaft 582 to deflect the diaphragm 567 and thereby modulate the conductance through the valve by changing the control gap.",
"In the present FIG. 5 illustration the valve 500 is completely closed in a no-flow condition so there is no control gap shown.",
"[0050] The metallic control plate 540 can be machined from an annealed or preferably fully annealed corrosion resistant alloy, of less hardness than the orifice ridge, as a flat disk having a blind central counterbore 542 on the side intended to face the diaphragm 567 .",
"In manufacturing the illustrated valve design 500 the control plate 540 may be press fit onto a shank 581 , projecting from the control shaft 582 and diaphragm 567 .",
"Alternatively, the shank 581 and control plate 540 may be welded together using electron beam, laser, or any equivalently energetic welding process suitable to penetrate the thin central portion 530 of the control plate 540 and fuse it to the shank 581 .",
"It should be noted that in the embodiment depicted in FIG. 5 , the shank 581 may extend deeper into the control plate 540 than, for example, the embodiments depicted in FIGS. 3 and 4 to aid in the welding process.",
"The thin central portion 530 may further include a detent or other type of weld preparation (not shown) to reduce the amount of material in the central portion 530 of the control plate to minimize the amount of energy or time needed to weld the central portion 530 of the control plate 540 to the shank 581 .",
"Any resulting minor weld bead excess may be machined off and the complete assembly may then undergo final finishing for flatness (by lapping, or single point diamond turning, for example, or another method) as needed for good valve function.",
"This design approach is especially advantageous due to the lesser number of machined pieces and its suitability for use with a variety of orifice ridge sizes and shapes.",
"It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure and an ensemble plurality of coplanar orifice ridges is also contemplated.",
"In a typical application the orifice ridge 518 will be made of one alloy while the metallic control plate 540 will be made from a different alloy.",
"One usual choice of materials is type 316 stainless for the orifice ridge 518 and a corrosion resistant nickel alloy (such as Hastelloy® C-22® available from Haynes International) for the control plate 540 .",
"[0051] The control plate 540 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 518 [0052] FIG. 6A and FIG. 6B illustrate a representative example of a proportional control valve 600 using diaphragm sealing and also having a control plate 640 which abuts an orifice ridge 618 surrounding an inner fluid conduit opening 612 .",
"The proportional control valve 600 comprises a valve body 619 having a first fluid conduit 610 and a second fluid conduit 614 , each of which communicates fluid to or from a valve chamber 650 , and a valve bonnet 669 sealed to the valve body 619 by a gasket 665 , the bonnet 669 having a diaphragm 667 allowing movement of the attached control plate 640 within the valve chamber 650 .",
"The manner of controlling fluid flow may be further understood by considering the inner fluid conduit opening 612 , in fluid communication with the first fluid conduit 610 and surrounded by the orifice ridge 618 , whereby at least a portion of the control plate 640 may be moved toward or away from the orifice ridge 618 to create a small clearance control gap (not shown) through which fluid may controllably flow.",
"The controllable fluid flow may transit into the valve chamber 650 from whence it may exit through an outer fluid conduit opening 616 in fluid communication with the second fluid conduit 614 .",
"In the present example valve 600 , an actuator (not shown) may apply a retracting force to a control shaft 682 to deflect the diaphragm 667 and thereby modulate the conductance through the valve by changing the control gap.",
"In the present FIG. 6A illustration the valve 600 is completely closed in a no-flow condition so there is no control gap shown.",
"[0053] In the representative proportional control valve 600 the goal of reducing polymer content is achieved by creating a control plate 640 comprising a metallic control plate body 646 and a molded insert 630 of polymer material.",
"As may be seen in FIG. 6B , the metallic control plate body 646 of the control plate 640 can be machined as a flat disk having a central thru-hole 642 and a plurality of concentric ring-shaped grooves 648 on the side intended to face the inner fluid conduit opening 612 .",
"The grooves 648 enable the metallic control plate body 646 to function as a seat housing whereby a polymer material insert 630 may be retained therein, as will be further explained, to provide a more compliant sealing material of reduced volume.",
"The remaining metal 649 between the concentric grooves 648 in the control plate body 646 provides meaningful reduction of the total volume of the molded insert 630 .",
"Vent holes 644 , defined in the flat back side of the disk facing away from the inner fluid opening 612 , are made centered between the grooves 648 deep enough with sufficient diameter to intersect the bottoms of adjacent grooves 648 while leaving the majority of the remaining metal 649 intact.",
"In manufacturing the illustrated control plate 640 the polymer material insert 630 may be formed by compression molding (e.g. starting with polychlorotrifluoroethene (PCTFE) powder and polymerizing under the effect of heat and pressure) directly into the control plate body 646 by known methods.",
"During the molding process bridges 634 of polymer material will surround parts of the remaining metal 649 and fill the vent holes 644 .",
"The polymer material bridges 634 surrounding the remaining metal 649 thus lock the molded polymer insert 630 into the metallic control plate body 646 .",
"FIG. 6C shows a perspective view of a molded polymer insert 630 , with the metallic control plate body 646 not shown for the purpose of illustrating the geometry of the molded polymer insert 630 .",
"The molded polymer insert 630 has a plurality of annular ridges 638 , that are complementary with the grooves 648 and which fill the grooves 648 that are defined in the control plate body 646 .",
"[0054] The control plate 640 comprising the metallic control plate body 646 including the molded polymer insert 630 may be attached to a shank 681 , projecting from the control shaft 682 and diaphragm 667 , by press fit into the central thru-hole 642 .",
"Alternatively, prior to the above described molding, the control plate body 646 may first be placed onto the shank 681 and welded together at the central thru-hole 642 interface using electron beam, laser, TIG, or any equivalent welding process.",
"Any resulting minor weld bead excess may be machined off the control plate body 646 surface before molding the insert 630 into the control plate body 646 .",
"The process sequence choice will depend upon practitioners'",
"preference in compression molding techniques.",
"The complete assembly may then undergo final finishing for flatness (by lapping, for example) as needed for good valve function.",
"This design approach is especially advantageous for use with valve bodies having a variety of orifice ridge sizes and shapes.",
"It should be appreciated the orifice ridge maximal span may be other than a diameter in the case of a non-circular orifice ridge structure.",
"Careful examination of the illustrated example of FIG. 6A will reveal the orifice ridge 618 is circular but placed off geometric center of the diaphragm 667 and control plate 640 to accommodate a correspondingly large non-circular outer fluid opening 617 because the orifice ridge is so large in diameter.",
"[0055] An alternate control plate 660 suitable for use in the representative proportional control valve 600 is illustrated in FIG. 6D .",
"A metallic control plate body 676 of the control plate 660 can be machined as a flat disk having a central thru-hole 672 and a wide shallow ring-shaped groove 675 on the side intended to face the inner fluid conduit opening 612 .",
"The groove 675 enables the metallic control plate body 676 to function as a seat housing whereby a polymer material insert 670 may be retained therein, as will be further explained, to provide a more compliant sealing material of reduced volume.",
"A plurality of thru-holes 674 defined in the flat back side of the disk facing away from the inner fluid opening 612 penetrate the wide shallow ring-shaped groove 675 .",
"In manufacturing the illustrated control plate 660 the polymer material insert 670 may be formed by compression molding (e.g. starting with PCTFE powder and polymerizing under the effect of heat and pressure) directly into the control plate body 676 by known methods.",
"During the molding process a plurality of columns 673 of polymer material will fill the thru-holes 674 thereby frictionally locking the polymer material into the groove 675 defined in the metallic control plate body 676 .",
"The geometry of the polymer material insert 670 that is formed by the molding process is shown in FIG. 6E , with the control plate body 676 not shown for illustration purposes.",
"The control plate 660 comprising the metallic control plate body 676 including the molded polymer insert 670 may be attached to a shank 681 , projecting from the control shaft 682 and diaphragm 667 , by press fit into the central thru-hole 672 , or attached in another manner as previously described.",
"[0056] Another alternate control plate 680 suitable for use in the representative proportional control valve 600 is illustrated in FIG. 6F .",
"A metallic control plate body 696 of the control plate 680 can be machined as a flat disk having a central thru-hole 692 , a wide shallow counterbore 695 , and a plurality of wedge-shaped (being approximately circular sectors) cavities 697 , 698 cut into the bottom of the counterbore 695 on the side intended to face the inner fluid conduit opening 612 .",
"The counterbore 695 and plurality of cavities 697 , 698 enable the metallic control plate body 696 to function as a seat housing whereby a polymer material insert 690 may be retained therein, as will be further explained, to provide a more compliant sealing material of reduced volume.",
"The metal between the between the plurality of wedge-shaped cavities 697 , 698 , in the wide shallow counterbore 695 of the control plate body 696 , form radial ribs 699 .",
"Vent holes 691 , defined in the flat back side of the disk facing away from the inner fluid opening 612 , are made centered over the radial ribs 699 deep enough with sufficient diameter to intersect the bottoms of adjacent wedge-shaped cavities 697 , 698 while leaving the majority of the remaining metal rib 699 intact.",
"A plurality of thru-holes 694 , also defined in the flat back side of the disk facing away from the inner fluid opening 612 , penetrate the bottom of each of the wedge-shaped cavities 697 , 698 .",
"In manufacturing the illustrated valve design 600 the polymer material insert 690 may be formed by compression molding (e.g. starting with PCTFE powder and polymerizing under the effect of heat and pressure) directly into the control plate body 696 by known methods.",
"During the molding process polymer material will fill the thru-holes 694 and surround the metal radial ribs 699 to fill the vent holes 691 .",
"The molded polymer material forms bridges 689 to fill the vent holes and posts 693 to fill the thru-holes 694 .",
"The molded polymer material also forms wedge portions of the insert 690 to fill respective wedge-shaped cavities 697 , 698 .",
"The polymer material surrounding the metal ribs 699 thus lock the molded insert 690 into the metallic control plate body 696 .",
"The geometry of the polymer material insert 690 that is formed by the molding process is shown in FIG. 6G , with the control plate body 696 not shown for illustration purposes.",
"The control plate 680 comprising the metallic control plate body 696 including the molded polymer insert 690 may be attached to a shank 681 , projecting from the control shaft 682 and diaphragm 670 , by press fit into the central thru-hole 692 , or attached in another manner as previously described.",
"[0057] In each of FIGS. 6A-6G , the respective polymer material insert 630 , 670 , 690 includes a planar first surface configured to sealingly engage the planar upper end of the orifice ridge 618 .",
"[0058] It should be appreciated that the specific sizes of features shown in FIGS. 6A-6G may be varied and are not necessarily drawn to scale.",
"[0059] Referring again to FIG. 2 , the ring-shaped insert 230 could be molded in the control plate body 246 of the control plate 240 and secured within the control plate body 246 of the control plate 240 by retaining features such as the structure of FIGS. 6A-6G .",
"That is, for example, the ring-shaped insert 230 could have columns that are positioned in thru-holes defined in the control plate body 246 , posts that are positioned in thru-holes defined in the control plate body 246 , and/or bridges that are positioned in vent holes defined in the control plate body in a manner similar to that described with respect to FIGS. 6A-6G .",
"[0060] The counterbores and grooves described above are examples of recesses that can be defined in a control plate body.",
"In some embodiments, an insert can be secured in another type of recess that is defined in the control plate body.",
"[0061] In some embodiments, a retention mechanism is used to retain an insert in one or more counterbores and/or one or more grooves defined in a control plate body.",
"Some examples of a retention mechanism include a retaining ring located at an outer periphery of the insert, an inner retaining ring located at an inner periphery of the insert and an outer retaining ring located at an outer periphery of the insert, a post, a column, a bridge, and a weld.",
"Other retention mechanisms are possible.",
"It should be appreciated that although embodiments of the present disclosure have been primarily described with respect to diaphragm sealed valves in which a control plate is disposed below and attached to or integrally formed with the diaphragm, aspects of the present disclosure may be readily adapted for use with other types of valves, such as bellows sealed valves similar to those described in U.S. Pat. No. 3,295,191.",
"Moreover, although embodiments of the present disclosure have been described with respect to control valves in which an actuator is used to move an orifice ridge sealing surface of the control plate toward and away from an orifice ridge, this movement need not need not be uniform across the orifice ridge sealing surface of the control plate.",
"For example, embodiments of the present disclosure may readily be used with a valve stroke amplification mechanism, such as disclosed in US Patent Publication No. US2016/0138730 A1, in which an amplifier disc may be used to effect a wedge shaped gap having a higher conductance than would otherwise be obtained.",
"[0062] Although the embodiments depicted in FIGS. 1-6A are all depicted as showing a valve bonnet body 169 , 269 , 369 , 469 , 569 , 669 in which the diaphragm 167 , 267 , 367 , 467 , 567 , 667 is integrally formed with the bonnet body, it should be appreciated that the present invention is not so limited.",
"Indeed, embodiments of the present disclosure encompass diaphragms that are stamped, punched, or cut out of a piece of sheet metal that is later attached (for example, by welding) to a bonnet body, as well as those in which the diaphragm and bonnet body are integrally formed from a single block of starting material, as shown herein.",
"[0063] Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art.",
"Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the scope of the invention.",
"Accordingly, the foregoing description and drawings are by way of example only."
] |
CROSS REFERENCE TO RELATED APPLICATION
This application is a division of U.S. patent application Ser. No. 08/078,907, filed Jun. 18, 1993 now U.S. Pat. No. 5,372,604 and entitled "Suture Anchor for Soft Tissue Fixation".
BACKGROUND OF THE INVENTION
1. Technical Field
This invention pertains to methods and apparatus utilized in surgical procedures involving fixation of soft tissue to bone tissue and, more particularly, to a novel method and apparatus for anchoring sutures to bone tissue to permit the aforesaid fixation.
2. Discussion of the Prior Art
As part of various endoscopic or arthroscopic surgical procedures, it is necessary to permanently attach a suture to bone tissue. For example, in certain procedures requiring suturing of soft tissue (e.g., muscle, cartilage, tendons, ligaments, etc.) to bone tissue, the suture must be anchored to the bone tissue before suturing can proceed. The prior art includes numerous suture anchors adapted to be secured in pre-drilled holes or tunnels in the bone tissue, and most of these anchors have one or more disadvantageous characteristics. Some prior art suture anchors are required to be hammered into the bone tunnel. These anchors are exemplified by U.S. Pat. Nos. 5,102,421 (Anspach, Jr.); 5,141,520 (Goble et al); and 5,100,417 (Cerier et al). Hammering (or impacting as it is often described) has the disadvantage of potential trauma and damage to surrounding bone tissue, and has limited applicability where the location of the bone tunnel is not axially aligned with an arthroscopic portal to permit transmission of the impacting force through an impactor to the anchor.
Some suture anchors are threadedly mounted in the bone tunnel, as exemplified by U.S. Pat. Nos. 5,156,616 (Meadows et al) and 4,632,100 (Somers et al). The screw insertion procedure tends to be time-consuming in that a pilot hole must first be drilled into the bone and then the hole may have to be tapped to receive the screw.
Many suture anchors involve an insertion procedure wherein the inserter device must partially enter the bone tunnel, thereby requiring a larger diameter tunnel than would be necessary for the anchor alone. Examples of such suture anchors are found in U.S. Pat. Nos. 5,037,422 (Hayhurst et al); 4,741,330 (Hayhurst); 4,968,315 (Gatturna) and 4,899,743 (Nicholson et al).
Most of the foregoing exemplar prior art suture anchors suffer from the disadvantage of being automatically deployed upon initial insertion into the bone tunnel. Specifically, such anchors typically have permanently projecting barbs, or the like, that are forced into the tunnel during initial insertion and preclude proximally directed movement in the tunnel after at least one barb engages the surrounding bone tissue. It sometimes happens that a particular tunnel turns out to be unsuitable, either because of location or configuration, but the surgeon does not recognize this until after the anchor has been inserted. With most prior art anchors there is no possibility of removing the inserted anchor; thus, a new tunnel must be drilled and a second anchor inserted. Accordingly, two (or possibly more) anchors may be left at the surgical site, only one of which is functional. This problem is addressed in U.S. Pat. No. 5,176,682 (Chow) wherein a suture anchor is disclosed as having normally retracted fins capable of being selectively projected radially to engage the bone tunnel walls in a barb-like manner. Selective projection of the fins is effected by hammering a pin axially through the anchor to force the fins radially outward. Prior to hammering the pin, the inserted anchor is readily removable from the bone tunnel, thereby permitting the surgeon to test the adequacy of the drilled tunnel and its location. If the tunnel is unsatisfactory, the anchor can be removed, rather than being left in place. Although this technique solves the problem of having an unused anchor left in an unsatisfactory tunnel, it has some other disadvantages. Specifically, permanent installation of the anchor requires tools (i.e., a hammer and impactor) that are separate and apart from the inserter. Additionally, during impacting, the pin may be inadvertently driven entirely through the anchor and thereby damage bone tissue at the closed end of the tunnel.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide improved methods and apparatus for anchoring suture to bone.
It is another object of the invention to provide a suture anchor capable of being temporarily inserted into a bone tunnel to determine the desirability of the site, and then easily actuated for permanent deployment.
A further object of the invention is to provide a suture anchor that can be inserted and positively engaged in a bone tunnel without requiring hammering of the anchor or threading the tunnel.
It is yet another object of the present invention to provide a method and apparatus for securing a suture anchor in a bone tunnel without requiring the tunnel diameter to be larger than necessary to accommodate the anchor.
In accordance with the present invention, a suture anchor wire is configured from a deformable wire bent to provide a loop at the approximate center of the wire length. The loop constitutes the proximal end of the anchor. The wire is twisted to close off the loop at a twist juncture from which two legs extend generally distally and then bend away from one another through approximately 180° each to extend in a proximal direction along opposite transverse sides of the anchor. Ends of the wire are cut on a bias to define sharp points at the outer transverse sides of the leg ends. The 180° bend in each leg forms a U-shaped knee dividing the leg into substantially parallel inner and outer leg segments.
An anchor insertion tool includes an elongated hollow outer tube and an inner tube telescopically movable therein. Jaws at the distal end of the inner tube include one or more projections configured to permit the anchor wire loop to be selectively engaged between the jaws. With the anchor engaged, a generally annular actuator edge of the outer tube of the inserter tool, or of a sleeve disposed about the inner tube and extending forwardly of the outer tube, is axially spaced from the anchor wire legs. The actuator edge has an outside diameter made smaller than the transverse spacing between the outward sides of the outer leg segments, but larger than the transverse spacing between the inward sides of the outer leg segments. Suture or similar material can be looped about the twist between the two inner leg segments of the anchor wire and pulled back proximally before the engaged anchor is inserted into a pre-drilled tunnel in bone tissue. The transverse spacing between the proximally-directed anchor leg segments permits the anchor to be moved freely into and out of the tunnel. When the anchor wire is positioned as desired, the actuator inner tube is retracted into the outer tube, thereby causing the actuator edge to move distally relative to the anchor wire and into the space between the leg segments of each wire leg. As the actuator edge moves between the leg segments it forces the outer segments outwardly, thereby deforming the wire knee so that the pointed ends of the outer segments engage the wall in the bone tunnel. The entire tool can then be pulled in the proximal direction, with the anchor loop still engaged by the actuator, to cause the pointed ends of the now outwardly bent outer leg segments of the anchor to firmly engage the wall of the tunnel. Disengagement of the inserter tool from the anchor wire is effected by opening the jaws of the inner tube to disengage the wire loop. The tool can then be removed from the surgical site and the suture remains in the bone tunnel, firmly engaged about the anchor wire twist.
In one embodiment, the anchor also includes a sleeve on which the anchor wire, as described above, is mounted. The anchor sleeve has an open distal end and a proximal end wall having a central opening. The wire is mounted with its loop protruding rearwardly through the hole in the proximal end wall, and with its U-shaped knee bent over the edge of the open distal sleeve end. Recessed channels extend longitudinally along the outside of the sleeve from its distal end to receive the outer leg segments of the anchor wire. When thusly received, the entire diametric thickness of the outer leg segment is recessed in the channel. As in the first described embodiment, the rearward projecting wire loop is engageable between the jaws of the insertion tool. During deployment, instead of spreading the outer leg segments directly by means of the distal end of the insertion tool outer tube, the distal end of the tube is forced against the proximal end wall of the anchor sleeve. The sleeve, in turn, is thusly movable distally relative to the engaged anchor wire to force the outer leg segments of the wire radially outward. In this embodiment the anchor sleeve remains in the bone tunnel along with the anchor wire after deployment.
These and other objects, features and many of the attendant advantages of the present invention will be appreciated more readily as they become better understood from a reading of the following description considered in connection with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in plan of an anchor wire constructed in accordance with one embodiment of the present invention.
FIG. 2 is a side view, partly broken, of an inserter tool utilized in connection with the anchor wire according to the present invention showing the tool in its deployment position.
FIG. 3 is a side view, partly broken, of the inserter tool shown in its pre-deployment position.
FIG. 4 is a top view in plan of the combination of the anchor wire of FIG. 1 and the distal end of the insertion tool of FIG. 2, the combination being shown prior to engagement of the anchor wire.
FIG. 5 is a side view in elevation of the distal end of the insertion tool taken along lines 5--5 of FIG. 4.
FIG. 6 is a top view in plan of the anchor wire and the distal end of the insertion tool showing the anchor wire engaged prior to deployment and the inner tube of the insertion tool fully extended.
FIG. 7 is a top view in plan of the anchor wire and the distal end of the insertion tool showing the anchor wire in its inserted but non-deployed position and the inner tube of the insertion tool partially retracted.
FIG. 8 is a top view in plan of the anchor wire and the distal end of the insertion tool showing the anchor wire fully deployed and the inner tube of the insertion tool fully retracted.
FIG. 9 is a top view in plan of the anchor wire during as it appears prior to insertion into a bone tunnel and showing a suture engaged by the anchor wire.
FIG. 10 is a top view in plan of the anchor wire fully deployed in a bone tunnel and showing a suture engaged by the anchor wire and retained in the bone tunnel.
FIG. 11 is a view in perspective of a second embodiment of the anchor of the present invention utilizing an anchor sleeve in combination with the anchor wire, and an insertion tool for engaging the anchor wire.
FIG. 12 is an exploded view in perspective of the anchor wire and anchor sleeve of FIG. 11.
FIG. 13 is a distal end view in elevation of the anchor sleeve.
FIG. 14 is a view in section taken along lines 14--14 of FIG. 13.
FIG. 15 is a view in section taken along lines 15--15 of FIG. 13.
FIG. 16 is a view in perspective of the insertion tool of FIG. 11.
FIG. 17 is a side view in elevation of the anchor assembly of FIG. 11 engaged by the insertion tool immediately prior to insertion into a bone tunnel.
FIG. 18 is a side view in elevation of the anchor assembly of FIG. 11 and the insertion tool showing the anchor assembly partially inserted into a bone tunnel.
FIG. 19 is a view in plan of another anchor wire embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring specifically to FIG. 1, an anchor wire 10 is bent and twisted to provide an engagement loop 11 positioned approximately at the center of the length of the wire. Engagement loop 11 constitutes the proximal end of the anchor device and, in the preferred embodiment, has a generally elliptical configuration with its major axis extending longitudinally. The forward end of loop 11 terminates in a twist 13 formed in wire 10, the preferred twist being 180° about the longitudinal axis of the anchor to close off the loop from the distal end of the anchor. Specifically, each leg of the wire bends through approximately 90° to form twist 13. Extending forwardly from twist 13 are two legs, each having a 180° outward bend or knee 17, 23 to separate inner and outer leg segments. Specifically, one leg includes an inner segment 15 extending forwardly from twist 13 to knee 17, and an outer segment 19 extending rearwardly from knee 17 and substantially parallel to inner segment 15. Outer segment 19 constitutes the radially outwardmost part of one side of the anchor wire and terminates in a pointed end 20 formed by cutting the wire end on a bias in a proximal and outward direction. The other leg is a substantially mirror image (about the anchor longitudinal axis) of the first leg and has corresponding inner segment 21, knee 23, outer segment 25 and pointed end 27. The forward ends of knees 17 and 23 are longitudinally coextensive and define the distal end of the anchor wire.
Anchor wire 10 is preferably a metal wire, typically stainless steel, that is bendable but not significantly resilient. Accordingly, if, in the manner described below, outer leg segments 19 and 25 are bent outwardly about respective knees 17 and 23 to form some angle other than 180° with the inner segments 15 and 21, the resulting deformation of the anchor wire remains set after the bending force is removed.
In an exemplar embodiment of anchor wire 10, the wire has a round transverse cross-section with a diameter of 0.015". The overall length (i.e., from the proximal end of loop 11 to the distal ends of knees 17, 23) of the formed anchor wire is 0.220", with the outer leg segments each occupying 0.100" of that length. The maximum transverse width of the anchor wire between the outermost parts of outer leg segments 19 and 25 is 0.110". The transverse space between inner leg segments 15 and 21 is 0.030". Likewise, the transverse space between the long sides of loop 11 is 0.030". The angle of the bias cut in outer leg segments 19 and 25 to form respective points 20 and 27 is 30°. Again, it is to be noted that these dimensions are for purposes of example only and are not limiting on the scope of the present invention.
An anchor insertion tool 30 is illustrated in FIGS. 2 and 3 includes concentric inner and outer tubes 31 and 33, respectively. Outer tube 33 is fixedly secured to and extends forwardly from an actuator housing 35. A thumb-engaging handle arm 37 is fixedly secured to the proximal end of housing 35, extending rearwardly and transversely therefrom and terminating in a thumb-receiving loop 39. A finger-engaging handle arm 40 is pivotably secured within housing 35 and extends transversely forwardly therefrom to form an acute angle with arm 37. A finger-receiving loop 41 terminates the free end of arm 40. In a conventional manner, arm 40 is linked within housing 35 to the proximal end of inner tube 31 such that forward movement of arm 40 relative to arm 37 (i.e., increased angular separation) results in coaxially forward displacement of inner tube 31 within outer tube 33. Likewise, rearward movement of arm 40 (i.e., decreasing the angular separation) causes inner tube 31 to move axially rearward within outer tube 33. In this manner, the distal end of inner tube 31 may be selectively projected beyond the distal end of tube 33, or fully retracted within the outer tube. The diameters and lengths of tubes 31, 33 are such to permit their distal ends to be inserted through an endoscopic surgical portal and positioned at a surgical site. The particular embodiment illustrated herein is best suited for arthroscopic procedures.
The distal end of inner tube 31 terminates in a pair of resiliently spaced jaws 43 and 45. When inner tube 31 is fully extended forwardly, jaws 43 and 45 are exposed and maximally separated. In this position the spacing between the outside surfaces of the jaws exceeds the inner diameter of outer tube 33. As the inner tube is retracted into the outer tube, the interior wall of outer tube 33 serves as a cam to gradually urge jaws 43 and 45 together in opposition to their resilient separation bias. The interior or mutually facing surfaces of jaws 43 and 45 have respective engagement pins 44 and 46 projecting inwardly toward one another. In the fully open position of the jaws (i.e., in the fully extended position of inner tube 31), the spacing between engagement pins 44 and 46 is at least equal to the diameter of the wire used for anchor wire 10. The cross-sectional shape of pins 44 and 46 (i.e., transversely of their mutual projection directions) is chosen to permit the pins to fit into the loop 11 of the anchor wire when the jaws are closed. Preferably, the engagement pins are cylinders having a radius equal to or just slightly smaller than the radius of curvature of the proximal end of the interior portion of wire loop 11.
Referring to FIGS. 4 and 5, when it is desired to load anchor wire 10 onto insertion tool 30, inner tube 31 is extended to its most distal position relative to the outer tube by angularly separating handle arms 37 and 40 to their maximum separation. Jaws 43 and 45 are resiliently spread and pins 44 and 46 thereby are spaced from one another. The anchor wire loop may then be inserted between jaws 43, 45 and their engagement pins 44, 46. As illustrated in FIG. 6, the jaws may be closed, bringing engagement pins 44, 46 into contact through anchor wire loop 11. Closure of the jaws is effected by pivoting handle arm 40 partway toward handle arm 37, thereby causing partial retraction of inner tube 31 into outer tube 33. This retraction, in turn, causes the distal edge of the outer tube to force jaws 43 and 45 together in opposition to their resilient separation bias.
To ready the anchor wire for insertion into a bone tunnel, inner tube 31 is further retracted into outer tube 33, as illustrated in FIGS. 7 and 9, until the loaded anchor wire is disposed with the proximal end of loop 11 abutting the distal end of outer tube 33. In this position, a suture 50 can be disposed with an intermediate portion of its length between inner leg segments 15 and 21 and at the distal end of wire twist junction 13. The two ends of suture 50 are pulled rearwardly to extend along the outer tube 33 of the insertion tool. Suture 50 and the anchor wire 10, engaged by the insertion tool, can then be inserted into a predrilled bone tunnel 51. The bone tunnel diameter is substantially equal to or slightly larger than the maximum transverse spacing between the outer edges of outer legs segments 19 and 25 to readily permit insertion of the entire anchor wire and the distal end of the insertion tool into the bone tunnel. With the anchor wire thusly inserted in the tunnel, the surgeon can determine whether or not the tunnel and its location are satisfactory for the contemplated soft tissue anchoring procedure. If the bone tunnel is not satisfactory, the insertion tool and the engaged anchor wire may be readily withdrawn from the tunnel and inserted into a new tunnel appropriately drilled and positioned.
If the bone tunnel is determined to be satisfactory for the contemplated procedure, the anchor wire may be permanently deployed. In particular, and as illustrated in FIGS. 8 and 10, the outer leg segments 19, 25 of the inserted anchor wire are forced outwardly by fully retracting inner tube 31 into outer tube 33 while pulling rearwardly on the insertion tool and, in turn, on the engaged anchor wire. As the inner tube is retracted, the interior sides of knees 17 and 23 move axially toward the distal edge of outer tube 33. The outer tube end begins wedging between inner leg segment 15 and outer leg segment 19, and between inner leg segment 21 and outer leg segment 25, thereby causing the outer leg segments to bend outwardly about their respective knees. Pointed wire ends 20 and 27 diverge by virtue of this bending and dig into the wall of the bone tunnel as the assembly is pulled in a rearward direction. When sufficient resistance to rearward movement is encountered, the anchor wire is deemed properly implanted and the insertion tool can be disengaged from the anchor wire loop 11. This disengagement is effected by moving inner tube 31 proximally to permit jaws 43 and 45 to resiliently separate and release wire loop 11. The insertion tool may then be fully withdrawn from the surgical site, leaving the anchor wire firmly positioned within the bone tunnel and suture 50 looped around the anchor wire. The 180° twist 13 in the anchor wire prevents the suture from being drawn into loop 11 when the ends of the suture are pulled to achieve desired tension.
It is to be noted that, although the preferred embodiment of the insertion tool includes respective engagement pins secured to the jaws 43 and 45, other jaw configurations are possible and fall within the scope of the present invention. For example, only one of the jaws may have a projecting pin configured to engage the opposing jaw when the jaws are closed. Alternatively, the opposing jaw may have a recess or bore defined therethrough in position to receive the engagement pin from the first-mentioned jaw. The configurations of the engagement pins need not be cylindrical; rather, any configuration capable of serving the functions described above is appropriate for the engagement pins.
Likewise, the specific manner by which the jaws are opened and closed should not be a limiting feature of the invention. In particular, the preferred insertion tool described above effects closure of the jaws by withdrawing the resiliently spaced jaws into an outer tube. Rather than providing the illustrated inner tube and outer tube combination, a single tube may be provided with nonresilient jaws formed at its distal end. One of the jaws would be pivotable relative to the tubes so as to selectively close the jaws in a manner similar to that employed for arthroscopic graspers and cutters well known in the prior art. An outer sleeve may then be disposed over the distal end of the insertion tool to be selectively axially movable relative to the jaws to bend the outer leg segments of the anchor wire in a manner described.
An alternative embodiment of the anchor assembly and insertion tool are illustrated in FIGS. 11-18 to which specific reference is now made. In this embodiment the anchor assembly includes anchor wire 10, configured as described above, and a biocompatable anchor sleeve 60. The anchor sleeve 60 has a generally cylindrical configuration with a proximal end wall 61 having a central hole or opening 63 defined therethrough. The diameter of hole 60 is sufficient to permit loop 11 of the anchor wire to project proximally therethrough when the anchor wire is received in sleeve 60 in the manner described below. The opposite or distal end 65 of sleeve 60 is open to receive the anchor wire. Longitudinally extending wire relief channels or recesses 67, 69 are defined in the outer surface of sleeve 60 and extend along the entire length of the sleeve. Channels 67 and 69 are disposed at 180°-spaced locations about the sleeve circumference and are sufficiently deep to receive most, if not all, of the diametric thickness of respective outer leg segments 19 and 25. That is, anchor wire 10, when received in sleeve 60, has the inside surfaces of its knees 17 and 23 disposed in abutting relation with the distal edge of the sleeve. Further, the natural spacing between the outermost edges of inner leg segments 15 and 21 is greater than the inner diameter of sleeve 60. Accordingly, sleeve 60 is retained on anchor wire 10 by a forced fit created by the limited resilience of the anchor wire. In the preferred embodiment, distal end 65 has a pair of recesses 66, 68 serving as extensions of respective channels 67, 69 to receive the entire thickness of respective knees 17 and 23. In this received position of the anchor wire, inner leg segments 15, 21 and twist junction 13 are disposed inside sleeve 60.
At two 180°-spaced locations, spaced 90° from wire relief channels 67 and 69, the wall of sleeve 60 is completely removed along the entire sleeve length. The resulting open spaces 71, 73 are continued as respective arcuate recesses 75, 77 defined in the circumferential edge of proximal end wall 61. Spaces 71, 73 serve as suture relief spaces through which suture 50 extends when looped about the proximal end of wire twist 13 between inner leg segments 15 and 21.
The insertion tool 80 employed with the anchor assembly of wire 10 and sleeve 60 may be substantially the same tool described above. As shown in FIGS. 11-18, the outer tube 33' of the tool may have a pair of 180°-spaced slots 81, 83 cut through the entire tube wall thickness and extending a short distance rearward from the outer tube distal end. The suture ends thus extend through spaces 71, 73 and recesses 75, 77 to reside along the slots 81 and 83.
The operation of the anchor assembly of FIGS. 11-18 is similar to that described above in relation to FIGS. 1-10. Anchor wire loop 11, exposed through sleeve hole 63, is engaged in the same manner between jaws 43 and 45, and the sequence of deployment proceeds as previously described with two significant exceptions. First, instead of the outer leg segments 19 and 25 being deformably bent directly by the distal end of the outer tube 33' upon retraction of the inner tube, the outer tube distal end urges sleeve 60 forwardly relative to the anchor wire. The distal end of the sleeve thus deformably bends the outer leg segments of the wire outwardly under the urging of the distal end of the outer tube as the inner tube retracts.
A second significant distinction resides in the fact that biocompatable sleeve 60 may remain deployed with the anchor wire in the bone tunnel. The forced fit between the sleeve and the inner leg segments 15 and 21 assures that the sleeve will not become disengaged. Of course, the sleeve can be designed to be removed after deployment of the wire, if desired.
Sleeve 60 is made of any suitable bio-compatible metal or plastic material. In an exemplar embodiment, the sleeve has a length of 0.157" and an outside diameter of 0.100". Hole 63 in proximal end wall 61 has a diameter of 0.060" which is substantially equal to the maximum transverse dimension of anchor wire loop 11. Channels 67 and 69 are generally semi-cylindrical with a depth of 0.015", while spaces 71, 73 each subtend a circumferential angle on the order of 60°. The transverse space between interior walls across spaces 71, 73 is 0.040".
It may be desirable, in some instances, to configure the anchor wire in the manner illustrated in FIG. 19 wherein anchor wire 10' is configured to have its pointed ends 20', 27' curved outwardly and way from the longitudinal axis of the anchor. This curvature at the tips of the anchor facilitates penetration into the bone upon outward bending of outer segments 19 and 25 during deployment. In all other respects anchor wire 10' is substantially the same as anchor wire 10.
It will be understood that some of the specific details of the exemplary embodiments described above are not limiting on the scope of the invention. In particular, the feature of primary importance in the anchor is the presence of two or more wire legs capable of being deformably bent outward while in a bone tunnel to permit their pointed ends to penetrate the bone tunnel wall upon being pulled proximally toward the tunnel opening. On the other hand, prior to being bent, the wire legs are retracted such that the maximum transverse dimension of the anchor permits it to be readily inserted into and removed from the tunnel. In this regard, the anchor may comprise only the wire, or the wire engaged by a biocompatable anchor sleeve (both as described above); or it may comprise a body of biocompatable metal or plastic material having the bendable pointed legs embedded therein or otherwise secured at the distal end of the body, and with a loop or other anchor engagement structure at the proximal end of the body. The configuration of the anchor body is not, of itself, critical to the invention, although certain configurations, such as those described herein, are more advantageous than others. The key features, again, are the fact that the legs are deformable to effect deployment while the anchor is in the bone tunnel to permit the anchor to be removed after insertion but prior to bending for deployment, a passage for engaging a suture looped about or through the anchor, and a mechanism for engaging the anchor with a removable insertion tool capable of selectively deploying the anchor in the tunnel by causing the legs to deformably bend outwardly without hammering or impacting the anchor. The specific insertion tool configurations described herein, although particularly advantageous, can also be varied within the scope of the invention. The key features of the tool are the capability of engaging the anchor for selective insertion into and removal from the bone tunnel, and the capability of selectively deploying the anchor by causing deformation of the anchor legs. It should also be noted that inner tube 31 of the illustrated insertion tool may be any rod-like member, whether or not tubular.
From the foregoing description it will be appreciated that the invention makes available a novel suture anchor for soft tissue fixation characterized by being removable from a bone tunnel after insertion but before deployment, easily actuated for permanent deployment, and deployable without requiring hammering of the anchor suture or threading of the bone tunnel.
In accordance with the present invention, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as defined by the appended claims. | A method and apparatus for anchoring suture to bone includes an anchor formed by twisting a wire to provide a loop with two legs extending distally from the twist. Each leg bends outwardly through 180° to define respective knee segments between inner and outer leg segments, the outer leg segments terminating in sharp points for penetrating a bone tunnel wall. The outer leg segments are initially parallel and define an anchor width smaller than the bone tunnel diameter, thereby permitting the anchor to be inserted into and removed from the tunnel. The anchor is deployed with an insertion tool arranged to deformably pivot the outer leg segments about the knee segments, thereby causing the pointed ends to penetrate the tunnel wall in response to applied withdrawal forces. The anchor wire may be assembled on an anchor sleeve through which the loop projects proximally while the outer leg segments reside in wire relief recesses defined in the sleeve periphery. The insertion tool selectively forces the sleeve against the inside of the knee segments while engaging the loop to thereby deformably pivot the outer leg segments. The insertion tool may include resiliently spaced jaws for engaging the wire loop, the jaws being disposed at the distal end of a rod selectively retractable into a tube to force the jaws closed. Further retraction of the rod applies the axial force for bending the wire legs. | Briefly outline the background technology and the problem the invention aims to solve. | [
"CROSS REFERENCE TO RELATED APPLICATION This application is a division of U.S. patent application Ser.",
"No. 08/078,907, filed Jun. 18, 1993 now U.S. Pat. No. 5,372,604 and entitled "Suture Anchor for Soft Tissue Fixation".",
"BACKGROUND OF THE INVENTION 1.",
"Technical Field This invention pertains to methods and apparatus utilized in surgical procedures involving fixation of soft tissue to bone tissue and, more particularly, to a novel method and apparatus for anchoring sutures to bone tissue to permit the aforesaid fixation.",
"Discussion of the Prior Art As part of various endoscopic or arthroscopic surgical procedures, it is necessary to permanently attach a suture to bone tissue.",
"For example, in certain procedures requiring suturing of soft tissue (e.g., muscle, cartilage, tendons, ligaments, etc.) to bone tissue, the suture must be anchored to the bone tissue before suturing can proceed.",
"The prior art includes numerous suture anchors adapted to be secured in pre-drilled holes or tunnels in the bone tissue, and most of these anchors have one or more disadvantageous characteristics.",
"Some prior art suture anchors are required to be hammered into the bone tunnel.",
"These anchors are exemplified by U.S. Pat. Nos. 5,102,421 (Anspach, Jr.);",
"5,141,520 (Goble et al);",
"and 5,100,417 (Cerier et al).",
"Hammering (or impacting as it is often described) has the disadvantage of potential trauma and damage to surrounding bone tissue, and has limited applicability where the location of the bone tunnel is not axially aligned with an arthroscopic portal to permit transmission of the impacting force through an impactor to the anchor.",
"Some suture anchors are threadedly mounted in the bone tunnel, as exemplified by U.S. Pat. Nos. 5,156,616 (Meadows et al) and 4,632,100 (Somers et al).",
"The screw insertion procedure tends to be time-consuming in that a pilot hole must first be drilled into the bone and then the hole may have to be tapped to receive the screw.",
"Many suture anchors involve an insertion procedure wherein the inserter device must partially enter the bone tunnel, thereby requiring a larger diameter tunnel than would be necessary for the anchor alone.",
"Examples of such suture anchors are found in U.S. Pat. Nos. 5,037,422 (Hayhurst et al);",
"4,741,330 (Hayhurst);",
"4,968,315 (Gatturna) and 4,899,743 (Nicholson et al).",
"Most of the foregoing exemplar prior art suture anchors suffer from the disadvantage of being automatically deployed upon initial insertion into the bone tunnel.",
"Specifically, such anchors typically have permanently projecting barbs, or the like, that are forced into the tunnel during initial insertion and preclude proximally directed movement in the tunnel after at least one barb engages the surrounding bone tissue.",
"It sometimes happens that a particular tunnel turns out to be unsuitable, either because of location or configuration, but the surgeon does not recognize this until after the anchor has been inserted.",
"With most prior art anchors there is no possibility of removing the inserted anchor;",
"thus, a new tunnel must be drilled and a second anchor inserted.",
"Accordingly, two (or possibly more) anchors may be left at the surgical site, only one of which is functional.",
"This problem is addressed in U.S. Pat. No. 5,176,682 (Chow) wherein a suture anchor is disclosed as having normally retracted fins capable of being selectively projected radially to engage the bone tunnel walls in a barb-like manner.",
"Selective projection of the fins is effected by hammering a pin axially through the anchor to force the fins radially outward.",
"Prior to hammering the pin, the inserted anchor is readily removable from the bone tunnel, thereby permitting the surgeon to test the adequacy of the drilled tunnel and its location.",
"If the tunnel is unsatisfactory, the anchor can be removed, rather than being left in place.",
"Although this technique solves the problem of having an unused anchor left in an unsatisfactory tunnel, it has some other disadvantages.",
"Specifically, permanent installation of the anchor requires tools (i.e., a hammer and impactor) that are separate and apart from the inserter.",
"Additionally, during impacting, the pin may be inadvertently driven entirely through the anchor and thereby damage bone tissue at the closed end of the tunnel.",
"OBJECTS AND SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide improved methods and apparatus for anchoring suture to bone.",
"It is another object of the invention to provide a suture anchor capable of being temporarily inserted into a bone tunnel to determine the desirability of the site, and then easily actuated for permanent deployment.",
"A further object of the invention is to provide a suture anchor that can be inserted and positively engaged in a bone tunnel without requiring hammering of the anchor or threading the tunnel.",
"It is yet another object of the present invention to provide a method and apparatus for securing a suture anchor in a bone tunnel without requiring the tunnel diameter to be larger than necessary to accommodate the anchor.",
"In accordance with the present invention, a suture anchor wire is configured from a deformable wire bent to provide a loop at the approximate center of the wire length.",
"The loop constitutes the proximal end of the anchor.",
"The wire is twisted to close off the loop at a twist juncture from which two legs extend generally distally and then bend away from one another through approximately 180° each to extend in a proximal direction along opposite transverse sides of the anchor.",
"Ends of the wire are cut on a bias to define sharp points at the outer transverse sides of the leg ends.",
"The 180° bend in each leg forms a U-shaped knee dividing the leg into substantially parallel inner and outer leg segments.",
"An anchor insertion tool includes an elongated hollow outer tube and an inner tube telescopically movable therein.",
"Jaws at the distal end of the inner tube include one or more projections configured to permit the anchor wire loop to be selectively engaged between the jaws.",
"With the anchor engaged, a generally annular actuator edge of the outer tube of the inserter tool, or of a sleeve disposed about the inner tube and extending forwardly of the outer tube, is axially spaced from the anchor wire legs.",
"The actuator edge has an outside diameter made smaller than the transverse spacing between the outward sides of the outer leg segments, but larger than the transverse spacing between the inward sides of the outer leg segments.",
"Suture or similar material can be looped about the twist between the two inner leg segments of the anchor wire and pulled back proximally before the engaged anchor is inserted into a pre-drilled tunnel in bone tissue.",
"The transverse spacing between the proximally-directed anchor leg segments permits the anchor to be moved freely into and out of the tunnel.",
"When the anchor wire is positioned as desired, the actuator inner tube is retracted into the outer tube, thereby causing the actuator edge to move distally relative to the anchor wire and into the space between the leg segments of each wire leg.",
"As the actuator edge moves between the leg segments it forces the outer segments outwardly, thereby deforming the wire knee so that the pointed ends of the outer segments engage the wall in the bone tunnel.",
"The entire tool can then be pulled in the proximal direction, with the anchor loop still engaged by the actuator, to cause the pointed ends of the now outwardly bent outer leg segments of the anchor to firmly engage the wall of the tunnel.",
"Disengagement of the inserter tool from the anchor wire is effected by opening the jaws of the inner tube to disengage the wire loop.",
"The tool can then be removed from the surgical site and the suture remains in the bone tunnel, firmly engaged about the anchor wire twist.",
"In one embodiment, the anchor also includes a sleeve on which the anchor wire, as described above, is mounted.",
"The anchor sleeve has an open distal end and a proximal end wall having a central opening.",
"The wire is mounted with its loop protruding rearwardly through the hole in the proximal end wall, and with its U-shaped knee bent over the edge of the open distal sleeve end.",
"Recessed channels extend longitudinally along the outside of the sleeve from its distal end to receive the outer leg segments of the anchor wire.",
"When thusly received, the entire diametric thickness of the outer leg segment is recessed in the channel.",
"As in the first described embodiment, the rearward projecting wire loop is engageable between the jaws of the insertion tool.",
"During deployment, instead of spreading the outer leg segments directly by means of the distal end of the insertion tool outer tube, the distal end of the tube is forced against the proximal end wall of the anchor sleeve.",
"The sleeve, in turn, is thusly movable distally relative to the engaged anchor wire to force the outer leg segments of the wire radially outward.",
"In this embodiment the anchor sleeve remains in the bone tunnel along with the anchor wire after deployment.",
"These and other objects, features and many of the attendant advantages of the present invention will be appreciated more readily as they become better understood from a reading of the following description considered in connection with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference numerals.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view in plan of an anchor wire constructed in accordance with one embodiment of the present invention.",
"FIG. 2 is a side view, partly broken, of an inserter tool utilized in connection with the anchor wire according to the present invention showing the tool in its deployment position.",
"FIG. 3 is a side view, partly broken, of the inserter tool shown in its pre-deployment position.",
"FIG. 4 is a top view in plan of the combination of the anchor wire of FIG. 1 and the distal end of the insertion tool of FIG. 2, the combination being shown prior to engagement of the anchor wire.",
"FIG. 5 is a side view in elevation of the distal end of the insertion tool taken along lines 5--5 of FIG. 4. FIG. 6 is a top view in plan of the anchor wire and the distal end of the insertion tool showing the anchor wire engaged prior to deployment and the inner tube of the insertion tool fully extended.",
"FIG. 7 is a top view in plan of the anchor wire and the distal end of the insertion tool showing the anchor wire in its inserted but non-deployed position and the inner tube of the insertion tool partially retracted.",
"FIG. 8 is a top view in plan of the anchor wire and the distal end of the insertion tool showing the anchor wire fully deployed and the inner tube of the insertion tool fully retracted.",
"FIG. 9 is a top view in plan of the anchor wire during as it appears prior to insertion into a bone tunnel and showing a suture engaged by the anchor wire.",
"FIG. 10 is a top view in plan of the anchor wire fully deployed in a bone tunnel and showing a suture engaged by the anchor wire and retained in the bone tunnel.",
"FIG. 11 is a view in perspective of a second embodiment of the anchor of the present invention utilizing an anchor sleeve in combination with the anchor wire, and an insertion tool for engaging the anchor wire.",
"FIG. 12 is an exploded view in perspective of the anchor wire and anchor sleeve of FIG. 11.",
"FIG. 13 is a distal end view in elevation of the anchor sleeve.",
"FIG. 14 is a view in section taken along lines 14--14 of FIG. 13.",
"FIG. 15 is a view in section taken along lines 15--15 of FIG. 13.",
"FIG. 16 is a view in perspective of the insertion tool of FIG. 11.",
"FIG. 17 is a side view in elevation of the anchor assembly of FIG. 11 engaged by the insertion tool immediately prior to insertion into a bone tunnel.",
"FIG. 18 is a side view in elevation of the anchor assembly of FIG. 11 and the insertion tool showing the anchor assembly partially inserted into a bone tunnel.",
"FIG. 19 is a view in plan of another anchor wire embodiment of the present invention.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring specifically to FIG. 1, an anchor wire 10 is bent and twisted to provide an engagement loop 11 positioned approximately at the center of the length of the wire.",
"Engagement loop 11 constitutes the proximal end of the anchor device and, in the preferred embodiment, has a generally elliptical configuration with its major axis extending longitudinally.",
"The forward end of loop 11 terminates in a twist 13 formed in wire 10, the preferred twist being 180° about the longitudinal axis of the anchor to close off the loop from the distal end of the anchor.",
"Specifically, each leg of the wire bends through approximately 90° to form twist 13.",
"Extending forwardly from twist 13 are two legs, each having a 180° outward bend or knee 17, 23 to separate inner and outer leg segments.",
"Specifically, one leg includes an inner segment 15 extending forwardly from twist 13 to knee 17, and an outer segment 19 extending rearwardly from knee 17 and substantially parallel to inner segment 15.",
"Outer segment 19 constitutes the radially outwardmost part of one side of the anchor wire and terminates in a pointed end 20 formed by cutting the wire end on a bias in a proximal and outward direction.",
"The other leg is a substantially mirror image (about the anchor longitudinal axis) of the first leg and has corresponding inner segment 21, knee 23, outer segment 25 and pointed end 27.",
"The forward ends of knees 17 and 23 are longitudinally coextensive and define the distal end of the anchor wire.",
"Anchor wire 10 is preferably a metal wire, typically stainless steel, that is bendable but not significantly resilient.",
"Accordingly, if, in the manner described below, outer leg segments 19 and 25 are bent outwardly about respective knees 17 and 23 to form some angle other than 180° with the inner segments 15 and 21, the resulting deformation of the anchor wire remains set after the bending force is removed.",
"In an exemplar embodiment of anchor wire 10, the wire has a round transverse cross-section with a diameter of 0.015".",
"The overall length (i.e., from the proximal end of loop 11 to the distal ends of knees 17, 23) of the formed anchor wire is 0.220", with the outer leg segments each occupying 0.100"",
"of that length.",
"The maximum transverse width of the anchor wire between the outermost parts of outer leg segments 19 and 25 is 0.110".",
"The transverse space between inner leg segments 15 and 21 is 0.030".",
"Likewise, the transverse space between the long sides of loop 11 is 0.030".",
"The angle of the bias cut in outer leg segments 19 and 25 to form respective points 20 and 27 is 30°.",
"Again, it is to be noted that these dimensions are for purposes of example only and are not limiting on the scope of the present invention.",
"An anchor insertion tool 30 is illustrated in FIGS. 2 and 3 includes concentric inner and outer tubes 31 and 33, respectively.",
"Outer tube 33 is fixedly secured to and extends forwardly from an actuator housing 35.",
"A thumb-engaging handle arm 37 is fixedly secured to the proximal end of housing 35, extending rearwardly and transversely therefrom and terminating in a thumb-receiving loop 39.",
"A finger-engaging handle arm 40 is pivotably secured within housing 35 and extends transversely forwardly therefrom to form an acute angle with arm 37.",
"A finger-receiving loop 41 terminates the free end of arm 40.",
"In a conventional manner, arm 40 is linked within housing 35 to the proximal end of inner tube 31 such that forward movement of arm 40 relative to arm 37 (i.e., increased angular separation) results in coaxially forward displacement of inner tube 31 within outer tube 33.",
"Likewise, rearward movement of arm 40 (i.e., decreasing the angular separation) causes inner tube 31 to move axially rearward within outer tube 33.",
"In this manner, the distal end of inner tube 31 may be selectively projected beyond the distal end of tube 33, or fully retracted within the outer tube.",
"The diameters and lengths of tubes 31, 33 are such to permit their distal ends to be inserted through an endoscopic surgical portal and positioned at a surgical site.",
"The particular embodiment illustrated herein is best suited for arthroscopic procedures.",
"The distal end of inner tube 31 terminates in a pair of resiliently spaced jaws 43 and 45.",
"When inner tube 31 is fully extended forwardly, jaws 43 and 45 are exposed and maximally separated.",
"In this position the spacing between the outside surfaces of the jaws exceeds the inner diameter of outer tube 33.",
"As the inner tube is retracted into the outer tube, the interior wall of outer tube 33 serves as a cam to gradually urge jaws 43 and 45 together in opposition to their resilient separation bias.",
"The interior or mutually facing surfaces of jaws 43 and 45 have respective engagement pins 44 and 46 projecting inwardly toward one another.",
"In the fully open position of the jaws (i.e., in the fully extended position of inner tube 31), the spacing between engagement pins 44 and 46 is at least equal to the diameter of the wire used for anchor wire 10.",
"The cross-sectional shape of pins 44 and 46 (i.e., transversely of their mutual projection directions) is chosen to permit the pins to fit into the loop 11 of the anchor wire when the jaws are closed.",
"Preferably, the engagement pins are cylinders having a radius equal to or just slightly smaller than the radius of curvature of the proximal end of the interior portion of wire loop 11.",
"Referring to FIGS. 4 and 5, when it is desired to load anchor wire 10 onto insertion tool 30, inner tube 31 is extended to its most distal position relative to the outer tube by angularly separating handle arms 37 and 40 to their maximum separation.",
"Jaws 43 and 45 are resiliently spread and pins 44 and 46 thereby are spaced from one another.",
"The anchor wire loop may then be inserted between jaws 43, 45 and their engagement pins 44, 46.",
"As illustrated in FIG. 6, the jaws may be closed, bringing engagement pins 44, 46 into contact through anchor wire loop 11.",
"Closure of the jaws is effected by pivoting handle arm 40 partway toward handle arm 37, thereby causing partial retraction of inner tube 31 into outer tube 33.",
"This retraction, in turn, causes the distal edge of the outer tube to force jaws 43 and 45 together in opposition to their resilient separation bias.",
"To ready the anchor wire for insertion into a bone tunnel, inner tube 31 is further retracted into outer tube 33, as illustrated in FIGS. 7 and 9, until the loaded anchor wire is disposed with the proximal end of loop 11 abutting the distal end of outer tube 33.",
"In this position, a suture 50 can be disposed with an intermediate portion of its length between inner leg segments 15 and 21 and at the distal end of wire twist junction 13.",
"The two ends of suture 50 are pulled rearwardly to extend along the outer tube 33 of the insertion tool.",
"Suture 50 and the anchor wire 10, engaged by the insertion tool, can then be inserted into a predrilled bone tunnel 51.",
"The bone tunnel diameter is substantially equal to or slightly larger than the maximum transverse spacing between the outer edges of outer legs segments 19 and 25 to readily permit insertion of the entire anchor wire and the distal end of the insertion tool into the bone tunnel.",
"With the anchor wire thusly inserted in the tunnel, the surgeon can determine whether or not the tunnel and its location are satisfactory for the contemplated soft tissue anchoring procedure.",
"If the bone tunnel is not satisfactory, the insertion tool and the engaged anchor wire may be readily withdrawn from the tunnel and inserted into a new tunnel appropriately drilled and positioned.",
"If the bone tunnel is determined to be satisfactory for the contemplated procedure, the anchor wire may be permanently deployed.",
"In particular, and as illustrated in FIGS. 8 and 10, the outer leg segments 19, 25 of the inserted anchor wire are forced outwardly by fully retracting inner tube 31 into outer tube 33 while pulling rearwardly on the insertion tool and, in turn, on the engaged anchor wire.",
"As the inner tube is retracted, the interior sides of knees 17 and 23 move axially toward the distal edge of outer tube 33.",
"The outer tube end begins wedging between inner leg segment 15 and outer leg segment 19, and between inner leg segment 21 and outer leg segment 25, thereby causing the outer leg segments to bend outwardly about their respective knees.",
"Pointed wire ends 20 and 27 diverge by virtue of this bending and dig into the wall of the bone tunnel as the assembly is pulled in a rearward direction.",
"When sufficient resistance to rearward movement is encountered, the anchor wire is deemed properly implanted and the insertion tool can be disengaged from the anchor wire loop 11.",
"This disengagement is effected by moving inner tube 31 proximally to permit jaws 43 and 45 to resiliently separate and release wire loop 11.",
"The insertion tool may then be fully withdrawn from the surgical site, leaving the anchor wire firmly positioned within the bone tunnel and suture 50 looped around the anchor wire.",
"The 180° twist 13 in the anchor wire prevents the suture from being drawn into loop 11 when the ends of the suture are pulled to achieve desired tension.",
"It is to be noted that, although the preferred embodiment of the insertion tool includes respective engagement pins secured to the jaws 43 and 45, other jaw configurations are possible and fall within the scope of the present invention.",
"For example, only one of the jaws may have a projecting pin configured to engage the opposing jaw when the jaws are closed.",
"Alternatively, the opposing jaw may have a recess or bore defined therethrough in position to receive the engagement pin from the first-mentioned jaw.",
"The configurations of the engagement pins need not be cylindrical;",
"rather, any configuration capable of serving the functions described above is appropriate for the engagement pins.",
"Likewise, the specific manner by which the jaws are opened and closed should not be a limiting feature of the invention.",
"In particular, the preferred insertion tool described above effects closure of the jaws by withdrawing the resiliently spaced jaws into an outer tube.",
"Rather than providing the illustrated inner tube and outer tube combination, a single tube may be provided with nonresilient jaws formed at its distal end.",
"One of the jaws would be pivotable relative to the tubes so as to selectively close the jaws in a manner similar to that employed for arthroscopic graspers and cutters well known in the prior art.",
"An outer sleeve may then be disposed over the distal end of the insertion tool to be selectively axially movable relative to the jaws to bend the outer leg segments of the anchor wire in a manner described.",
"An alternative embodiment of the anchor assembly and insertion tool are illustrated in FIGS. 11-18 to which specific reference is now made.",
"In this embodiment the anchor assembly includes anchor wire 10, configured as described above, and a biocompatable anchor sleeve 60.",
"The anchor sleeve 60 has a generally cylindrical configuration with a proximal end wall 61 having a central hole or opening 63 defined therethrough.",
"The diameter of hole 60 is sufficient to permit loop 11 of the anchor wire to project proximally therethrough when the anchor wire is received in sleeve 60 in the manner described below.",
"The opposite or distal end 65 of sleeve 60 is open to receive the anchor wire.",
"Longitudinally extending wire relief channels or recesses 67, 69 are defined in the outer surface of sleeve 60 and extend along the entire length of the sleeve.",
"Channels 67 and 69 are disposed at 180°-spaced locations about the sleeve circumference and are sufficiently deep to receive most, if not all, of the diametric thickness of respective outer leg segments 19 and 25.",
"That is, anchor wire 10, when received in sleeve 60, has the inside surfaces of its knees 17 and 23 disposed in abutting relation with the distal edge of the sleeve.",
"Further, the natural spacing between the outermost edges of inner leg segments 15 and 21 is greater than the inner diameter of sleeve 60.",
"Accordingly, sleeve 60 is retained on anchor wire 10 by a forced fit created by the limited resilience of the anchor wire.",
"In the preferred embodiment, distal end 65 has a pair of recesses 66, 68 serving as extensions of respective channels 67, 69 to receive the entire thickness of respective knees 17 and 23.",
"In this received position of the anchor wire, inner leg segments 15, 21 and twist junction 13 are disposed inside sleeve 60.",
"At two 180°-spaced locations, spaced 90° from wire relief channels 67 and 69, the wall of sleeve 60 is completely removed along the entire sleeve length.",
"The resulting open spaces 71, 73 are continued as respective arcuate recesses 75, 77 defined in the circumferential edge of proximal end wall 61.",
"Spaces 71, 73 serve as suture relief spaces through which suture 50 extends when looped about the proximal end of wire twist 13 between inner leg segments 15 and 21.",
"The insertion tool 80 employed with the anchor assembly of wire 10 and sleeve 60 may be substantially the same tool described above.",
"As shown in FIGS. 11-18, the outer tube 33'",
"of the tool may have a pair of 180°-spaced slots 81, 83 cut through the entire tube wall thickness and extending a short distance rearward from the outer tube distal end.",
"The suture ends thus extend through spaces 71, 73 and recesses 75, 77 to reside along the slots 81 and 83.",
"The operation of the anchor assembly of FIGS. 11-18 is similar to that described above in relation to FIGS. 1-10.",
"Anchor wire loop 11, exposed through sleeve hole 63, is engaged in the same manner between jaws 43 and 45, and the sequence of deployment proceeds as previously described with two significant exceptions.",
"First, instead of the outer leg segments 19 and 25 being deformably bent directly by the distal end of the outer tube 33'",
"upon retraction of the inner tube, the outer tube distal end urges sleeve 60 forwardly relative to the anchor wire.",
"The distal end of the sleeve thus deformably bends the outer leg segments of the wire outwardly under the urging of the distal end of the outer tube as the inner tube retracts.",
"A second significant distinction resides in the fact that biocompatable sleeve 60 may remain deployed with the anchor wire in the bone tunnel.",
"The forced fit between the sleeve and the inner leg segments 15 and 21 assures that the sleeve will not become disengaged.",
"Of course, the sleeve can be designed to be removed after deployment of the wire, if desired.",
"Sleeve 60 is made of any suitable bio-compatible metal or plastic material.",
"In an exemplar embodiment, the sleeve has a length of 0.157"",
"and an outside diameter of 0.100".",
"Hole 63 in proximal end wall 61 has a diameter of 0.060"",
"which is substantially equal to the maximum transverse dimension of anchor wire loop 11.",
"Channels 67 and 69 are generally semi-cylindrical with a depth of 0.015", while spaces 71, 73 each subtend a circumferential angle on the order of 60°.",
"The transverse space between interior walls across spaces 71, 73 is 0.040".",
"It may be desirable, in some instances, to configure the anchor wire in the manner illustrated in FIG. 19 wherein anchor wire 10'",
"is configured to have its pointed ends 20', 27'",
"curved outwardly and way from the longitudinal axis of the anchor.",
"This curvature at the tips of the anchor facilitates penetration into the bone upon outward bending of outer segments 19 and 25 during deployment.",
"In all other respects anchor wire 10'",
"is substantially the same as anchor wire 10.",
"It will be understood that some of the specific details of the exemplary embodiments described above are not limiting on the scope of the invention.",
"In particular, the feature of primary importance in the anchor is the presence of two or more wire legs capable of being deformably bent outward while in a bone tunnel to permit their pointed ends to penetrate the bone tunnel wall upon being pulled proximally toward the tunnel opening.",
"On the other hand, prior to being bent, the wire legs are retracted such that the maximum transverse dimension of the anchor permits it to be readily inserted into and removed from the tunnel.",
"In this regard, the anchor may comprise only the wire, or the wire engaged by a biocompatable anchor sleeve (both as described above);",
"or it may comprise a body of biocompatable metal or plastic material having the bendable pointed legs embedded therein or otherwise secured at the distal end of the body, and with a loop or other anchor engagement structure at the proximal end of the body.",
"The configuration of the anchor body is not, of itself, critical to the invention, although certain configurations, such as those described herein, are more advantageous than others.",
"The key features, again, are the fact that the legs are deformable to effect deployment while the anchor is in the bone tunnel to permit the anchor to be removed after insertion but prior to bending for deployment, a passage for engaging a suture looped about or through the anchor, and a mechanism for engaging the anchor with a removable insertion tool capable of selectively deploying the anchor in the tunnel by causing the legs to deformably bend outwardly without hammering or impacting the anchor.",
"The specific insertion tool configurations described herein, although particularly advantageous, can also be varied within the scope of the invention.",
"The key features of the tool are the capability of engaging the anchor for selective insertion into and removal from the bone tunnel, and the capability of selectively deploying the anchor by causing deformation of the anchor legs.",
"It should also be noted that inner tube 31 of the illustrated insertion tool may be any rod-like member, whether or not tubular.",
"From the foregoing description it will be appreciated that the invention makes available a novel suture anchor for soft tissue fixation characterized by being removable from a bone tunnel after insertion but before deployment, easily actuated for permanent deployment, and deployable without requiring hammering of the anchor suture or threading of the bone tunnel.",
"In accordance with the present invention, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein.",
"It is therefore understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as defined by the appended claims."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to toy vehicles and more particularly to toy vehicles having a biased action feature responsive to impact.
2. Background Art
There are toy vehicles in the prior art in which a part or all of the body breaks or explodes away from a unitary chassis that carries the surface engaging wheels on spaced apart parallel axles as a result of a crash or impact. Examples of such prior art toy vehicles are shown in U.S. Pat. Nos. 2,757,482; 3,176,429; 3,734,500; 3,959,920; and 4,413,443. Other prior art toy vehicles such as those shown in U.S. Pat. Nos. 2,597,094 and 1,363,891 have chassis parts that are pivotally connected together along an axis parallel to the surface engaging wheel axles and open up in response to impact. Still other prior art toy vehicles like those shown in U.S. Pat. Nos. 3,000,137; 3,445,959; and 4,466,214 plus published British Patent Application GB2,033,766A have spring loaded lever arms that are released in response to impact to engage the surface supporting the vehicle in order to flip or overturn the vehicle. Particularly as such crash responsive toy wheeled vehicles have long been popular toys, there is a continuing demand for more entertaining and exciting devices of this type. It would be particularly desirable to have an impact responsive toy wheeled vehicle that would both break apart and flip over without requiring a separate spring loaded lever arm to flip the vehicle. In addition to providing such an impact responsive toy vehicle with a lock-out to prevent the impact responsive action during normal play it would also be desirable to provide a virtually fail-safe way of putting the parts of the vehicle together with the impact responsive feature rendered totally inoperative.
SUMMARY OF THE INVENTION
The present invention in concerned with providing a toy wheeled vehicle having parts that separate and flip over when the vehicle impacts an obstruction and also having a lock-out to selectively prevent such a response on impact as well as a fail-safe way of putting the parts together to render the impact responsive feature inoperative. These and other objects and advantages of the invention are achieved by providing a toy vehicle with connectable separate first and second parts each having surface engaging wheels and joinable together at one end with a spring carried by one of the parts to bias away the joinable end of the other part when the parts are connected together in a combination supported on the surface engaging wheels. A resilient latch on one part cooperates with a bar on the other part to retain the parts connected against the bias. In response to impact on an exposed end, a moveable lever pushes against the resilient latch with the inner end of the lever to disengage the latch from the bar. Carried for rotation by the vehicle is a lug, which in one rotational position engages an abutment sill on the lever to lock the lever against movement upon impact. The separate parts can be connected together in another combination with the biasing spring so positioned as to not bias the parts to separate and so render the impact responsive inoperative.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention reference may be had to the accompanying drawings in which:
FIG. 1 is a perspective view of a vehicle embodying the present invention prior to impact;
FIG. 2 is a perspective view of the vehicle after impact;
FIG. 3 is an enlarged scale, top plan view of the vehicle partially in section;
FIG. 4 is an elevational view of the joinable end of the front half of the vehicle;
FIG. 5 is an elevational view of the joinable end of the rear half of the vehicle;
FIG. 6 is a sectional view taken generally along the line 6--6 of FIG. 3;
FIG. 7 is a sectional view taken generally along the ling 7--7 of FIG. 3;
FIG. 8 is a sectional view taken generally along the line 8--8 of FIG. 6;
FIG. 9 is a further enlarged scale perspective view of the trigger;
FIG. 10 is a perspective view of the rotatable lock; and
FIG. 11 is a fragmentary view showing the rotatable lock in the trigger locking position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in which like parts are designated by like reference numerals throughout the several views, there is shown in FIG. 1 a toy vehicle 20 in a sports car style. The vehicle is separable into a front half 22 and a rear half 24 transverse to the longitudinal center line of the vehicle. Front half 22 has a lower chassis 26 and an upper body 28 that are attached together by respective posts 30 (only one of which is shown) fitting into wells 32 (only one of which is shown). Rear half 24 is similarly composed of a rear chassis 34 with an upper rear body 36 attached together by posts 38 (only one of which is shown) projecting upwardly from the chassis and received in wells 40 (only one of which is shown) depending downwardly from the underside of the rear body. Only one post and well combination for each of the front and rear halves of the vehicle is illustrated to facilitate showing the other parts of the vehicle.
Mounted for rotation relative to a playing surface is a front axle 42 with end mounted front wheels 44 on the front half 22 and rear axle 46 with end mounted rear wheels 48 on the rear half 24. A motor 50 of any conventional battery, spring, or inertia powered type may be housed in the rear half and drivingly connected to the rear axle 46. Each of the front half and the rear half parts have a joinable end 52 and 54, respectively. In addition, each of the parts has a respective free end 56 and 58. When the front half 22 and rear half 24 are connected together at the joinable ends, the combination is a vehicle supportable on the surface engaging front and rear wheels 44 and 48.
Carried in the front half 22 is a torsion spring 60 which lies along the joinable end of the front chassis 26 and has end arms 62 bearing against the inside upper surface of the chassis. A center arm 64 of the torsion spring is formed as an extending loop and lies generally along the longitudinal center line of the vehicle. Center arm 64 is pivotally moveable from the loaded, upraised, position best illustrated in FIGS. 6 and 8 to an unloaded, at rest, position, as illustrated in FIG. 4, in which the center arm lies generally in a horizontal plane.
Extending upwardly from the front chassis 26 adjacent the joinable end 52 are a pair of spaced apart upright standards 68. The center arm 64 of the torsion spring extends through the space between the standards. Bridging across the top of the standards 68 is a generally horizontally disposed bar 70. A shelf 72 is connected across the standards 68 spaced above the chassis 26 and extending toward the free end 56. The space between the upper side of the chassis and the lower side of the shelf 72 accommodates and retains the torsion spring 60. Spaced outboard of the standards 68, and for the most part lying generally parallel to the longitudinal center line are a pair of deflector fins 74 that are formed as an integral part of the front chassis 26 and extend upwardly from the chassis. Adjacent the joinable end the deflector fins flare outwardly towards the sides of the vehicle. Front chassis 26 includes a pair of slots or notches 76 spaced apart on either side of the longitudinal center line of the vehicle and extending upwardly from the underside of the chassis at the forward end of the notches is a ledge 78.
A trigger lever 80 is carried by the front half for sliding movement between the free end and the joinable end. Lever 80 includes an exposed end in the form of a front bumper 82 and an inner actuator end 84. Intermediate the ends an oblong opening 86 accommodates the post 30 and well 32 during sliding movement of the trigger lever 80. Depending downwardly from the lever is an abutment sill 88. Chassis 26 includes an integrally formed upwardly extending strut 92 and body 28 includes a downwardly extending retainer extension 94, both of which provide support for the trigger lever 80.
Front chassis 26 includes a circular opening 96 which receives a rotatable lock 100. The lock includes a middle body portion 102 which is received for rotational movement within the circular opening 96. A lower annular flange 104 limits the extent to which the lock 100 may be inserted into the opening from the underside of the chassis. Extending radially from the flange 104 is a handle 106. Projecting upwardly from the cylindrical body 102 are a pair of spaced apart angled lips 108 and 110. The lips may be sufficiently compressed together for insertion of the lock into the central opening and then by their inherent resiliency expand to, as best shown in FIGS. 6 and 11, rotatably retain the lock 100 within the circular opening 96 against removal. Lip 110 includes an outwardly projecting lug 112.
Rear half 24 has, adjacent the joinable end 54, an integrally formed wall 120 extending upwardly from the rear chassis 34. Wall 120 provides a bearing surface 122 against which the center arm 64 of the torsion spring 60 is urged when the front and rear half parts are connected together with the spring in its loaded position. Generally along the longitudinal center line of the vehicle a recess 124 is provided on the chassis 34 adjacent the joinable end to accommodate the center arm 64 of the torsion spring in the generally horizontal rest or unloaded position.
A latch 130 is attached at its back end to the underside of the rear body 36 by an upset plastic rivet 132 or other suitable fastening means. Bead 134 on the underside of the rear body 36 intermediate the attachment of the back end of the latch and the joinable end 54 of the rear half spaces the latch 130 from the underside of the body. Latch 130 is made of a material that is sufficiently resilient to permit the normally downwardly biased latch to be deflected upwardly. The front edge 136 of the latch is angled to provide a camming surface while the rear edge 138 is generally vertical. Rear edge 138 of the latch 130 engages the bar 70 carried by the front half when the two parts are connected together and the front edge 136 is in proximity to the inner actuator end 84 of the trigger lever 80. Depending downwardly from the underside of the rear body 36 on either side of the latch 130 are spaced apart side braces 139.
Extending outwardly from the joinable end 54 of the rear half and spaced apart generally parallel to the longitudinal center line of the vehicle are a pair of hooks 140 connected together by wall 120. The hooks, which are rigid relative to the latch 130, along with the wall may be integrally formed as part of the chassis 34. When the front and rear parts are connected together, the hooks 140 mate with, or are received in, the notches 76 of the front chassis 26. Deflector fins 74 facilitate connecting the parts together by guiding the insertion of the hooks 140 into position to be received in the notches.
In operation, the two separable halves may be connected together by placing the lower edges of the two joinable ends adjacent each other and then pivoting the two parts together to close the upper opening. This pivotal closing together of the parts brings the center arm 64 of the spring up against the bearing surface 122 loading the spring as the parts are brought together and at the same time inserts the hooks 140 in the spaces between the deflector fins 74 and the upright standards 68 to bring the hooks into position to be received in the notches 76. As the two parts finally come together, the front edge 136 of the latch is cammed over the bar 70 until the downward bias of the latch drops the rear edge over the bar securing the two parts together.
With the rotatable lock 100 in the position illustrated in FIG. 6, the trigger lever 80 is free to move rearwardly which would bring the actuator end 84 against the front camming edge 136 to push the latch 130 up and back over the bar 70. When the latch 130 is released from the bar 70, the downward and outward bias exerted by the center arm 64 of the spring against the bearing surface 122 of the rear half forces the two halves apart and at the same time causes them to each flip over as illustrated in FIG. 2. The necessary rearward movement of the trigger lever 80 results from propelling the vehicle 20 forwardly against an obstruction 150 so that the front bumper 82 impacts against the obstruction.
If desired, the parts may be connected together with the spring loaded and the impact responsive feature momentarily locked out by rotating the lock 100 to bring the lug 112 into a position 180 degrees opposed from that shown in FIG. 6 to the position shown in FIG. 11 where the lug 112 is abutting the downwardly depending sill 88. Trigger lever 80 would then be locked or prevented from moving inwardly even should the front bumper 82 impact an obstruction.
For fail-safe connection of the two halves together so that the impact responsive feature is totally inoperative, the two halves are connected together in a manner similar to that already described except that at the outset the outwardly extending, generally horizontally disposed center arm 64 of the spring is positioned in the recess 124 in the rear chassis 34 so that the spring is not loaded as the parts are pivoted together. This second type of alternative combination of the two parts may be particularly desirable for storage or shipment of the toy vehicle.
While a particular embodiment of the invention has been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the invention. It is intended in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention. | An impact responsive toy vehicle in which two separable halves each carrying surface engaging wheels are connected together to provide a vehicle supported on the surface engaging wheels. A torsion spring biases the joinable ends of the two halves to separate and each flip over. The parts are retained together by a connecting latch that is disengageable by a slidable lever that moves in reponse to a force on an extending front bumper. One half carries a rotatable lock including a lug that cooperates with an abutment on the lever to lock the trigger lever against sliding movement in response to impact on the bumper. Fail-safe combination of the two parts rendering the impact responsive feature totally inoperative is accomplished by assembling the parts together with the arm of the torsion spring received in a recess on the underside of the chassis of the other half. | Concisely explain the essential features and purpose of the invention. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates generally to toy vehicles and more particularly to toy vehicles having a biased action feature responsive to impact.",
"Background Art There are toy vehicles in the prior art in which a part or all of the body breaks or explodes away from a unitary chassis that carries the surface engaging wheels on spaced apart parallel axles as a result of a crash or impact.",
"Examples of such prior art toy vehicles are shown in U.S. Pat. Nos. 2,757,482;",
"3,176,429;",
"3,734,500;",
"3,959,920;",
"and 4,413,443.",
"Other prior art toy vehicles such as those shown in U.S. Pat. Nos. 2,597,094 and 1,363,891 have chassis parts that are pivotally connected together along an axis parallel to the surface engaging wheel axles and open up in response to impact.",
"Still other prior art toy vehicles like those shown in U.S. Pat. Nos. 3,000,137;",
"3,445,959;",
"and 4,466,214 plus published British Patent Application GB2,033,766A have spring loaded lever arms that are released in response to impact to engage the surface supporting the vehicle in order to flip or overturn the vehicle.",
"Particularly as such crash responsive toy wheeled vehicles have long been popular toys, there is a continuing demand for more entertaining and exciting devices of this type.",
"It would be particularly desirable to have an impact responsive toy wheeled vehicle that would both break apart and flip over without requiring a separate spring loaded lever arm to flip the vehicle.",
"In addition to providing such an impact responsive toy vehicle with a lock-out to prevent the impact responsive action during normal play it would also be desirable to provide a virtually fail-safe way of putting the parts of the vehicle together with the impact responsive feature rendered totally inoperative.",
"SUMMARY OF THE INVENTION The present invention in concerned with providing a toy wheeled vehicle having parts that separate and flip over when the vehicle impacts an obstruction and also having a lock-out to selectively prevent such a response on impact as well as a fail-safe way of putting the parts together to render the impact responsive feature inoperative.",
"These and other objects and advantages of the invention are achieved by providing a toy vehicle with connectable separate first and second parts each having surface engaging wheels and joinable together at one end with a spring carried by one of the parts to bias away the joinable end of the other part when the parts are connected together in a combination supported on the surface engaging wheels.",
"A resilient latch on one part cooperates with a bar on the other part to retain the parts connected against the bias.",
"In response to impact on an exposed end, a moveable lever pushes against the resilient latch with the inner end of the lever to disengage the latch from the bar.",
"Carried for rotation by the vehicle is a lug, which in one rotational position engages an abutment sill on the lever to lock the lever against movement upon impact.",
"The separate parts can be connected together in another combination with the biasing spring so positioned as to not bias the parts to separate and so render the impact responsive inoperative.",
"BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present invention reference may be had to the accompanying drawings in which: FIG. 1 is a perspective view of a vehicle embodying the present invention prior to impact;",
"FIG. 2 is a perspective view of the vehicle after impact;",
"FIG. 3 is an enlarged scale, top plan view of the vehicle partially in section;",
"FIG. 4 is an elevational view of the joinable end of the front half of the vehicle;",
"FIG. 5 is an elevational view of the joinable end of the rear half of the vehicle;",
"FIG. 6 is a sectional view taken generally along the line 6--6 of FIG. 3;",
"FIG. 7 is a sectional view taken generally along the ling 7--7 of FIG. 3;",
"FIG. 8 is a sectional view taken generally along the line 8--8 of FIG. 6;",
"FIG. 9 is a further enlarged scale perspective view of the trigger;",
"FIG. 10 is a perspective view of the rotatable lock;",
"and FIG. 11 is a fragmentary view showing the rotatable lock in the trigger locking position.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings in which like parts are designated by like reference numerals throughout the several views, there is shown in FIG. 1 a toy vehicle 20 in a sports car style.",
"The vehicle is separable into a front half 22 and a rear half 24 transverse to the longitudinal center line of the vehicle.",
"Front half 22 has a lower chassis 26 and an upper body 28 that are attached together by respective posts 30 (only one of which is shown) fitting into wells 32 (only one of which is shown).",
"Rear half 24 is similarly composed of a rear chassis 34 with an upper rear body 36 attached together by posts 38 (only one of which is shown) projecting upwardly from the chassis and received in wells 40 (only one of which is shown) depending downwardly from the underside of the rear body.",
"Only one post and well combination for each of the front and rear halves of the vehicle is illustrated to facilitate showing the other parts of the vehicle.",
"Mounted for rotation relative to a playing surface is a front axle 42 with end mounted front wheels 44 on the front half 22 and rear axle 46 with end mounted rear wheels 48 on the rear half 24.",
"A motor 50 of any conventional battery, spring, or inertia powered type may be housed in the rear half and drivingly connected to the rear axle 46.",
"Each of the front half and the rear half parts have a joinable end 52 and 54, respectively.",
"In addition, each of the parts has a respective free end 56 and 58.",
"When the front half 22 and rear half 24 are connected together at the joinable ends, the combination is a vehicle supportable on the surface engaging front and rear wheels 44 and 48.",
"Carried in the front half 22 is a torsion spring 60 which lies along the joinable end of the front chassis 26 and has end arms 62 bearing against the inside upper surface of the chassis.",
"A center arm 64 of the torsion spring is formed as an extending loop and lies generally along the longitudinal center line of the vehicle.",
"Center arm 64 is pivotally moveable from the loaded, upraised, position best illustrated in FIGS. 6 and 8 to an unloaded, at rest, position, as illustrated in FIG. 4, in which the center arm lies generally in a horizontal plane.",
"Extending upwardly from the front chassis 26 adjacent the joinable end 52 are a pair of spaced apart upright standards 68.",
"The center arm 64 of the torsion spring extends through the space between the standards.",
"Bridging across the top of the standards 68 is a generally horizontally disposed bar 70.",
"A shelf 72 is connected across the standards 68 spaced above the chassis 26 and extending toward the free end 56.",
"The space between the upper side of the chassis and the lower side of the shelf 72 accommodates and retains the torsion spring 60.",
"Spaced outboard of the standards 68, and for the most part lying generally parallel to the longitudinal center line are a pair of deflector fins 74 that are formed as an integral part of the front chassis 26 and extend upwardly from the chassis.",
"Adjacent the joinable end the deflector fins flare outwardly towards the sides of the vehicle.",
"Front chassis 26 includes a pair of slots or notches 76 spaced apart on either side of the longitudinal center line of the vehicle and extending upwardly from the underside of the chassis at the forward end of the notches is a ledge 78.",
"A trigger lever 80 is carried by the front half for sliding movement between the free end and the joinable end.",
"Lever 80 includes an exposed end in the form of a front bumper 82 and an inner actuator end 84.",
"Intermediate the ends an oblong opening 86 accommodates the post 30 and well 32 during sliding movement of the trigger lever 80.",
"Depending downwardly from the lever is an abutment sill 88.",
"Chassis 26 includes an integrally formed upwardly extending strut 92 and body 28 includes a downwardly extending retainer extension 94, both of which provide support for the trigger lever 80.",
"Front chassis 26 includes a circular opening 96 which receives a rotatable lock 100.",
"The lock includes a middle body portion 102 which is received for rotational movement within the circular opening 96.",
"A lower annular flange 104 limits the extent to which the lock 100 may be inserted into the opening from the underside of the chassis.",
"Extending radially from the flange 104 is a handle 106.",
"Projecting upwardly from the cylindrical body 102 are a pair of spaced apart angled lips 108 and 110.",
"The lips may be sufficiently compressed together for insertion of the lock into the central opening and then by their inherent resiliency expand to, as best shown in FIGS. 6 and 11, rotatably retain the lock 100 within the circular opening 96 against removal.",
"Lip 110 includes an outwardly projecting lug 112.",
"Rear half 24 has, adjacent the joinable end 54, an integrally formed wall 120 extending upwardly from the rear chassis 34.",
"Wall 120 provides a bearing surface 122 against which the center arm 64 of the torsion spring 60 is urged when the front and rear half parts are connected together with the spring in its loaded position.",
"Generally along the longitudinal center line of the vehicle a recess 124 is provided on the chassis 34 adjacent the joinable end to accommodate the center arm 64 of the torsion spring in the generally horizontal rest or unloaded position.",
"A latch 130 is attached at its back end to the underside of the rear body 36 by an upset plastic rivet 132 or other suitable fastening means.",
"Bead 134 on the underside of the rear body 36 intermediate the attachment of the back end of the latch and the joinable end 54 of the rear half spaces the latch 130 from the underside of the body.",
"Latch 130 is made of a material that is sufficiently resilient to permit the normally downwardly biased latch to be deflected upwardly.",
"The front edge 136 of the latch is angled to provide a camming surface while the rear edge 138 is generally vertical.",
"Rear edge 138 of the latch 130 engages the bar 70 carried by the front half when the two parts are connected together and the front edge 136 is in proximity to the inner actuator end 84 of the trigger lever 80.",
"Depending downwardly from the underside of the rear body 36 on either side of the latch 130 are spaced apart side braces 139.",
"Extending outwardly from the joinable end 54 of the rear half and spaced apart generally parallel to the longitudinal center line of the vehicle are a pair of hooks 140 connected together by wall 120.",
"The hooks, which are rigid relative to the latch 130, along with the wall may be integrally formed as part of the chassis 34.",
"When the front and rear parts are connected together, the hooks 140 mate with, or are received in, the notches 76 of the front chassis 26.",
"Deflector fins 74 facilitate connecting the parts together by guiding the insertion of the hooks 140 into position to be received in the notches.",
"In operation, the two separable halves may be connected together by placing the lower edges of the two joinable ends adjacent each other and then pivoting the two parts together to close the upper opening.",
"This pivotal closing together of the parts brings the center arm 64 of the spring up against the bearing surface 122 loading the spring as the parts are brought together and at the same time inserts the hooks 140 in the spaces between the deflector fins 74 and the upright standards 68 to bring the hooks into position to be received in the notches 76.",
"As the two parts finally come together, the front edge 136 of the latch is cammed over the bar 70 until the downward bias of the latch drops the rear edge over the bar securing the two parts together.",
"With the rotatable lock 100 in the position illustrated in FIG. 6, the trigger lever 80 is free to move rearwardly which would bring the actuator end 84 against the front camming edge 136 to push the latch 130 up and back over the bar 70.",
"When the latch 130 is released from the bar 70, the downward and outward bias exerted by the center arm 64 of the spring against the bearing surface 122 of the rear half forces the two halves apart and at the same time causes them to each flip over as illustrated in FIG. 2. The necessary rearward movement of the trigger lever 80 results from propelling the vehicle 20 forwardly against an obstruction 150 so that the front bumper 82 impacts against the obstruction.",
"If desired, the parts may be connected together with the spring loaded and the impact responsive feature momentarily locked out by rotating the lock 100 to bring the lug 112 into a position 180 degrees opposed from that shown in FIG. 6 to the position shown in FIG. 11 where the lug 112 is abutting the downwardly depending sill 88.",
"Trigger lever 80 would then be locked or prevented from moving inwardly even should the front bumper 82 impact an obstruction.",
"For fail-safe connection of the two halves together so that the impact responsive feature is totally inoperative, the two halves are connected together in a manner similar to that already described except that at the outset the outwardly extending, generally horizontally disposed center arm 64 of the spring is positioned in the recess 124 in the rear chassis 34 so that the spring is not loaded as the parts are pivoted together.",
"This second type of alternative combination of the two parts may be particularly desirable for storage or shipment of the toy vehicle.",
"While a particular embodiment of the invention has been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the invention.",
"It is intended in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention."
] |
FIELD OF THE INVENTION
The present invention relates to a laundry appliance such as a washing machine or washer-dryer and to a control apparatus for such a machine.
BACKGROUND OF THE INVENTION
Conventional washing machines operate by agitating textile articles within a rotating drum in the presence of water and detergent so that dirt is released from the fibres of the textile articles into the water. The agitation is caused, in the case of front-loading washing machines, by the rotation of the drum about a generally horizontal axis so that the textile articles tumble over one another and rub against each other and against the walls of the drum. However, the rotational speed of the drum is limited because, if the speed is too high, the textile articles will merely be pressed under centrifugal forces against the interior walls of the drum. The articles then rotate with the drum and no agitation with respect to the drum or with respect to other articles is achieved. The amount of agitation which can be applied to the textile articles by front-loading washing machines is therefore limited. This means that, in order to achieve a specific standard of cleanliness, the machine must operate for a minimum period of time.
International Patent Application WO99/58753 describes a washing machine in which the drum comprises two rotatable drum portions which are driven in such a way that relative rotation is produced between the drum portions. The relative rotation between the drum portions gives a more vigorous agitation of the articles within the drum, treating them more intensively than they would be in conventional apparatus and consequently dirt is released from the textile articles at a higher rate than in other machines.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved laundry apparatus.
Accordingly, a first aspect of the invention provides a laundry appliance comprising a drum for receiving articles to be laundered, the drum comprising at least two rotatable drum portions and a drive capable of operating the drum in a plurality of different drum modes, including a drum mode in which the rotatable drum portions are driven so as to cause relative rotation between the adjacent rotatable drum portions, and a controller which is capable of controlling the appliance to perform a plurality of different wash programmes, each wash programme having an associated drum mode.
This has the advantage that each wash programme uses a drum mode which is appropriate for the type of load that is to be washed during that wash programme.
Preferably, in one of the wash programmes, the controller controls the drive to operate in a drum mode in which the drum portions are not rotated relative to one another at any point during the wash programme. This has the advantage that the drum can accommodate a load of the type which would not normally be suited to this type of appliance, such as a duvet.
The portions of the drum can be rotated in opposite directions at the same or different speeds. Alternatively, each of the portions of the drum can be rotated at a different speed in the same direction.
Preferably the appliance has a control panel for allowing a user to select an intensity for the chosen wash programme, such as when clothes are more heavily or more lightly soiled than normal. The controller is arranged to vary, in use, the intensity of the wash programme in accordance with the selection made by a user. The intensity of the wash programme can be varied by varying the length of the wash portion of the wash programme, varying the ratio of time during which the drum portions are rotated relative to one another compared to the time during which the drum portions are not rotated or varying the speed of relative rotation between the drum portions. The latter two options have the advantage of allowing the wash intensity to be varied without increasing the length of the wash programme.
BRIEF DESCRIPTION OF THE DRAWINGS
A further aspect of the invention provides a control apparatus for the laundry appliance.
Embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a cross-sectional view of a washing machine embodying the present invention;
FIG. 2 shows a control system for the machine of FIG. 1 ;
FIG. 3 shows one form of control panel for the, machine of FIG. 1 ;
FIGS. 4A-4C show one drum mode performed by the machine of FIG. 1 ;
FIGS. 5A-5C show another drum mode performed by the machine of FIG. 1 ;
FIGS. 6 and 7 are tables which give details of the wash programmes performed by the machine of FIG. 1 and FIG. 8 is a key for these tables.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a washing machine 10 which includes an outer casing 12 in which a stationary tub 40 is located. A drum 50 is mounted inside the tub 40 so as to be rotatable about an axis 85 . The tub 40 is watertight except for an inlet 21 and outlet 22 . The washing machine 10 includes a soap tray 20 capable of receiving detergent in a known manner. At least one water inlet 23 communicates with the soap tray 20 and is provided with suitable means for connection to a water supply within the environment in which the washing machine 10 is to be used. A conduit 21 is provided between the soap tray 20 and the tub 40 so as to allow water introduced via the inlet 23 to enter the tub 40 . The tub 40 has a sump 26 located beneath the drum 50 . A drainage pipe 28 communicates with the sump 26 and leads to a water outlet 30 via which water can be discharged from the washing machine 10 . A pump 42 is provided to allow water to be pumped from the sump 26 to the water outlet 30 at appropriate stages of the washing cycle carried out by the washing machine 10 .
The drum 50 is rotatably mounted about the axis 85 by way of a shaft 80 . The shaft 80 is mounted in a known manner, allowing the tub 40 to remain stationary whilst the drum 50 is rotatable with the shaft 80 . The shaft 80 is rotatably driven by a motor (not shown) mounted within the outer casing 12 of the washing machine 10 . A door 66 is located in the front panel 12 a of the outer casing 12 to allow access to the interior of the drum 50 . It is via the door 66 that a wash load can be deposited within the drum 50 before a wash cycle commences and removed from the drum 50 at the end of the wash cycle.
Drum 50 comprises two portions 60 , 70 which are mounted such that they can be rotated with respect to one another. A drum of this type is described more fully in International Patent Application WO99/58753. Typically the drum portions 60 , 70 are rotated in opposite directions to one another, i.e. one portion clockwise, one counter-clockwise, but they can also be rotated together in the same direction. The drum 50 is mounted in a cantilever fashion on the wall of the tub 40 remote from the door 66 . The first outer rotatable portion 60 , is supported on a hollow cylindrical shaft 81 . An angular contact bearing 82 is located between the rear wall of the tub 40 and the hollow cylindrical shaft 81 . The outer rotatable portion 60 is dimensioned so as to substantially fill the interior of the tub 40 . More specifically, the outer rotatable portion 60 has a generally circular rear wall 63 extending from the hollow cylindrical shaft 81 towards the cylindrical wall of the tub 40 , a generally cylindrical wall 61 extending generally parallel to the cylindrical walls of the tub 40 from the rear wall 63 towards the front wall of the tub 40 , and a generally annular front face 64 extending from the cylindrical wall 61 towards the door 66 . Sufficient clearance is allowed between the walls 61 , 63 , 64 of the outer rotatable portion 60 and the tub 40 to prevent the outer rotatable portion 60 from coming into contact with the tub 40 when the drum 50 is made to spin.
An inner cylindrical wall 62 is also provided on the interior of the cylindrical wall 61 of the outer rotatable portion 60 . The inner cylindrical wall 62 extends from a point which is substantially midway between the rear wall 63 and the front face 64 to the front face 565 . The space between the interior cylindrical wall 62 and the cylindrical wall 61 is hollow but, if desired, could be filled with a strengthening material. In this event, the strengthening material must be lightweight. The provision of parallel cylindrical walls 61 , 62 in the portion of the outer rotatable portion 60 closest to the front face 64 provides strength to the whole of the outer rotatable portion 60 whilst reducing the internal diameter of the outer rotatable portion 60 in this region.
The inner rotatable portion 70 is supported on a central shaft 80 , which in turn, is supported by deep groove bearings 83 located between the central shaft 80 and the hollow cylindrical shaft 81 . The inner rotatable portion 70 essentially comprises a generally circular rear wall 71 extending from the central shaft 80 towards the cylindrical wall of the tub 40 , and a cylindrical wall 74 extending from the periphery of the rear wall 71 towards the front wall of the tub 40 . The diameter of the cylindrical wall 74 of the inner rotatable portion 70 is substantially the same as the diameter of the inner cylindrical wall 62 of the outer rotatable portion 60 . The cylindrical wall 74 of the inner rotatable portion 70 is dimensioned so that its distal end approaches the end of the cylindrical wall 62 closest to it. It is advantageous to keep the gap between these two cylindrical walls 62 , 74 as small as possible. An annular sealing ring 76 is located on the cylindrical wall 61 of the outer cylindrical portion 60 immediately adjacent to the end of the inner cylindrical wall 62 closest to the inner cylindrical portion 70 so as to provide support for the distal end of the cylindrical wall 76 thereof.
FIG. 2 shows part of the control system of the machine 10 . A controller 100 operates according to a control program stored on a non-volatile memory 105 . The controller 100 is preferably implemented in the form of a microcontroller but other ways of implementing the controller, such as an implementation entirely in hardware, will be apparent to the reader and are intended to fall within the scope of this invention.
An interface 110 interfaces the controller 100 to other parts of the machine 10 . Sensors placed on the machine return signals to the interface 110 . The sensors include a water temperature sensor for monitoring temperature of the wash water in the sump of the machine 10 and a motor speed sensor. The interface 110 also outputs signals to control operation of the display 220 to display text messages and signals to control the illumination of indicator lamps 215 , 265 on the control panel 120 . Interface 110 also receives inputs from each of the control buttons 210 , 230 , 240 , 250 , 260 on the control panel 120 which allows the controller 100 to determine what button a user has pressed. The interface 110 also outputs a set of control signals 140 to control the operating state of various parts of the machine, such as the door lock, water inlet valves, and the motor M. In a well-known manner, the control software 105 controls operation of the machine according to the inputs it receives and issues outputs 140 for controlling various parts of the machine.
The speed of motor M is controlled on the basis of the monitored supply voltage and motor speed inputs to the interface and an output signal 145 to motor drive 130 . Control signal 145 controls the firing angle of the triac (or other power switching device) in the motor drive circuit 130 . Another output signal 144 controls the direction of rotation of the motor M and a further output signal 146 controls the state of the gearbox. The state of the gearbox determines whether the drum portions 60 , 70 are rotated in unison or whether they are rotated relative to one another. Motor M can be used to drive both drum portions 60 , 70 or two separate motors may be provided, one motor being used to drive each of the drum portions 60 , 70 .
FIG. 3 shows one embodiment of control panel 120 in more detail. It will be appreciated that the control panel can vary from the one shown here. For example, the control panel 120 may provide a different range of options, the type of control may vary e.g. push button, touch-sensitive control, switch, rotatable control knob or slider. Also, the range and type of visual indicators can vary, e.g. the indicators can include LEDs, an LCD or electroluminescent display.
The control panel of FIG. 3 includes an on/off button 201 to turn the mains power supply to the machine on/off; a set of control buttons 210 and associated indicators 215 for selecting the wash programme (cotton, synthetics, wool, delicates etc.); a control button 230 and an associated set of indicators for selecting the wash temperature (20-85° C.); a control button 240 and an associated set of indicators for selecting spin speed (0-1600 rpm); a control button 250 and an associated set of indicators for selecting wash intensity (light, normal, heavy); a set of control buttons 260 and an associated set of indicators 265 for selecting special features (minimum crease, pre-wash, extra rinse etc.); a plurality of memory buttons 270 , 271 , 272 for selecting a combination of stored settings; a start button 280 for starting the machine according to the settings programme by a user, and a cancel button 282 . A further indicator 283 indicates when the door 30 of the machine is locked and indicator 284 indicates when the child lock mode is active.
An LCD display 220 displays text messages at various stages during operation of the machine to help a user select programme settings and to indicate the progress of the machine through the wash cycle.
There are two basic types of drum mode: a counter-rotating mode in which the drum portions 60 , 70 are rotated relative to one another and a normal mode in which the drum portions 60 , 70 are rotated in unison in the same direction in a conventional manner.
The following table gives details of five drum modes. Each drum mode comprises a repeated sequence of four steps. For example, the ‘Counter Rotation’ operation performs: a first step which counter-rotates the drum portions 60 , 70 with respect to one another for 13 s ; a second step which rests for 6 s with no drum action; a third step which counter-rotates the drum portions 60 , 70 with respect to one another for 13 s in the opposite direction to that used in action 1 ; and a fourth step which rests for 6 s with no drum action. Clearly, any of the parameters of the drum operations defined here could be varied as appropriate.
Drum Mode
Step no.
Duration (s)
Drum speed (rpm)
Counter Rotation
1
13
52
(CR)
2
6
0
3
13
−52
4
6
0
Counter Rotation
1
10
52
Normal
2
32
0
(CRN)
3
10
−52
4
32
0
Normal Action
1
11
52
(NA)
2
5
0
3
11
−52
4
5
0
Gentle Action
1
6
52
(GA)
2
12
0
3
6
−52
4
12
0
Super Gentle Action
1
6
52
(SGA)
2
27
0
3
6
−52
4
27
0
FIGS. 4A-4C illustrate steps numbers 1 - 3 for the counter-rotating drum modes. The drum portions 50 , 60 firstly rotate in opposite directions (FIG. 4 A), then rest (FIG. 4 B), then rotate in opposite directions ( FIG. 4C ) with each drum portion 60 , 70 rotating in a different direction to that in FIG. 4 A and finally rest (not shown.) FIGS. 5A-5C illustrate actions for the normal drum modes. The drum portions 60 , 70 firstly rotate in unison in the same direction (FIG. 5 A), then rest (FIG. 5 B), then rotate in unison ( FIG. 5C ) in the opposite direction to that in FIG. 5 A and finally rest (not shown.)
In the above table, the Counter Rotations (CR) and Counter Rotation Normal (CRN) modes differ in the ratio of time when the drums are rotating (and therefore agitating the load) and when the drums are at rest. In the CR mode the drums are rotating for roughly twice the time that they are at rest whereas in the CRN mode the drums are at rest for roughly three times the time that they are rotating. Similarly, with the normal modes, the modes differ in the ratio of time when the drums are rotating (and therefore agitating the load) and when the drums are at rest. While the modes detailed above all operate at the same drum speed of 52 rpm it is possible to vary the drum speed between modes to vary the amount of agitation that these modes provide.
FIGS. 6 and 7 are tables which give full details of a set of wash programmes performed by the machine 10 and FIG. 8 is a key for these tables. A complete wash cycle comprises the following stages: prewash (if the user has selected this), main wash, rinse, final rinse and final spin. Each of these stages comprises a number of steps. During each step the machine operates with a combination of an amount of water, a water temperature and a drum mode 400 detailed in the tables. As is well-known with conventional wash programmes, the water temperature that is used during the wash programme varies according to the type of fabric being washed, with robust fabrics such as cotton being washed at a higher temperature than delicates.
During the stages of the wash cycle, and particularly during the main wash (see “Main Wash” step no. 3 , FIG. 6 ) the machine operates with a drum mode which is dependent on the wash programme. The most robust fabric types such as cottons, synthetics and dedicates use the CR drum mode (long burst of counter-rotation followed by a short rest); wool and care+ use the CRN drum mode (short burst of counter-rotation followed by a long rest) and the duvet programme does not use counter-rotation at all, since the load comprises one large article which is expected to fill the drum, conditions which are not suited to the use of a counter-rotating drum mode. The length of the wash step (see “Main Wash” step no. 3 , FIG. 6 ) varies according to the amount of soiling of the articles in the wash load: 4 minutes for light soiling, 6 minutes for normal soiling and 10 minutes for heavy soiling. A user selects the intensity of the wash via control 250 on the control panel 120 . However, as an alternative to varying the length of time for the wash step, the controller can vary the amount of agitation by varying the drum mode. Increased agitation can be provided by using a drum mode which rotates the drum portions 60 , 70 at a higher speed relative to one another or with a longer ratio of rotation time to rest time.
Variations to the described embodiments are intended to fall within the scope of the present invention. While five drum modes are described here, it is possible to provide more modes which vary in the amount of agitation they apply to the wash load. The modes can vary in the ratio of rotating time to rest time and/or speed of rotation. The drum 50 can comprise more than just the two rotatable portions 60 , 70 . Three or more separately rotatable portions can be provided, all lying alongside one another along the axis of rotation. | A laundry appliance comprises a drum for receiving articles to be laundered, the drum comprising at least two rotatable drum portions and a drive capable of operating the drum in a plurality of different drum modes. The drum modes include a mode in which the rotatable drum portions are driven so as to cause relative rotation between them. A controller ( 100 ) controls the appliance to perform a plurality of different wash programs, each wash program having an associated drum mode. Each wash program comprises a sequence of stages, with a drum mode being associated with each stage. The drum modes can differ in respect of (a) use (or non-use) of relative rotation between the drum portions (b) the ratio of time that the drum portions rotate compared to the time that they are at rest, and (c) the speed at which the drum portions are rotated. The intensity of a wash program can be varied, inter alia, by varying the length of the wash stage. | Concisely explain the essential features and purpose of the invention. | [
"FIELD OF THE INVENTION The present invention relates to a laundry appliance such as a washing machine or washer-dryer and to a control apparatus for such a machine.",
"BACKGROUND OF THE INVENTION Conventional washing machines operate by agitating textile articles within a rotating drum in the presence of water and detergent so that dirt is released from the fibres of the textile articles into the water.",
"The agitation is caused, in the case of front-loading washing machines, by the rotation of the drum about a generally horizontal axis so that the textile articles tumble over one another and rub against each other and against the walls of the drum.",
"However, the rotational speed of the drum is limited because, if the speed is too high, the textile articles will merely be pressed under centrifugal forces against the interior walls of the drum.",
"The articles then rotate with the drum and no agitation with respect to the drum or with respect to other articles is achieved.",
"The amount of agitation which can be applied to the textile articles by front-loading washing machines is therefore limited.",
"This means that, in order to achieve a specific standard of cleanliness, the machine must operate for a minimum period of time.",
"International Patent Application WO99/58753 describes a washing machine in which the drum comprises two rotatable drum portions which are driven in such a way that relative rotation is produced between the drum portions.",
"The relative rotation between the drum portions gives a more vigorous agitation of the articles within the drum, treating them more intensively than they would be in conventional apparatus and consequently dirt is released from the textile articles at a higher rate than in other machines.",
"SUMMARY OF THE INVENTION The present invention seeks to provide an improved laundry apparatus.",
"Accordingly, a first aspect of the invention provides a laundry appliance comprising a drum for receiving articles to be laundered, the drum comprising at least two rotatable drum portions and a drive capable of operating the drum in a plurality of different drum modes, including a drum mode in which the rotatable drum portions are driven so as to cause relative rotation between the adjacent rotatable drum portions, and a controller which is capable of controlling the appliance to perform a plurality of different wash programmes, each wash programme having an associated drum mode.",
"This has the advantage that each wash programme uses a drum mode which is appropriate for the type of load that is to be washed during that wash programme.",
"Preferably, in one of the wash programmes, the controller controls the drive to operate in a drum mode in which the drum portions are not rotated relative to one another at any point during the wash programme.",
"This has the advantage that the drum can accommodate a load of the type which would not normally be suited to this type of appliance, such as a duvet.",
"The portions of the drum can be rotated in opposite directions at the same or different speeds.",
"Alternatively, each of the portions of the drum can be rotated at a different speed in the same direction.",
"Preferably the appliance has a control panel for allowing a user to select an intensity for the chosen wash programme, such as when clothes are more heavily or more lightly soiled than normal.",
"The controller is arranged to vary, in use, the intensity of the wash programme in accordance with the selection made by a user.",
"The intensity of the wash programme can be varied by varying the length of the wash portion of the wash programme, varying the ratio of time during which the drum portions are rotated relative to one another compared to the time during which the drum portions are not rotated or varying the speed of relative rotation between the drum portions.",
"The latter two options have the advantage of allowing the wash intensity to be varied without increasing the length of the wash programme.",
"BRIEF DESCRIPTION OF THE DRAWINGS A further aspect of the invention provides a control apparatus for the laundry appliance.",
"Embodiments of the invention will now be described with reference to the accompanying drawings, in which: FIG. 1 is a cross-sectional view of a washing machine embodying the present invention;",
"FIG. 2 shows a control system for the machine of FIG. 1 ;",
"FIG. 3 shows one form of control panel for the, machine of FIG. 1 ;",
"FIGS. 4A-4C show one drum mode performed by the machine of FIG. 1 ;",
"FIGS. 5A-5C show another drum mode performed by the machine of FIG. 1 ;",
"FIGS. 6 and 7 are tables which give details of the wash programmes performed by the machine of FIG. 1 and FIG. 8 is a key for these tables.",
"DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a washing machine 10 which includes an outer casing 12 in which a stationary tub 40 is located.",
"A drum 50 is mounted inside the tub 40 so as to be rotatable about an axis 85 .",
"The tub 40 is watertight except for an inlet 21 and outlet 22 .",
"The washing machine 10 includes a soap tray 20 capable of receiving detergent in a known manner.",
"At least one water inlet 23 communicates with the soap tray 20 and is provided with suitable means for connection to a water supply within the environment in which the washing machine 10 is to be used.",
"A conduit 21 is provided between the soap tray 20 and the tub 40 so as to allow water introduced via the inlet 23 to enter the tub 40 .",
"The tub 40 has a sump 26 located beneath the drum 50 .",
"A drainage pipe 28 communicates with the sump 26 and leads to a water outlet 30 via which water can be discharged from the washing machine 10 .",
"A pump 42 is provided to allow water to be pumped from the sump 26 to the water outlet 30 at appropriate stages of the washing cycle carried out by the washing machine 10 .",
"The drum 50 is rotatably mounted about the axis 85 by way of a shaft 80 .",
"The shaft 80 is mounted in a known manner, allowing the tub 40 to remain stationary whilst the drum 50 is rotatable with the shaft 80 .",
"The shaft 80 is rotatably driven by a motor (not shown) mounted within the outer casing 12 of the washing machine 10 .",
"A door 66 is located in the front panel 12 a of the outer casing 12 to allow access to the interior of the drum 50 .",
"It is via the door 66 that a wash load can be deposited within the drum 50 before a wash cycle commences and removed from the drum 50 at the end of the wash cycle.",
"Drum 50 comprises two portions 60 , 70 which are mounted such that they can be rotated with respect to one another.",
"A drum of this type is described more fully in International Patent Application WO99/58753.",
"Typically the drum portions 60 , 70 are rotated in opposite directions to one another, i.e. one portion clockwise, one counter-clockwise, but they can also be rotated together in the same direction.",
"The drum 50 is mounted in a cantilever fashion on the wall of the tub 40 remote from the door 66 .",
"The first outer rotatable portion 60 , is supported on a hollow cylindrical shaft 81 .",
"An angular contact bearing 82 is located between the rear wall of the tub 40 and the hollow cylindrical shaft 81 .",
"The outer rotatable portion 60 is dimensioned so as to substantially fill the interior of the tub 40 .",
"More specifically, the outer rotatable portion 60 has a generally circular rear wall 63 extending from the hollow cylindrical shaft 81 towards the cylindrical wall of the tub 40 , a generally cylindrical wall 61 extending generally parallel to the cylindrical walls of the tub 40 from the rear wall 63 towards the front wall of the tub 40 , and a generally annular front face 64 extending from the cylindrical wall 61 towards the door 66 .",
"Sufficient clearance is allowed between the walls 61 , 63 , 64 of the outer rotatable portion 60 and the tub 40 to prevent the outer rotatable portion 60 from coming into contact with the tub 40 when the drum 50 is made to spin.",
"An inner cylindrical wall 62 is also provided on the interior of the cylindrical wall 61 of the outer rotatable portion 60 .",
"The inner cylindrical wall 62 extends from a point which is substantially midway between the rear wall 63 and the front face 64 to the front face 565 .",
"The space between the interior cylindrical wall 62 and the cylindrical wall 61 is hollow but, if desired, could be filled with a strengthening material.",
"In this event, the strengthening material must be lightweight.",
"The provision of parallel cylindrical walls 61 , 62 in the portion of the outer rotatable portion 60 closest to the front face 64 provides strength to the whole of the outer rotatable portion 60 whilst reducing the internal diameter of the outer rotatable portion 60 in this region.",
"The inner rotatable portion 70 is supported on a central shaft 80 , which in turn, is supported by deep groove bearings 83 located between the central shaft 80 and the hollow cylindrical shaft 81 .",
"The inner rotatable portion 70 essentially comprises a generally circular rear wall 71 extending from the central shaft 80 towards the cylindrical wall of the tub 40 , and a cylindrical wall 74 extending from the periphery of the rear wall 71 towards the front wall of the tub 40 .",
"The diameter of the cylindrical wall 74 of the inner rotatable portion 70 is substantially the same as the diameter of the inner cylindrical wall 62 of the outer rotatable portion 60 .",
"The cylindrical wall 74 of the inner rotatable portion 70 is dimensioned so that its distal end approaches the end of the cylindrical wall 62 closest to it.",
"It is advantageous to keep the gap between these two cylindrical walls 62 , 74 as small as possible.",
"An annular sealing ring 76 is located on the cylindrical wall 61 of the outer cylindrical portion 60 immediately adjacent to the end of the inner cylindrical wall 62 closest to the inner cylindrical portion 70 so as to provide support for the distal end of the cylindrical wall 76 thereof.",
"FIG. 2 shows part of the control system of the machine 10 .",
"A controller 100 operates according to a control program stored on a non-volatile memory 105 .",
"The controller 100 is preferably implemented in the form of a microcontroller but other ways of implementing the controller, such as an implementation entirely in hardware, will be apparent to the reader and are intended to fall within the scope of this invention.",
"An interface 110 interfaces the controller 100 to other parts of the machine 10 .",
"Sensors placed on the machine return signals to the interface 110 .",
"The sensors include a water temperature sensor for monitoring temperature of the wash water in the sump of the machine 10 and a motor speed sensor.",
"The interface 110 also outputs signals to control operation of the display 220 to display text messages and signals to control the illumination of indicator lamps 215 , 265 on the control panel 120 .",
"Interface 110 also receives inputs from each of the control buttons 210 , 230 , 240 , 250 , 260 on the control panel 120 which allows the controller 100 to determine what button a user has pressed.",
"The interface 110 also outputs a set of control signals 140 to control the operating state of various parts of the machine, such as the door lock, water inlet valves, and the motor M. In a well-known manner, the control software 105 controls operation of the machine according to the inputs it receives and issues outputs 140 for controlling various parts of the machine.",
"The speed of motor M is controlled on the basis of the monitored supply voltage and motor speed inputs to the interface and an output signal 145 to motor drive 130 .",
"Control signal 145 controls the firing angle of the triac (or other power switching device) in the motor drive circuit 130 .",
"Another output signal 144 controls the direction of rotation of the motor M and a further output signal 146 controls the state of the gearbox.",
"The state of the gearbox determines whether the drum portions 60 , 70 are rotated in unison or whether they are rotated relative to one another.",
"Motor M can be used to drive both drum portions 60 , 70 or two separate motors may be provided, one motor being used to drive each of the drum portions 60 , 70 .",
"FIG. 3 shows one embodiment of control panel 120 in more detail.",
"It will be appreciated that the control panel can vary from the one shown here.",
"For example, the control panel 120 may provide a different range of options, the type of control may vary e.g. push button, touch-sensitive control, switch, rotatable control knob or slider.",
"Also, the range and type of visual indicators can vary, e.g. the indicators can include LEDs, an LCD or electroluminescent display.",
"The control panel of FIG. 3 includes an on/off button 201 to turn the mains power supply to the machine on/off;",
"a set of control buttons 210 and associated indicators 215 for selecting the wash programme (cotton, synthetics, wool, delicates etc.);",
"a control button 230 and an associated set of indicators for selecting the wash temperature (20-85° C.);",
"a control button 240 and an associated set of indicators for selecting spin speed (0-1600 rpm);",
"a control button 250 and an associated set of indicators for selecting wash intensity (light, normal, heavy);",
"a set of control buttons 260 and an associated set of indicators 265 for selecting special features (minimum crease, pre-wash, extra rinse etc.);",
"a plurality of memory buttons 270 , 271 , 272 for selecting a combination of stored settings;",
"a start button 280 for starting the machine according to the settings programme by a user, and a cancel button 282 .",
"A further indicator 283 indicates when the door 30 of the machine is locked and indicator 284 indicates when the child lock mode is active.",
"An LCD display 220 displays text messages at various stages during operation of the machine to help a user select programme settings and to indicate the progress of the machine through the wash cycle.",
"There are two basic types of drum mode: a counter-rotating mode in which the drum portions 60 , 70 are rotated relative to one another and a normal mode in which the drum portions 60 , 70 are rotated in unison in the same direction in a conventional manner.",
"The following table gives details of five drum modes.",
"Each drum mode comprises a repeated sequence of four steps.",
"For example, the ‘Counter Rotation’ operation performs: a first step which counter-rotates the drum portions 60 , 70 with respect to one another for 13 s ;",
"a second step which rests for 6 s with no drum action;",
"a third step which counter-rotates the drum portions 60 , 70 with respect to one another for 13 s in the opposite direction to that used in action 1 ;",
"and a fourth step which rests for 6 s with no drum action.",
"Clearly, any of the parameters of the drum operations defined here could be varied as appropriate.",
"Drum Mode Step no. Duration (s) Drum speed (rpm) Counter Rotation 1 13 52 (CR) 2 6 0 3 13 −52 4 6 0 Counter Rotation 1 10 52 Normal 2 32 0 (CRN) 3 10 −52 4 32 0 Normal Action 1 11 52 (NA) 2 5 0 3 11 −52 4 5 0 Gentle Action 1 6 52 (GA) 2 12 0 3 6 −52 4 12 0 Super Gentle Action 1 6 52 (SGA) 2 27 0 3 6 −52 4 27 0 FIGS. 4A-4C illustrate steps numbers 1 - 3 for the counter-rotating drum modes.",
"The drum portions 50 , 60 firstly rotate in opposite directions (FIG.",
"4 A), then rest (FIG.",
"4 B), then rotate in opposite directions ( FIG. 4C ) with each drum portion 60 , 70 rotating in a different direction to that in FIG. 4 A and finally rest (not shown.) FIGS. 5A-5C illustrate actions for the normal drum modes.",
"The drum portions 60 , 70 firstly rotate in unison in the same direction (FIG.",
"5 A), then rest (FIG.",
"5 B), then rotate in unison ( FIG. 5C ) in the opposite direction to that in FIG. 5 A and finally rest (not shown.) In the above table, the Counter Rotations (CR) and Counter Rotation Normal (CRN) modes differ in the ratio of time when the drums are rotating (and therefore agitating the load) and when the drums are at rest.",
"In the CR mode the drums are rotating for roughly twice the time that they are at rest whereas in the CRN mode the drums are at rest for roughly three times the time that they are rotating.",
"Similarly, with the normal modes, the modes differ in the ratio of time when the drums are rotating (and therefore agitating the load) and when the drums are at rest.",
"While the modes detailed above all operate at the same drum speed of 52 rpm it is possible to vary the drum speed between modes to vary the amount of agitation that these modes provide.",
"FIGS. 6 and 7 are tables which give full details of a set of wash programmes performed by the machine 10 and FIG. 8 is a key for these tables.",
"A complete wash cycle comprises the following stages: prewash (if the user has selected this), main wash, rinse, final rinse and final spin.",
"Each of these stages comprises a number of steps.",
"During each step the machine operates with a combination of an amount of water, a water temperature and a drum mode 400 detailed in the tables.",
"As is well-known with conventional wash programmes, the water temperature that is used during the wash programme varies according to the type of fabric being washed, with robust fabrics such as cotton being washed at a higher temperature than delicates.",
"During the stages of the wash cycle, and particularly during the main wash (see “Main Wash”",
"step no. 3 , FIG. 6 ) the machine operates with a drum mode which is dependent on the wash programme.",
"The most robust fabric types such as cottons, synthetics and dedicates use the CR drum mode (long burst of counter-rotation followed by a short rest);",
"wool and care+ use the CRN drum mode (short burst of counter-rotation followed by a long rest) and the duvet programme does not use counter-rotation at all, since the load comprises one large article which is expected to fill the drum, conditions which are not suited to the use of a counter-rotating drum mode.",
"The length of the wash step (see “Main Wash”",
"step no. 3 , FIG. 6 ) varies according to the amount of soiling of the articles in the wash load: 4 minutes for light soiling, 6 minutes for normal soiling and 10 minutes for heavy soiling.",
"A user selects the intensity of the wash via control 250 on the control panel 120 .",
"However, as an alternative to varying the length of time for the wash step, the controller can vary the amount of agitation by varying the drum mode.",
"Increased agitation can be provided by using a drum mode which rotates the drum portions 60 , 70 at a higher speed relative to one another or with a longer ratio of rotation time to rest time.",
"Variations to the described embodiments are intended to fall within the scope of the present invention.",
"While five drum modes are described here, it is possible to provide more modes which vary in the amount of agitation they apply to the wash load.",
"The modes can vary in the ratio of rotating time to rest time and/or speed of rotation.",
"The drum 50 can comprise more than just the two rotatable portions 60 , 70 .",
"Three or more separately rotatable portions can be provided, all lying alongside one another along the axis of rotation."
] |
FIELD OF THE INVENTION
The present invention relates to the field of surgical clips generally, and, in particular, to the field of surgical clips formed of a shape memory alloy.
BACKGROUND OF THE INVENTION
Several methods are known in the art for joining portions of hollow organs, such as the gastrointestinal tract. These include threads for manual suturing, staplers for mechanical suturing, and compression rings and clips.
While manual suturing is universally known and relatively inexpensive, the degree of success depends considerably on the skill of the surgeon. Another disadvantage is that post-operative complications are common. Further, suturing an organ results in lack of smoothness of the tissue therein, which, when the sutured organ is part of the gastrointestinal tract, hampers peristalsis in the sutured area. Finally, suturing is both labor and time consuming.
Staplers for mechanical suturing ensure a reliable joining of tissue and enable the time needed for surgery to be reduced, compared with manual suturing. However, due to the facts that such staples are not reusable and that a great many types and sizes are required, the price of staples is high. Also, after healing, metal staples remain in place along the perimeter of the which reduces elasticity of the junction and adversely affects peristalsis when the sutured organ is part of the gastrointestinal tract.
Junctions using compression devices such as rings and clips ensure the best seal and post-operative functioning of the organs. Two types of compression devices are known, namely, rings made of resorption plastics and clips made of memory alloys. Plastic rings are cumbersome and expensive. Also, the compression force is applied only momentarily at the junction and is reduced as the tissue is crushed. Clips made of shape memory alloys enable portions of tissue to be pressed together when equilibrium with body temperature is reached, whereat, due to the inherent properties of the alloys, the clips resume their memorized shape.
Development of clips made of memory alloy materials has increased recently, as they have many advantages over other devices. Their design is simple, they are cheap, they are small in size and possess universal qualities, and they are self-evacuated from the gastrointestinal tract.
It is known in the art to provide a surgical fastening clip which applies a clamping force to a site, such as a blood vessel, thereby reducing its cross-sectional area. It is also known to provide a surgical fastening clip formed of a shape memory alloy which deforms to a closed configuration when heated, such that the clamping force applied thereby is increased as it is heated. For example, U.S. Pat. No. 5,171,252 discloses a surgical fastening clip formed of a shape memory alloy; the device disclosed therein includes separate legs which close tightly around a site. Such a device is limited in its uses, such as for clamping blood vessels, and is not suitable for joining portions of the gastrointestinal tract.
EP 0,326,757 discloses a device for anastomosing a digestive tract, which includes a plurality of U-shaped retaining clips disposed around a soluble support tube. The tube is positioned inside portions of the digestive tract to be joined, and includes an outer groove around which are disposed the U-shaped retaining clips. The retaining clips are made of a shape memory alloy such that the open ends thereof close at a predetermined temperature, thus joining ends of the digestive tract. Once the ends of the digestive tract have been joined, the tube is dissolved. Such a device is disadvantageous in that its use requires that a plurality of clips to be properly positioned simultaneously. Also, there is no assurance that the resulting junction will be smooth, due to the plurality of sites of the digestive tract joined by the plurality of clips.
SU 1,186,199 discloses a memory alloy clip consisting of two parallel coils to be used for joining portions of a hollow organ, such as an organ of the gastrointestinal tract. The portions of the organ to be joined are aligned, and each of the plastic coils is introduced through a puncture formed in the wall of one of the portions. The coils are positioned such that, when heated, they compress the aligned walls therebetween, thus maintaining the portions of the walls held within the loops of the coils adjacent each other. Thereafter, incisions are made through the portions of the walls held within the loops of the coils, such that a passageway is created between the two organ portions. The punctures in the organ walls must then be surgically sewn closed with interrupted surgical sutures.
A major disadvantage of known memory alloy clips is that they permit compression of only approximately 80-85% of the junction perimeter, thus requiring additional manual sutures, which reduce the seal of the junction during the healing period and its elasticity during the post-operative period. Also, this additional suturing is problematic inasmuch as it has to carried out across a joint which includes a portion of the clip, thereby rendering difficult the sealing and anastomosis of the organ portions. Furthermore, once in place, clips according to the prior art require further surgery to be performed, namely, incisions through tissue so as to create a passageway between the two organ portions which have been joined by the clip.
There is thus a need for a surgical device which facilitates compression of substantially the entire perimeter of the junction between the organ portions being joined, which would obviate the need for additional manual sutures and which ensure the smooth seal of the junction during the healing period and its elasticity during the post-operative period. Additionally, there is a need for a surgical device which, once in place, would enable a passageway to be created between the two organ portions which have been joined together, without requiring further surgery to be performed on the organ.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved surgical clip formed of a shape memory alloy, and a method of joining two portions of a hollow organ, which overcome disadvantages of prior art.
There is thus provided, in accordance with a preferred embodiment of the present invention, a surgical clip formed at least partly of a shape memory alloy, the clip including: a first length of a wire defining a closed geometrical shape having a central opening; a second length of a wire defining a closed geometrical shape similar in configuration and magnitude to that of the first length of wire, wherein, when placed in side-by-side registration, the first and second lengths of wire fully overlap; an intermediate portion located between the first length of wire and the second length of wire, the intermediate portion formed of a shape memory alloy; a cutting element associated with the first length of wire; a counter element associated with the second length of wire and arranged for cutting engagement with the cutting element; wherein when at a first temperature or higher, the first and second lengths of wire are positioned in a side-by-side closed position and the shape memory alloy is in an elastic state, and further, when at a second temperature or lower, below the first temperature, the shape memory alloy is in a plastic state, thereby enabling the first and second lengths of wire to be moved into and to retain a spaced apart position, and upon heating of the clip to a temperature at least equal to the first temperature, the first and second lengths of wire return to the side-by-side closed position, thereby to apply a compressive force to tissue located therebetween.
Additionally in accordance with a first embodiment of the present invention, the surgical clip further includes apparatus for pressing the cutting element into cutting engagement with the counter element wherein, when at the first temperature or higher, the apparatus for pressing presses the cutting element into cutting engagement with the counter element.
In accordance with an alternative embodiment of the present invention, the surgical clip further includes apparatus for pressing the cutting element into cutting engagement with the counter element wherein, when at the first temperature or higher, the apparatus for pressing is actuatable by an outside force.
Further in accordance with an embodiment of the present invention, the geometrical shape of the surgical clip is a circle.
Yet further in accordance with an alternative embodiment of the present invention, the geometrical shape of the surgical clip is an ellipse.
In accordance with an embodiment of the present invention, the first length of wire and the second length of wire are defined by a continuous coil.
Still further in accordance with an alternative embodiment of the present invention, the first length of wire and the second length of wire are two distinct lengths of wire, each defining a closed geometrical shape.
Still further in accordance with a preferred embodiment of the present invention the counter element also includes a cutting element.
According to the present invention, there is also provided a method for anastomosing a gastrointestinal tract, the method including the following steps: (a) providing a surgical clip formed at least partly of a shape memory alloy, the clip including: a first length of a wire defining a closed geometrical shape having a central opening; a second length of a wire defining a closed geometrical shape similar in configuration and magnitude to that of the first length of wire, wherein, when placed in side-by-side registration, the first and second lengths of wire fully overlap; an intermediate portion located between the first length of wire and the second length of wire, the intermediate portion formed of a shape memory alloy; a cutting element associated with the first length of wire; a counter element associated with the second length of wire and arranged for cutting engagement with the cutting element; (b) cooling at least the intermediate portion to a temperature below a lower phase transition temperature thereof, whereat the intermediate portion is in a plastic state, thereby enabling the first and second lengths of wire to be moved into and to retain a spaced apart position; (c) manually moving apart the first and second lengths of wire; (d) drawing together portions of the gastrointestinal tract wherein anastomosis is desired, such that the portions are in adjacent, side-by-side relationship, at least one of the portions being open-ended; (e) surgically sealing the open ends of the portions of the gastrointestinal tract; (f) forming punctures in walls of the gastrointestinal tract adjacent to each other, the puncture being adjacent; (g) introducing the clip through the punctures, such that the a wall of each portion of the gastrointestinal tract is situated between the first and second lengths of wire; (h) maintaining the relative positions of the portions of the gastrointestinal tract and the clip in relation thereto, while raising the temperature of at least the intermediate portion to a temperature above its upper phase transition temperature, whereat the intermediate portion is in an elastic state, thereby causing the first and second lengths of wire to attain the side-by-side registration, thereby to apply a compressive force to tissue located therebetween.
Additionally in accordance with a preferred embodiment of the present invention, according to the method, in step (h), the temperature of the clip is raised to the temperature above its upper phase transition temperature by the heat of the gastrointestinal tract.
Further in accordance with a preferred embodiment of the present invention, according to the method, the clip further including apparatus for pressing the cutting element into cutting engagement with the counter element wherein, when at the upper phase transition temperature or higher, the apparatus for pressing presses the cutting element into cutting engagement with the counter element, thereby creating an opening in the tissue located between the first and second lengths of wire, thereby creating initial patency of the gastrointestinal tract; and the method includes after step (h), the additional step of widening the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood and appreciated from the following detailed description, in which:
FIGS. 1A and 1B are pictorial illustrations of a surgical clip according to a first embodiment of the present invention, the clip being in an open configuration and a closed configuration, respectively;
FIGS. 2A and 2B are pictorial illustrations of a surgical clip according to a second embodiment of the present invention, the clip being in an open configuration and in a closed configuration, respectively;
FIG. 3A is a pictorial illustration of a surgical clip according to a third embodiment of the present invention, the clip being in an open configuration;
FIG. 3B is a side view of the surgical clip shown in FIG. 3A;
FIG. 3C is a side view of the surgical clip shown in FIG. 3B, the clip being in a closed configuration;
FIG. 3D is a side view of the surgical clip shown in FIG. 3C, wherein the cutting element and counter element are being pressed against each other;
FIGS. 4A and 4B are respective pictorial and side view illustrations of a surgical clip according to a fourth embodiment of the present invention, the clip being in an open configuration;
FIG. 4C is a side view of the surgical clip shown in FIG. 4A, the clip being in a closed configuration;
FIG. 4D is a side view of the surgical clip shown in FIG. 4C, wherein the cutting element and counter element are being pressed together;
FIG. 4E is a pictorial view of a surgical clip according to a fifth embodiment of the present invention, the clip being in an open configuration;
FIGS. 5A and 5B are pictorial illustrations of respective counter and cutting elements which may be employed in the surgical clip according to the embodiment shown in FIG. 4E;
FIG. 5C is a pictorial illustration of a cutting element and a corresponding counter element which may be employed in the surgical clip according to either of FIGS. 1A and 1B;
FIG. 5D is a pictorial illustration of a surgical clip in accordance with the present invention, wherein a further embodiment of a cutting element and counter element are employed;
FIGS. 5E, 5 F, 5 G, 5 H, and 5 I are further alternative embodiments of cutting elements and counter elements which may be employed in the surgical clip according to the present invention;
FIG. 6A is a pictorial illustration of a surgical clip according to a sixth embodiment of the present invention;
FIG. 6B is a side view illustration of the surgical clip shown in FIG. 6A, the clip being in a closed configuration;
FIGS. 6C, and 6 D are side view illustrations of the surgical clip shown in FIG. 6A, the clip being in a closed position, wherein the cutting element is being pressed into cutting engagement with the counter element and wherein the cutting element has been released from cutting engagement with the counter element, respectively;
FIG. 7A is a pictorial illustration of a hollow organ inside which there has been placed the surgical clip of FIGS. 1A and 1B, in accordance with the present invention, the surgical clip being in a plastic state;
FIG. 7B is a cross-sectional view, taken in the direction of line 7 B— 7 B, of the hollow organ and surgical clip shown in FIG. 7A;
FIG. 7C is a view of the hollow organ and surgical clip shown in FIG. 7A, the surgical clip being in an elastic state; and
FIG. 7D is a cross-sectional view, taken in the direction of line 7 D— 7 D, of the hollow organ and surgical clip shown in FIG. 7 C.
DETAILED DESCRIPTION OF THE INVENTION
The present invention seeks to provide a surgical clip, formed at least partly of a shape memory alloy, such as is known in the art, and which provides organ tissue compression along the entire periphery of the clip, thereby to ensure satisfactory joining or anastomosis of portions of an organ, and which provides apparatus for cutting a portion of tissue, whereby initial patency of the gastrointestinal tract is created. The present invention further seeks to provide a method for performing anastomosis of organ portions, such as those of the gastrointestinal tract, the method employing the clip of the present invention, and for cutting a portion of tissue, whereby initial patency of the gastrointestinal tract is created.
Referring now to the drawings, FIGS. 1A and 1B illustrate a surgical clip, referenced generally 10 , according to a first embodiment of the present invention, the clip 10 shown in respective open and closed configurations. Clip 10 is typically wire-like, formed at least partly of a shape memory alloy, and is of a coiled configuration so as to include a pair of loops 12 and 22 , having respective ends 14 and 24 . Each of loops 12 and 22 defines a complete circle from its end to a point 30 midway along the coil. Thus, the coil defines two complete circles from end 14 of loop 12 to end 24 of loop 22 . While the various embodiments of the clip of the present invention are illustrated as defining circular shapes, it will be appreciated by persons skilled in the art that the present invention may, alternatively, define any closed geometric shape, such as an ellipse.
At least an intermediate portion 13 of clip 10 is formed of a shape memory alloy such that, when cooled to below a predetermined temperature, the clip is in a plastic state, such that loops 12 and 22 may be moved apart, as to the position shown in FIG. 1 A. When heated to above the predetermined temperature, the clip 10 is in an elastic state, such that the loops 12 and 22 are adjacent each other, as in the position shown in FIG. 1 B. The change in temperature, as it affects the shape memory alloy, will be discussed further, with reference to FIGS. 7A-D.
Loops 12 , 22 of clip 10 are provided with a pair of crossbars 16 , 26 , respectively, which extend across respective loops 12 , 22 . Crossbars 16 and 26 may be fastened to respective loops 12 and 22 by any suitable means. Crossbar 16 is provided with an aperture 18 , and crossbar 26 is provided with a hollow cutting element 20 having a blade portion 48 which circumscribes an aperture 28 . Blade portion 48 of cutting element 20 has a configuration and size relative to aperture 18 so as fit snugly therein (FIG. 1 B). Crossbar 16 extends between points 32 and 34 along the circle defined by loop 12 , and crossbar 26 extends between points 42 and 44 along the circle defined by loop 22 . The distance along loop 12 from point 30 to point 32 is the same as the distance along loop 22 from end 24 to point 42 . Similarly, the distance along loop 12 from end 14 to point 34 is the same as the distance along loop 22 from point 30 to point 44 . Thus, as shown in FIG. 1B, when loops 12 and 22 are adjacent, crossbars 16 and 26 overlie each other, and cutting element 20 is aligned with aperture 18 . While crossbars 16 and 26 are shown at a particular orientation relative to loops 12 and 22 , respectively, it will be appreciated by persons skilled in the art that any orientation whereby crossbars 16 and 26 overlie each other is possible, without departing from the scope of the invention.
As shown in FIG. 1B, when in the closed configuration, loops 12 and 22 are adjacent to each other, crossbars 16 and 26 are adjacent to each other, and cutting element 20 is positioned snugly within aperture 18 . The crossbar 16 thus acts as a counter element for cutting element 20 .
With reference to FIGS. 2A and 2B, there is shown a surgical clip, referenced generally 110 , according to a second embodiment of the present invention, the clip being in an open configuration and in a closed configuration, respectively. Clip 110 is similar to clip 10 (FIGS. 1A, 1 B) in that it defines a coil of two complete circles, including an intermediate portion 113 formed of a shape memory alloy, but clip 110 is provided with a crossbar 116 and bar 126 on respective loops 112 , 122 . Crossbar 116 and bar 126 may be fastened to respective loops 12 and 22 by any suitable means. Bar 126 is also provided with a surgical blade 128 which extends out of bar 126 such that, when the clip 110 is in the closed configuration, blade 128 presses against crossbar 116 . Thus, crossbar 116 acts as a counter element for blade 128 .
FIGS. 3A-D illustrate a surgical clip, referenced generally 130 , according to a third embodiment of the present invention. Clip 130 includes an intermediate portion 13 formed of a shape memory alloy and defines a coil of two complete circles, as does clip 10 , and has similar loops 12 and 22 . However, in this embodiment of the present invention, loop 22 of clip 130 is provided with a cutting element 133 in the form of an L-shaped arm 132 having a blade 134 at its end which extends towards the center of loop 22 . Loop 12 is provided with a counter element 136 in the form of an arm 137 having a U-shaped portion 138 at its end, the open end of the U facing towards the center of loop 12 . L-shaped element 132 and counter element 136 may be fastened to respective loops 22 and 12 by any suitable means. It will be appreciated by persons skilled in the art that cutting element 133 and arm 132 may be configured as having any other suitable shapes whereby they will function as a cutting element and counter element for the purposes of the present invention.
FIGS. 3A-B shows clip 130 with intermediate portion 13 in a plastic state, wherein the loops 12 and 22 have been moved apart. When intermediate portion 13 is in an elastic state, as shown in FIGS. 3C-D, loops 12 and 22 are pressed against each other. As shown in FIG. 3C, blade 134 of cutting element 133 is positioned adjacent yet apart from U-shaped portion 138 of counter element 136 . By manually applying external pressure to both cutting element 133 and counter element 136 , in the direction of arrows A and B, respectively, these elements are forced together such that they make contact, as shown in FIG. 3D, blade 134 being pressed against counter element 136 at approximately the center of the U-shaped portion 138 thereof. After release of cutting element 133 and counter element 136 , these elements are allowed to return to their positions shown in FIG. 3 C.
FIGS. 4A, 4 B, 4 C, and 4 D illustrate a surgical clip, referenced generally 140 , according at to a fourth embodiment of the present invention. Clip 140 includes two ring portions 142 , 144 , which are attached at an intermediate portion 150 . While, if desired, the entire clip 140 may be formed of a shape memory alloy, it is essential that at least the intermediate portion 150 be formed of a shape memory alloy. Ring portions 142 and 144 are provided with respective crossbars 146 and 148 . At the center of crossbar 146 there is provided a cutting element 152 which is slidably attached therethrough. Cutting element 152 includes a ring-shaped head portion 156 and a cylindrical portion 158 having an aperture 159 . Crossbar 148 is provided with a counter element 162 in the form of a cylindrical aperture 154 , of size and configuration similar to that of cylindrical portion 158 of cutting element 152 , and of a flange portion 160 (FIGS. 4B, 4 C, 4 D), positioned about aperture 154 on the side of crossbar 148 which is distal to crossbar 146 .
While the cutting element 152 and counter element 162 of clip 140 are shown as having a particular size and shape, it will be appreciated by persons skilled in the art that any suitable configuration of cutting element and counter element may be employed, whereby tissue located therebetween may be sliced or cut out.
In FIGS. 4A-B, intermediate portion 150 of clip 140 is shown in its plastic state, wherein ring portions 142 and 144 have been moved apart. When intermediate portion 150 of the clip 140 is in an elastic state, as shown in FIGS. 4C-D, ring portions 142 and 144 are firmly pressed against each other, and cylindrical portion 158 of cutting element 152 is positioned adjacent aperture 154 of counter element 162 . By applying pressure to head portion 156 of cutting element 152 on crossbar 146 , in the direction of arrow B, and to flange portion 160 on counter element 162 , in the direction of arrow C, cylindrical portion 158 is forced into aperture 154 , where it is held in position by the snug fit between cylindrical portion 158 and the inner surface of aperture 154 .
It may be noted that, as opposed to the clip 130 (FIGS. 3 A-D), wherein both cutting element 133 and counter element 136 are movable relative to their respective rings 22 and 12 , in the clip 140 only cutting element 152 is movable relative to ring portion 142 , while counter element 162 does not move relative to ring portion 144 .
FIG. 4E illustrates a surgical clip according to a fifth embodiment of the present invention. Clip 170 is similar to clip 140 (FIGS. 4A, 4 B, 4 C, 4 D) in that it includes an intermediate portion 150 formed of a shape memory alloy and is provided with ring portions 142 and 144 . However, ring portions 142 and 144 are provided with respective arms 172 , 174 which extend from corresponding points along ring portions 142 , 144 into the interior thereof. Arms 172 , 174 may be fastened to respective ring portions 142 , 144 by any suitable means. On the end of arm 172 there is formed a cutting element 176 having a head portion 178 and a cylindrical portion 180 having an aperture 181 . The end of arm 174 is provided with a counter element 186 having a cylindrical portion 182 and a cylindrical aperture 184 of size and configuration similar to that of cylindrical portion 180 of cutting element 176 .
In FIG. 4E, intermediate portion 150 of clip 170 is shown in a plastic state, wherein the ring portions 142 and 144 have been moved apart. When, however, intermediate portion 150 of clip 170 is in an elastic state (not shown), ring portions 142 and 144 are firmly pressed against each other, and cylindrical portion 178 of cutting element 176 is positioned adjacent aperture 184 of counter element 186 . By applying pressure to head portion 178 of cutting element 176 on arm 172 and to cylindrical portion 182 of counter element 186 , cylindrical portion 180 of cutting element 176 is forced into aperture 184 , where it is held in position by the snug fit between cylindrical portion 180 and the inner surface of aperture 184 . FIGS. 5A and 5B are pictorial illustrations of a counter element, referenced generally 200 , and of a cutting element, referenced generally 210 , which may be employed in the surgical clip 170 shown in
FIG. 4 E. Counter element 200 is provided with an X-shaped aperture 202 which corresponds in configuration and size to blade 212 of cutting element 210 . Thus, when employing counter element 200 and cutting element 210 in the device of the present invention, when the intermediate portion of the clip is in an elastic state, as discussed above, counter element 200 and cutting element 210 may be pressed together, thus forcing blade 212 into aperture 202 .
A further embodiment of the present invention is illustrated in FIG. 5C, which shows a cutting element 220 and a corresponding counter element 230 which may be employed in the surgical clip according to either of FIGS. 1A and 1B. Cutting element 220 is provided with an elliptically shaped base portion 222 having a pair of needle-like blades 224 protruding therefrom. Counter element 230 is provided with an elliptically shaped base portion 232 , similar in configuration and size to base portion 222 of cutting element 220 , and a flange 234 extending therefrom. Base portion 232 also has an elliptical aperture 236 , whose width is similar to that of blades 224 and whose length is at least equal to the distance between the outer edge of one blade to the outer edge of the other blade. Thus, when employing counter element 230 and cutting element 220 in the device of the present invention, when the intermediate portion of the clip is in an elastic state, as discussed above, counter element 230 and cutting element 220 are pressed together, thus forcing blades 224 into aperture 236 .
FIGS. 5D, 5 E, 5 F, 5 G, 5 H, and 5 I illustrate several particular examples of the relationship between specific blade element and counter element combinations, which may replace the blade elements and counter element employed in the embodiments of the present invention shown in FIGS. 2-4. As shown in FIG. 5D, when the shape memory alloy of the device is in an elastic state, loops 12 and 22 are pressed against each other. FIGS. 5D and 5E show blade 240 when it has made contact with each of the flat-surfaced counter elements 242 and 244 . In FIG. 5F there are shown a blade 240 and a counter element 248 having a recess 250 shaped to accommodate the tip of blade 240 . FIG. 5G shows a blade 246 and a counter element 252 having a cylindrical recess 254 extending therethrough. Recess 254 is large enough to receive the tip 256 of blade 246 . However, if blade 246 is moved further into recess 254 , its movement will be stopped when it has reached the point at which the width of blade 246 which has entered recess 254 is equal to the width of recess 254 . In FIG. 5H, there is provided a counter element 258 having a triangular recess 260 shaped to accommodate the tip of blade 246 . FIG. 5I shows an alternative embodiment, wherein the blade element and counter element combination has been replaced by a pair of blade elements 268 in the form of blades 262 which come into contact, when loops 12 and 22 (FIG. 5D) are pressed against each other, such that the tip 264 of each blade 262 lies along a side 266 of the other blade 262 .
FIGS. 6A-D show a surgical clip 300 according to a sixth embodiment of the present invention. Clip 300 includes two ring portions 302 , 304 , which are attached at an intermediate portion 306 formed of a shape memory alloy. Ring portion 302 is provided with an off-center crossbar 308 having a rotatable blade element 310 thereon. Cutting element 310 includes a blade 312 and a head portion 314 by means of which the blade 312 may be rotated downward toward the center of ring portion 302 . Across the center of ring 304 there is provided a counter element 316 configured as a pair of parallel bars 318 having a generally rectangular gap 320 therebetween. Bars 318 are positioned such that gap 320 is wide enough to accommodate blade 312 , yet narrow enough to provide a snug fit therefor. It will be appreciated by persons skilled in the art that counter element 316 may be replaced by any other counter element suitable for use with cutting blade 312 .
When intermediate portion 306 is in a plastic state, ring portions 203 and 304 may be moved apart, as to the position shown in FIG. 6 A. When, however, as shown in FIGS. 6B-D, intermediate portion 306 of the clip 300 is in an elastic state, ring portions 302 and 304 are firmly pressed against each other. As shown in FIG. 6B, by applying pressure in the general direction of arrow D to head portion 314 of cutting element 310 , blade 312 is rotated about crossbar 308 , such that it moves downward, in the sense of FIG. 6 B. This will result in the cutting element 310 being in the position shown in FIG. 6C, wherein blade 312 is snugly fit within gap 320 of counter element 316 . If desired, the cutting element 310 may be provided with biasing or similar means (not shown), whereby the blade 312 is pulled or pushed out of gap 320 so that it is automatically returned to its upper position, as shown in FIG. 6 D.
With reference to FIGS. 7A-D, there are shown portions 52 and 54 of a hollow organ 50 , which it is desired to join together by anastomosis. Hollow organ 50 may be a colon, or any other hollow organ which requires anastomosis. Alternatively, the method of the present invention may be employed for the connection of a portion of a first hollow organ to a second hollow organ, such as the connection of a colon portion to a stomach. The method of the present invention will now be described with reference to clip 10 . However, it will be appreciated by persons skilled in the art that the method of the present invention may be carried out by utilizing any embodiment of the clip, or by employing any of the elements described above, in accordance with the present invention.
Additionally, it will be appreciated by persons skilled in the art that a device employing a shape memory alloy, such as a clip according to the present invention, may be described as being of one of two different types. A first type of device employs a shape memory alloy which is in an easily deformable, martensitic state when it is cooled to below room temperature, which achieves a fully or partial austenitic state at room temperature, and which is in a completely austenitic state when heated to at least its upper phase transition temperature, which is somewhere between room temperature and body temperature. According to the second type of device, the shape memory alloy is in an easily deformable, martensitic state at room temperature, whereat the device is deformed and applied, and the shape memory alloy achieves a completely austenitic state when heated to above room temperature. The difference between the two types of devices is in the temperature range at which the shape memory alloy is easily deformable. Thus, by utilizing a device including a shape memory alloy of the second type, allows more freedom in application. The method of the present invention discussed hereinbelow will be described with regard to a device of the first type.
Referring again to FIGS. 7A-D, at least the shape memory alloy portion 13 of clip 10 is cooled to at least its lower phase transition temperature, whereat the shape memory alloy is in its martensitic state, as known in the art, the intermediate portion 13 of clip 10 thus being in a plastic state. The lower phase transition temperature may be generally any temperature above −273° C., although more generally it is approximately 25-35° C. below body temperature, preferably approximately 0° C. Loops 12 and 22 are manually moved apart a desired distance and clip 10 is preserved in the cooled state for as long as required until insertion into the organ 50 .
Open ends 56 and 58 of separate organ portions 52 and 54 are surgically stapled or sewn closed, as by sutures 72 , thereby resulting in separate closed ends 56 a and 58 a. Portions 52 and 54 of organ 50 are drawn together in an adjacent, side-by-side relationship, and adjacent walls 60 and 62 are perforated at punctures 64 and 66 , respectively, the punctures 64 and 66 being adjacent. The size and shape of punctures 64 and 66 are chosen as desired, so as to be able to facilitate positioning of loops 12 and 22 inside respective organ portion 52 and 54 . Clip 10 is introduced into organ portions 52 and 54 by inserting loops 12 and 22 via punctures 64 and 66 , respectively, such that loops 12 and 22 are situated inside organ portions 52 and 54 , so as to straddle respective walls 60 and 62 . While the method of the present invention is described herein in relation to FIGS. 7A-D, wherein both organ portions 52 and 54 are first surgically stapled or sewn closed, it will be understood by persons skilled in the art that either one or both of the organ portions 52 and 54 may be sewn closed after insertion of the surgical clip, without departing from the scope of the invention.
The relative positions of portions 52 and 54 of organ 50 and the relative position of clip 10 in relation thereto must be maintained for a period of time during which the temperature of organ 50 is effective to cause the temperature of the intermediate portion 13 of the clip 10 to rise to a temperature at least equal to its upper phase transition temperature, whereat the clip 10 achieves its austenitic state, which is, preferably, below body temperature. During the time that the temperature of the intermediate portion 13 of the clip 10 rises towards its transition temperature, loops 12 and 22 continue to converge and to press the tissue portions 68 and 70 of organ walls 60 and 62 located therebetween more and more tightly against each other. Tissue portions 68 and 70 are defined by the portions of respective walls 60 and 62 located between loops 12 and 22 . Thus, each of tissue portions 68 and 70 is configured as an area similar in shape and size to the loops 12 and 22 of clip 10 .
The rate by which the temperature of intermediate portion 13 of clip 10 rises may be accelerated by heating clip 10 , for example, by any method known in the art.
Once the temperature of the intermediate portion 13 of clip 10 has risen above its transition temperature, clip 10 has returned to its elastic phase, as shown in FIGS. 7C and 7D, wherein loops 12 and 22 are pressing against each other, and thus maintains walls 60 and 62 in fixed position relative to each other. At the same time, blade 48 of cutting element 20 is being pressed into aperture 18 , thus slicing out a portion of tissue portions 68 and 70 which is similar in size and shape to that of blade 48 . This slicing out of a portion of the tissue will create initial patency of the gastrointestinal tract.
It will be appreciated by persons skilled in the art that, if another embodiment of the present invention were employed, such as clip 130 of FIGS. 3A-D, wherein the cutting element 33 and counter-element 136 are actuatable by external manual pressure, such pressure may be provided by any means known in the art, such as by use of an instrument (not shown) designed for this purpose.
After a portion of the tissue has been sliced out of tissue portions 68 and 70 , the only pathway from portion 52 to portion 54 of organ 50 is via aperture 18 on crossbar 16 and aperture 28 of cutting element 20 .
Due to the pressure exerted by clip 10 on walls 60 and 62 of organ 50 , respective tissue portions 68 and 70 are pressed so tightly against each other that blood flow to these tissue portions ceases, resulting in eventual necrosis of these tissue portions 68 and 70 . As tissue 68 and 70 die, the tissue portions 68 a and 70 a immediately thereoutside mend together such that portions 52 and 54 of organ 50 are joined, and organ 50 may function as one continuous organ. Once tissue portions 68 and 70 die, they, together with clip 10 , become separated from walls 62 and 60 , resulting in a hole 74 (FIG. 7 C). Dead tissue portions 70 and 68 , together with clip 10 are passed out of organ 50 , via hole 74 , by the normal activity of the organ. For example, if organ 50 is the small intestine, and the direction of peristalsis is from portion 52 towards portion 54 , then clip 10 and tissue portions 70 and 68 will be passed through portion 54 by the normal activity of the small intestine.
It will be appreciated by persons skilled in the art that, if desired, instead of employing clip 10 in the surgical procedure as discussed above, and as illustrated in FIGS. 7A-D, either of clips 140 and 170 may be employed. The use of either of these embodiments of the present invention would require that, after a clip ( 140 , 170 ) has been introduced into the organ 50 and the intermediate portion thereof has attained its elastic (martensitic) state, as discussed above, the respective cutting element ( 152 , 176 ) and counter element ( 162 , 186 ) would have to be manually forced into cutting engagement. This would cause the cutting element ( 152 , 176 ), together with the counter element ( 162 , 186 ), to slice out a portion of the tissues located therebetween, the size and shape of the tissue sliced out being similar in size and shape to that of the cylindrical portion ( 158 , 180 ). This slicing out of a portion of the tissue will create initial patency of the gastrointestinal tract.
Alternatively, if desired, any of clips 110 , 130 , and 300 may be employed in the surgical procedure discussed above. The use of clip 110 would enable the blade 128 and crossbar 116 to automatically make an incision through the portions of the tissue located therebetween, as the blade 128 is forced into cutting engagement with the crossbar 116 when the clip 110 is in an elastic state, as discussed above with regard to FIGS. 2A-B. The use of either of clips 130 and 300 would require that, after the clip ( 130 , 300 ) has been introduced into the organ 50 and has attained its elastic state, as discussed above, the respective cutting element ( 133 , 310 ) and counter element ( 136 , 316 ) would have to be manually forced into cutting engagement. This would cause the cutting element ( 133 , 310 ), together with the counter element ( 136 , 316 ), to make an incision through the portions of the tissue located therebetween. This incision through a portion of the tissue will create initial patency of the gastrointestinal tract. If desired, after an incision has been made by any of the clips ( 110 , 130 , 300 ), the incision may be widened somewhat, although should not be widened to the entire area of the tissue portions 68 and 70 .
It will be appreciated by persons skilled in the art that there is a direct relationship between the size and shape of the clip used in the surgical procedure described above and the size and shape of the resulting hole in the organ. It is thus possible to chose to perform the procedure with a clip of a particular size and shape so as to achieve a hole of a desired size and shape.
It will be appreciated by persons skilled in the art that the present invention is not limited by what has been shown and described hereinabove, merely by way of illustrative example. Rather, the scope of the present invention is limited solely by the claims, which follow: | A surgical clip and method for anastomosing a gastrointestinal tract, the clip being formed at least partly of a shape memory alloy, the clip including: a first length of a wire defining a closed geometrical shape having a central opening; a second length of a wire defining a closed geometrical shape similar in configuration and magnitude to that of the first length of wire, wherein, when placed in side-by-side registration, the first and second lengths of wire fully overlap; an intermediate portion located between the first length of wire and the second length of wire, the intermediate portion formed of a shape memory alloy; a cutting element associated with the first length of wire; a counter element associated with the second length of wire and arranged for cutting engagement with the cutting element; wherein when at a first temperature or higher, the first and second lengths of wire are positioned in a side-by-side closed position and the shape memory alloy is in an elastic state, and further, when at a second temperature or lower, below the first temperature, the shape memory alloy is in a plastic state, thereby enabling the first and second lengths of wire to be moved into and to retain a spaced apart position, and upon heating of the clip to a temperature at least equal to the first temperature, the first and second lengths of wire return to the side-by-side closed position, thereby to apply a compressive force to tissue located therebetween. | Analyze the document's illustrations and descriptions to summarize the main idea's core structure and function. | [
"FIELD OF THE INVENTION The present invention relates to the field of surgical clips generally, and, in particular, to the field of surgical clips formed of a shape memory alloy.",
"BACKGROUND OF THE INVENTION Several methods are known in the art for joining portions of hollow organs, such as the gastrointestinal tract.",
"These include threads for manual suturing, staplers for mechanical suturing, and compression rings and clips.",
"While manual suturing is universally known and relatively inexpensive, the degree of success depends considerably on the skill of the surgeon.",
"Another disadvantage is that post-operative complications are common.",
"Further, suturing an organ results in lack of smoothness of the tissue therein, which, when the sutured organ is part of the gastrointestinal tract, hampers peristalsis in the sutured area.",
"Finally, suturing is both labor and time consuming.",
"Staplers for mechanical suturing ensure a reliable joining of tissue and enable the time needed for surgery to be reduced, compared with manual suturing.",
"However, due to the facts that such staples are not reusable and that a great many types and sizes are required, the price of staples is high.",
"Also, after healing, metal staples remain in place along the perimeter of the which reduces elasticity of the junction and adversely affects peristalsis when the sutured organ is part of the gastrointestinal tract.",
"Junctions using compression devices such as rings and clips ensure the best seal and post-operative functioning of the organs.",
"Two types of compression devices are known, namely, rings made of resorption plastics and clips made of memory alloys.",
"Plastic rings are cumbersome and expensive.",
"Also, the compression force is applied only momentarily at the junction and is reduced as the tissue is crushed.",
"Clips made of shape memory alloys enable portions of tissue to be pressed together when equilibrium with body temperature is reached, whereat, due to the inherent properties of the alloys, the clips resume their memorized shape.",
"Development of clips made of memory alloy materials has increased recently, as they have many advantages over other devices.",
"Their design is simple, they are cheap, they are small in size and possess universal qualities, and they are self-evacuated from the gastrointestinal tract.",
"It is known in the art to provide a surgical fastening clip which applies a clamping force to a site, such as a blood vessel, thereby reducing its cross-sectional area.",
"It is also known to provide a surgical fastening clip formed of a shape memory alloy which deforms to a closed configuration when heated, such that the clamping force applied thereby is increased as it is heated.",
"For example, U.S. Pat. No. 5,171,252 discloses a surgical fastening clip formed of a shape memory alloy;",
"the device disclosed therein includes separate legs which close tightly around a site.",
"Such a device is limited in its uses, such as for clamping blood vessels, and is not suitable for joining portions of the gastrointestinal tract.",
"EP 0,326,757 discloses a device for anastomosing a digestive tract, which includes a plurality of U-shaped retaining clips disposed around a soluble support tube.",
"The tube is positioned inside portions of the digestive tract to be joined, and includes an outer groove around which are disposed the U-shaped retaining clips.",
"The retaining clips are made of a shape memory alloy such that the open ends thereof close at a predetermined temperature, thus joining ends of the digestive tract.",
"Once the ends of the digestive tract have been joined, the tube is dissolved.",
"Such a device is disadvantageous in that its use requires that a plurality of clips to be properly positioned simultaneously.",
"Also, there is no assurance that the resulting junction will be smooth, due to the plurality of sites of the digestive tract joined by the plurality of clips.",
"SU 1,186,199 discloses a memory alloy clip consisting of two parallel coils to be used for joining portions of a hollow organ, such as an organ of the gastrointestinal tract.",
"The portions of the organ to be joined are aligned, and each of the plastic coils is introduced through a puncture formed in the wall of one of the portions.",
"The coils are positioned such that, when heated, they compress the aligned walls therebetween, thus maintaining the portions of the walls held within the loops of the coils adjacent each other.",
"Thereafter, incisions are made through the portions of the walls held within the loops of the coils, such that a passageway is created between the two organ portions.",
"The punctures in the organ walls must then be surgically sewn closed with interrupted surgical sutures.",
"A major disadvantage of known memory alloy clips is that they permit compression of only approximately 80-85% of the junction perimeter, thus requiring additional manual sutures, which reduce the seal of the junction during the healing period and its elasticity during the post-operative period.",
"Also, this additional suturing is problematic inasmuch as it has to carried out across a joint which includes a portion of the clip, thereby rendering difficult the sealing and anastomosis of the organ portions.",
"Furthermore, once in place, clips according to the prior art require further surgery to be performed, namely, incisions through tissue so as to create a passageway between the two organ portions which have been joined by the clip.",
"There is thus a need for a surgical device which facilitates compression of substantially the entire perimeter of the junction between the organ portions being joined, which would obviate the need for additional manual sutures and which ensure the smooth seal of the junction during the healing period and its elasticity during the post-operative period.",
"Additionally, there is a need for a surgical device which, once in place, would enable a passageway to be created between the two organ portions which have been joined together, without requiring further surgery to be performed on the organ.",
"SUMMARY OF THE INVENTION The present invention seeks to provide an improved surgical clip formed of a shape memory alloy, and a method of joining two portions of a hollow organ, which overcome disadvantages of prior art.",
"There is thus provided, in accordance with a preferred embodiment of the present invention, a surgical clip formed at least partly of a shape memory alloy, the clip including: a first length of a wire defining a closed geometrical shape having a central opening;",
"a second length of a wire defining a closed geometrical shape similar in configuration and magnitude to that of the first length of wire, wherein, when placed in side-by-side registration, the first and second lengths of wire fully overlap;",
"an intermediate portion located between the first length of wire and the second length of wire, the intermediate portion formed of a shape memory alloy;",
"a cutting element associated with the first length of wire;",
"a counter element associated with the second length of wire and arranged for cutting engagement with the cutting element;",
"wherein when at a first temperature or higher, the first and second lengths of wire are positioned in a side-by-side closed position and the shape memory alloy is in an elastic state, and further, when at a second temperature or lower, below the first temperature, the shape memory alloy is in a plastic state, thereby enabling the first and second lengths of wire to be moved into and to retain a spaced apart position, and upon heating of the clip to a temperature at least equal to the first temperature, the first and second lengths of wire return to the side-by-side closed position, thereby to apply a compressive force to tissue located therebetween.",
"Additionally in accordance with a first embodiment of the present invention, the surgical clip further includes apparatus for pressing the cutting element into cutting engagement with the counter element wherein, when at the first temperature or higher, the apparatus for pressing presses the cutting element into cutting engagement with the counter element.",
"In accordance with an alternative embodiment of the present invention, the surgical clip further includes apparatus for pressing the cutting element into cutting engagement with the counter element wherein, when at the first temperature or higher, the apparatus for pressing is actuatable by an outside force.",
"Further in accordance with an embodiment of the present invention, the geometrical shape of the surgical clip is a circle.",
"Yet further in accordance with an alternative embodiment of the present invention, the geometrical shape of the surgical clip is an ellipse.",
"In accordance with an embodiment of the present invention, the first length of wire and the second length of wire are defined by a continuous coil.",
"Still further in accordance with an alternative embodiment of the present invention, the first length of wire and the second length of wire are two distinct lengths of wire, each defining a closed geometrical shape.",
"Still further in accordance with a preferred embodiment of the present invention the counter element also includes a cutting element.",
"According to the present invention, there is also provided a method for anastomosing a gastrointestinal tract, the method including the following steps: (a) providing a surgical clip formed at least partly of a shape memory alloy, the clip including: a first length of a wire defining a closed geometrical shape having a central opening;",
"a second length of a wire defining a closed geometrical shape similar in configuration and magnitude to that of the first length of wire, wherein, when placed in side-by-side registration, the first and second lengths of wire fully overlap;",
"an intermediate portion located between the first length of wire and the second length of wire, the intermediate portion formed of a shape memory alloy;",
"a cutting element associated with the first length of wire;",
"a counter element associated with the second length of wire and arranged for cutting engagement with the cutting element;",
"(b) cooling at least the intermediate portion to a temperature below a lower phase transition temperature thereof, whereat the intermediate portion is in a plastic state, thereby enabling the first and second lengths of wire to be moved into and to retain a spaced apart position;",
"(c) manually moving apart the first and second lengths of wire;",
"(d) drawing together portions of the gastrointestinal tract wherein anastomosis is desired, such that the portions are in adjacent, side-by-side relationship, at least one of the portions being open-ended;",
"(e) surgically sealing the open ends of the portions of the gastrointestinal tract;",
"(f) forming punctures in walls of the gastrointestinal tract adjacent to each other, the puncture being adjacent;",
"(g) introducing the clip through the punctures, such that the a wall of each portion of the gastrointestinal tract is situated between the first and second lengths of wire;",
"(h) maintaining the relative positions of the portions of the gastrointestinal tract and the clip in relation thereto, while raising the temperature of at least the intermediate portion to a temperature above its upper phase transition temperature, whereat the intermediate portion is in an elastic state, thereby causing the first and second lengths of wire to attain the side-by-side registration, thereby to apply a compressive force to tissue located therebetween.",
"Additionally in accordance with a preferred embodiment of the present invention, according to the method, in step (h), the temperature of the clip is raised to the temperature above its upper phase transition temperature by the heat of the gastrointestinal tract.",
"Further in accordance with a preferred embodiment of the present invention, according to the method, the clip further including apparatus for pressing the cutting element into cutting engagement with the counter element wherein, when at the upper phase transition temperature or higher, the apparatus for pressing presses the cutting element into cutting engagement with the counter element, thereby creating an opening in the tissue located between the first and second lengths of wire, thereby creating initial patency of the gastrointestinal tract;",
"and the method includes after step (h), the additional step of widening the opening.",
"BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be more fully understood and appreciated from the following detailed description, in which: FIGS. 1A and 1B are pictorial illustrations of a surgical clip according to a first embodiment of the present invention, the clip being in an open configuration and a closed configuration, respectively;",
"FIGS. 2A and 2B are pictorial illustrations of a surgical clip according to a second embodiment of the present invention, the clip being in an open configuration and in a closed configuration, respectively;",
"FIG. 3A is a pictorial illustration of a surgical clip according to a third embodiment of the present invention, the clip being in an open configuration;",
"FIG. 3B is a side view of the surgical clip shown in FIG. 3A;",
"FIG. 3C is a side view of the surgical clip shown in FIG. 3B, the clip being in a closed configuration;",
"FIG. 3D is a side view of the surgical clip shown in FIG. 3C, wherein the cutting element and counter element are being pressed against each other;",
"FIGS. 4A and 4B are respective pictorial and side view illustrations of a surgical clip according to a fourth embodiment of the present invention, the clip being in an open configuration;",
"FIG. 4C is a side view of the surgical clip shown in FIG. 4A, the clip being in a closed configuration;",
"FIG. 4D is a side view of the surgical clip shown in FIG. 4C, wherein the cutting element and counter element are being pressed together;",
"FIG. 4E is a pictorial view of a surgical clip according to a fifth embodiment of the present invention, the clip being in an open configuration;",
"FIGS. 5A and 5B are pictorial illustrations of respective counter and cutting elements which may be employed in the surgical clip according to the embodiment shown in FIG. 4E;",
"FIG. 5C is a pictorial illustration of a cutting element and a corresponding counter element which may be employed in the surgical clip according to either of FIGS. 1A and 1B;",
"FIG. 5D is a pictorial illustration of a surgical clip in accordance with the present invention, wherein a further embodiment of a cutting element and counter element are employed;",
"FIGS. 5E, 5 F, 5 G, 5 H, and 5 I are further alternative embodiments of cutting elements and counter elements which may be employed in the surgical clip according to the present invention;",
"FIG. 6A is a pictorial illustration of a surgical clip according to a sixth embodiment of the present invention;",
"FIG. 6B is a side view illustration of the surgical clip shown in FIG. 6A, the clip being in a closed configuration;",
"FIGS. 6C, and 6 D are side view illustrations of the surgical clip shown in FIG. 6A, the clip being in a closed position, wherein the cutting element is being pressed into cutting engagement with the counter element and wherein the cutting element has been released from cutting engagement with the counter element, respectively;",
"FIG. 7A is a pictorial illustration of a hollow organ inside which there has been placed the surgical clip of FIGS. 1A and 1B, in accordance with the present invention, the surgical clip being in a plastic state;",
"FIG. 7B is a cross-sectional view, taken in the direction of line 7 B— 7 B, of the hollow organ and surgical clip shown in FIG. 7A;",
"FIG. 7C is a view of the hollow organ and surgical clip shown in FIG. 7A, the surgical clip being in an elastic state;",
"and FIG. 7D is a cross-sectional view, taken in the direction of line 7 D— 7 D, of the hollow organ and surgical clip shown in FIG. 7 C. DETAILED DESCRIPTION OF THE INVENTION The present invention seeks to provide a surgical clip, formed at least partly of a shape memory alloy, such as is known in the art, and which provides organ tissue compression along the entire periphery of the clip, thereby to ensure satisfactory joining or anastomosis of portions of an organ, and which provides apparatus for cutting a portion of tissue, whereby initial patency of the gastrointestinal tract is created.",
"The present invention further seeks to provide a method for performing anastomosis of organ portions, such as those of the gastrointestinal tract, the method employing the clip of the present invention, and for cutting a portion of tissue, whereby initial patency of the gastrointestinal tract is created.",
"Referring now to the drawings, FIGS. 1A and 1B illustrate a surgical clip, referenced generally 10 , according to a first embodiment of the present invention, the clip 10 shown in respective open and closed configurations.",
"Clip 10 is typically wire-like, formed at least partly of a shape memory alloy, and is of a coiled configuration so as to include a pair of loops 12 and 22 , having respective ends 14 and 24 .",
"Each of loops 12 and 22 defines a complete circle from its end to a point 30 midway along the coil.",
"Thus, the coil defines two complete circles from end 14 of loop 12 to end 24 of loop 22 .",
"While the various embodiments of the clip of the present invention are illustrated as defining circular shapes, it will be appreciated by persons skilled in the art that the present invention may, alternatively, define any closed geometric shape, such as an ellipse.",
"At least an intermediate portion 13 of clip 10 is formed of a shape memory alloy such that, when cooled to below a predetermined temperature, the clip is in a plastic state, such that loops 12 and 22 may be moved apart, as to the position shown in FIG. 1 A. When heated to above the predetermined temperature, the clip 10 is in an elastic state, such that the loops 12 and 22 are adjacent each other, as in the position shown in FIG. 1 B. The change in temperature, as it affects the shape memory alloy, will be discussed further, with reference to FIGS. 7A-D.",
"Loops 12 , 22 of clip 10 are provided with a pair of crossbars 16 , 26 , respectively, which extend across respective loops 12 , 22 .",
"Crossbars 16 and 26 may be fastened to respective loops 12 and 22 by any suitable means.",
"Crossbar 16 is provided with an aperture 18 , and crossbar 26 is provided with a hollow cutting element 20 having a blade portion 48 which circumscribes an aperture 28 .",
"Blade portion 48 of cutting element 20 has a configuration and size relative to aperture 18 so as fit snugly therein (FIG.",
"1 B).",
"Crossbar 16 extends between points 32 and 34 along the circle defined by loop 12 , and crossbar 26 extends between points 42 and 44 along the circle defined by loop 22 .",
"The distance along loop 12 from point 30 to point 32 is the same as the distance along loop 22 from end 24 to point 42 .",
"Similarly, the distance along loop 12 from end 14 to point 34 is the same as the distance along loop 22 from point 30 to point 44 .",
"Thus, as shown in FIG. 1B, when loops 12 and 22 are adjacent, crossbars 16 and 26 overlie each other, and cutting element 20 is aligned with aperture 18 .",
"While crossbars 16 and 26 are shown at a particular orientation relative to loops 12 and 22 , respectively, it will be appreciated by persons skilled in the art that any orientation whereby crossbars 16 and 26 overlie each other is possible, without departing from the scope of the invention.",
"As shown in FIG. 1B, when in the closed configuration, loops 12 and 22 are adjacent to each other, crossbars 16 and 26 are adjacent to each other, and cutting element 20 is positioned snugly within aperture 18 .",
"The crossbar 16 thus acts as a counter element for cutting element 20 .",
"With reference to FIGS. 2A and 2B, there is shown a surgical clip, referenced generally 110 , according to a second embodiment of the present invention, the clip being in an open configuration and in a closed configuration, respectively.",
"Clip 110 is similar to clip 10 (FIGS.",
"1A, 1 B) in that it defines a coil of two complete circles, including an intermediate portion 113 formed of a shape memory alloy, but clip 110 is provided with a crossbar 116 and bar 126 on respective loops 112 , 122 .",
"Crossbar 116 and bar 126 may be fastened to respective loops 12 and 22 by any suitable means.",
"Bar 126 is also provided with a surgical blade 128 which extends out of bar 126 such that, when the clip 110 is in the closed configuration, blade 128 presses against crossbar 116 .",
"Thus, crossbar 116 acts as a counter element for blade 128 .",
"FIGS. 3A-D illustrate a surgical clip, referenced generally 130 , according to a third embodiment of the present invention.",
"Clip 130 includes an intermediate portion 13 formed of a shape memory alloy and defines a coil of two complete circles, as does clip 10 , and has similar loops 12 and 22 .",
"However, in this embodiment of the present invention, loop 22 of clip 130 is provided with a cutting element 133 in the form of an L-shaped arm 132 having a blade 134 at its end which extends towards the center of loop 22 .",
"Loop 12 is provided with a counter element 136 in the form of an arm 137 having a U-shaped portion 138 at its end, the open end of the U facing towards the center of loop 12 .",
"L-shaped element 132 and counter element 136 may be fastened to respective loops 22 and 12 by any suitable means.",
"It will be appreciated by persons skilled in the art that cutting element 133 and arm 132 may be configured as having any other suitable shapes whereby they will function as a cutting element and counter element for the purposes of the present invention.",
"FIGS. 3A-B shows clip 130 with intermediate portion 13 in a plastic state, wherein the loops 12 and 22 have been moved apart.",
"When intermediate portion 13 is in an elastic state, as shown in FIGS. 3C-D, loops 12 and 22 are pressed against each other.",
"As shown in FIG. 3C, blade 134 of cutting element 133 is positioned adjacent yet apart from U-shaped portion 138 of counter element 136 .",
"By manually applying external pressure to both cutting element 133 and counter element 136 , in the direction of arrows A and B, respectively, these elements are forced together such that they make contact, as shown in FIG. 3D, blade 134 being pressed against counter element 136 at approximately the center of the U-shaped portion 138 thereof.",
"After release of cutting element 133 and counter element 136 , these elements are allowed to return to their positions shown in FIG. 3 C. FIGS. 4A, 4 B, 4 C, and 4 D illustrate a surgical clip, referenced generally 140 , according at to a fourth embodiment of the present invention.",
"Clip 140 includes two ring portions 142 , 144 , which are attached at an intermediate portion 150 .",
"While, if desired, the entire clip 140 may be formed of a shape memory alloy, it is essential that at least the intermediate portion 150 be formed of a shape memory alloy.",
"Ring portions 142 and 144 are provided with respective crossbars 146 and 148 .",
"At the center of crossbar 146 there is provided a cutting element 152 which is slidably attached therethrough.",
"Cutting element 152 includes a ring-shaped head portion 156 and a cylindrical portion 158 having an aperture 159 .",
"Crossbar 148 is provided with a counter element 162 in the form of a cylindrical aperture 154 , of size and configuration similar to that of cylindrical portion 158 of cutting element 152 , and of a flange portion 160 (FIGS.",
"4B, 4 C, 4 D), positioned about aperture 154 on the side of crossbar 148 which is distal to crossbar 146 .",
"While the cutting element 152 and counter element 162 of clip 140 are shown as having a particular size and shape, it will be appreciated by persons skilled in the art that any suitable configuration of cutting element and counter element may be employed, whereby tissue located therebetween may be sliced or cut out.",
"In FIGS. 4A-B, intermediate portion 150 of clip 140 is shown in its plastic state, wherein ring portions 142 and 144 have been moved apart.",
"When intermediate portion 150 of the clip 140 is in an elastic state, as shown in FIGS. 4C-D, ring portions 142 and 144 are firmly pressed against each other, and cylindrical portion 158 of cutting element 152 is positioned adjacent aperture 154 of counter element 162 .",
"By applying pressure to head portion 156 of cutting element 152 on crossbar 146 , in the direction of arrow B, and to flange portion 160 on counter element 162 , in the direction of arrow C, cylindrical portion 158 is forced into aperture 154 , where it is held in position by the snug fit between cylindrical portion 158 and the inner surface of aperture 154 .",
"It may be noted that, as opposed to the clip 130 (FIGS.",
"3 A-D), wherein both cutting element 133 and counter element 136 are movable relative to their respective rings 22 and 12 , in the clip 140 only cutting element 152 is movable relative to ring portion 142 , while counter element 162 does not move relative to ring portion 144 .",
"FIG. 4E illustrates a surgical clip according to a fifth embodiment of the present invention.",
"Clip 170 is similar to clip 140 (FIGS.",
"4A, 4 B, 4 C, 4 D) in that it includes an intermediate portion 150 formed of a shape memory alloy and is provided with ring portions 142 and 144 .",
"However, ring portions 142 and 144 are provided with respective arms 172 , 174 which extend from corresponding points along ring portions 142 , 144 into the interior thereof.",
"Arms 172 , 174 may be fastened to respective ring portions 142 , 144 by any suitable means.",
"On the end of arm 172 there is formed a cutting element 176 having a head portion 178 and a cylindrical portion 180 having an aperture 181 .",
"The end of arm 174 is provided with a counter element 186 having a cylindrical portion 182 and a cylindrical aperture 184 of size and configuration similar to that of cylindrical portion 180 of cutting element 176 .",
"In FIG. 4E, intermediate portion 150 of clip 170 is shown in a plastic state, wherein the ring portions 142 and 144 have been moved apart.",
"When, however, intermediate portion 150 of clip 170 is in an elastic state (not shown), ring portions 142 and 144 are firmly pressed against each other, and cylindrical portion 178 of cutting element 176 is positioned adjacent aperture 184 of counter element 186 .",
"By applying pressure to head portion 178 of cutting element 176 on arm 172 and to cylindrical portion 182 of counter element 186 , cylindrical portion 180 of cutting element 176 is forced into aperture 184 , where it is held in position by the snug fit between cylindrical portion 180 and the inner surface of aperture 184 .",
"FIGS. 5A and 5B are pictorial illustrations of a counter element, referenced generally 200 , and of a cutting element, referenced generally 210 , which may be employed in the surgical clip 170 shown in FIG. 4 E. Counter element 200 is provided with an X-shaped aperture 202 which corresponds in configuration and size to blade 212 of cutting element 210 .",
"Thus, when employing counter element 200 and cutting element 210 in the device of the present invention, when the intermediate portion of the clip is in an elastic state, as discussed above, counter element 200 and cutting element 210 may be pressed together, thus forcing blade 212 into aperture 202 .",
"A further embodiment of the present invention is illustrated in FIG. 5C, which shows a cutting element 220 and a corresponding counter element 230 which may be employed in the surgical clip according to either of FIGS. 1A and 1B.",
"Cutting element 220 is provided with an elliptically shaped base portion 222 having a pair of needle-like blades 224 protruding therefrom.",
"Counter element 230 is provided with an elliptically shaped base portion 232 , similar in configuration and size to base portion 222 of cutting element 220 , and a flange 234 extending therefrom.",
"Base portion 232 also has an elliptical aperture 236 , whose width is similar to that of blades 224 and whose length is at least equal to the distance between the outer edge of one blade to the outer edge of the other blade.",
"Thus, when employing counter element 230 and cutting element 220 in the device of the present invention, when the intermediate portion of the clip is in an elastic state, as discussed above, counter element 230 and cutting element 220 are pressed together, thus forcing blades 224 into aperture 236 .",
"FIGS. 5D, 5 E, 5 F, 5 G, 5 H, and 5 I illustrate several particular examples of the relationship between specific blade element and counter element combinations, which may replace the blade elements and counter element employed in the embodiments of the present invention shown in FIGS. 2-4.",
"As shown in FIG. 5D, when the shape memory alloy of the device is in an elastic state, loops 12 and 22 are pressed against each other.",
"FIGS. 5D and 5E show blade 240 when it has made contact with each of the flat-surfaced counter elements 242 and 244 .",
"In FIG. 5F there are shown a blade 240 and a counter element 248 having a recess 250 shaped to accommodate the tip of blade 240 .",
"FIG. 5G shows a blade 246 and a counter element 252 having a cylindrical recess 254 extending therethrough.",
"Recess 254 is large enough to receive the tip 256 of blade 246 .",
"However, if blade 246 is moved further into recess 254 , its movement will be stopped when it has reached the point at which the width of blade 246 which has entered recess 254 is equal to the width of recess 254 .",
"In FIG. 5H, there is provided a counter element 258 having a triangular recess 260 shaped to accommodate the tip of blade 246 .",
"FIG. 5I shows an alternative embodiment, wherein the blade element and counter element combination has been replaced by a pair of blade elements 268 in the form of blades 262 which come into contact, when loops 12 and 22 (FIG.",
"5D) are pressed against each other, such that the tip 264 of each blade 262 lies along a side 266 of the other blade 262 .",
"FIGS. 6A-D show a surgical clip 300 according to a sixth embodiment of the present invention.",
"Clip 300 includes two ring portions 302 , 304 , which are attached at an intermediate portion 306 formed of a shape memory alloy.",
"Ring portion 302 is provided with an off-center crossbar 308 having a rotatable blade element 310 thereon.",
"Cutting element 310 includes a blade 312 and a head portion 314 by means of which the blade 312 may be rotated downward toward the center of ring portion 302 .",
"Across the center of ring 304 there is provided a counter element 316 configured as a pair of parallel bars 318 having a generally rectangular gap 320 therebetween.",
"Bars 318 are positioned such that gap 320 is wide enough to accommodate blade 312 , yet narrow enough to provide a snug fit therefor.",
"It will be appreciated by persons skilled in the art that counter element 316 may be replaced by any other counter element suitable for use with cutting blade 312 .",
"When intermediate portion 306 is in a plastic state, ring portions 203 and 304 may be moved apart, as to the position shown in FIG. 6 A. When, however, as shown in FIGS. 6B-D, intermediate portion 306 of the clip 300 is in an elastic state, ring portions 302 and 304 are firmly pressed against each other.",
"As shown in FIG. 6B, by applying pressure in the general direction of arrow D to head portion 314 of cutting element 310 , blade 312 is rotated about crossbar 308 , such that it moves downward, in the sense of FIG. 6 B. This will result in the cutting element 310 being in the position shown in FIG. 6C, wherein blade 312 is snugly fit within gap 320 of counter element 316 .",
"If desired, the cutting element 310 may be provided with biasing or similar means (not shown), whereby the blade 312 is pulled or pushed out of gap 320 so that it is automatically returned to its upper position, as shown in FIG. 6 D. With reference to FIGS. 7A-D, there are shown portions 52 and 54 of a hollow organ 50 , which it is desired to join together by anastomosis.",
"Hollow organ 50 may be a colon, or any other hollow organ which requires anastomosis.",
"Alternatively, the method of the present invention may be employed for the connection of a portion of a first hollow organ to a second hollow organ, such as the connection of a colon portion to a stomach.",
"The method of the present invention will now be described with reference to clip 10 .",
"However, it will be appreciated by persons skilled in the art that the method of the present invention may be carried out by utilizing any embodiment of the clip, or by employing any of the elements described above, in accordance with the present invention.",
"Additionally, it will be appreciated by persons skilled in the art that a device employing a shape memory alloy, such as a clip according to the present invention, may be described as being of one of two different types.",
"A first type of device employs a shape memory alloy which is in an easily deformable, martensitic state when it is cooled to below room temperature, which achieves a fully or partial austenitic state at room temperature, and which is in a completely austenitic state when heated to at least its upper phase transition temperature, which is somewhere between room temperature and body temperature.",
"According to the second type of device, the shape memory alloy is in an easily deformable, martensitic state at room temperature, whereat the device is deformed and applied, and the shape memory alloy achieves a completely austenitic state when heated to above room temperature.",
"The difference between the two types of devices is in the temperature range at which the shape memory alloy is easily deformable.",
"Thus, by utilizing a device including a shape memory alloy of the second type, allows more freedom in application.",
"The method of the present invention discussed hereinbelow will be described with regard to a device of the first type.",
"Referring again to FIGS. 7A-D, at least the shape memory alloy portion 13 of clip 10 is cooled to at least its lower phase transition temperature, whereat the shape memory alloy is in its martensitic state, as known in the art, the intermediate portion 13 of clip 10 thus being in a plastic state.",
"The lower phase transition temperature may be generally any temperature above −273° C., although more generally it is approximately 25-35° C. below body temperature, preferably approximately 0° C. Loops 12 and 22 are manually moved apart a desired distance and clip 10 is preserved in the cooled state for as long as required until insertion into the organ 50 .",
"Open ends 56 and 58 of separate organ portions 52 and 54 are surgically stapled or sewn closed, as by sutures 72 , thereby resulting in separate closed ends 56 a and 58 a. Portions 52 and 54 of organ 50 are drawn together in an adjacent, side-by-side relationship, and adjacent walls 60 and 62 are perforated at punctures 64 and 66 , respectively, the punctures 64 and 66 being adjacent.",
"The size and shape of punctures 64 and 66 are chosen as desired, so as to be able to facilitate positioning of loops 12 and 22 inside respective organ portion 52 and 54 .",
"Clip 10 is introduced into organ portions 52 and 54 by inserting loops 12 and 22 via punctures 64 and 66 , respectively, such that loops 12 and 22 are situated inside organ portions 52 and 54 , so as to straddle respective walls 60 and 62 .",
"While the method of the present invention is described herein in relation to FIGS. 7A-D, wherein both organ portions 52 and 54 are first surgically stapled or sewn closed, it will be understood by persons skilled in the art that either one or both of the organ portions 52 and 54 may be sewn closed after insertion of the surgical clip, without departing from the scope of the invention.",
"The relative positions of portions 52 and 54 of organ 50 and the relative position of clip 10 in relation thereto must be maintained for a period of time during which the temperature of organ 50 is effective to cause the temperature of the intermediate portion 13 of the clip 10 to rise to a temperature at least equal to its upper phase transition temperature, whereat the clip 10 achieves its austenitic state, which is, preferably, below body temperature.",
"During the time that the temperature of the intermediate portion 13 of the clip 10 rises towards its transition temperature, loops 12 and 22 continue to converge and to press the tissue portions 68 and 70 of organ walls 60 and 62 located therebetween more and more tightly against each other.",
"Tissue portions 68 and 70 are defined by the portions of respective walls 60 and 62 located between loops 12 and 22 .",
"Thus, each of tissue portions 68 and 70 is configured as an area similar in shape and size to the loops 12 and 22 of clip 10 .",
"The rate by which the temperature of intermediate portion 13 of clip 10 rises may be accelerated by heating clip 10 , for example, by any method known in the art.",
"Once the temperature of the intermediate portion 13 of clip 10 has risen above its transition temperature, clip 10 has returned to its elastic phase, as shown in FIGS. 7C and 7D, wherein loops 12 and 22 are pressing against each other, and thus maintains walls 60 and 62 in fixed position relative to each other.",
"At the same time, blade 48 of cutting element 20 is being pressed into aperture 18 , thus slicing out a portion of tissue portions 68 and 70 which is similar in size and shape to that of blade 48 .",
"This slicing out of a portion of the tissue will create initial patency of the gastrointestinal tract.",
"It will be appreciated by persons skilled in the art that, if another embodiment of the present invention were employed, such as clip 130 of FIGS. 3A-D, wherein the cutting element 33 and counter-element 136 are actuatable by external manual pressure, such pressure may be provided by any means known in the art, such as by use of an instrument (not shown) designed for this purpose.",
"After a portion of the tissue has been sliced out of tissue portions 68 and 70 , the only pathway from portion 52 to portion 54 of organ 50 is via aperture 18 on crossbar 16 and aperture 28 of cutting element 20 .",
"Due to the pressure exerted by clip 10 on walls 60 and 62 of organ 50 , respective tissue portions 68 and 70 are pressed so tightly against each other that blood flow to these tissue portions ceases, resulting in eventual necrosis of these tissue portions 68 and 70 .",
"As tissue 68 and 70 die, the tissue portions 68 a and 70 a immediately thereoutside mend together such that portions 52 and 54 of organ 50 are joined, and organ 50 may function as one continuous organ.",
"Once tissue portions 68 and 70 die, they, together with clip 10 , become separated from walls 62 and 60 , resulting in a hole 74 (FIG.",
"7 C).",
"Dead tissue portions 70 and 68 , together with clip 10 are passed out of organ 50 , via hole 74 , by the normal activity of the organ.",
"For example, if organ 50 is the small intestine, and the direction of peristalsis is from portion 52 towards portion 54 , then clip 10 and tissue portions 70 and 68 will be passed through portion 54 by the normal activity of the small intestine.",
"It will be appreciated by persons skilled in the art that, if desired, instead of employing clip 10 in the surgical procedure as discussed above, and as illustrated in FIGS. 7A-D, either of clips 140 and 170 may be employed.",
"The use of either of these embodiments of the present invention would require that, after a clip ( 140 , 170 ) has been introduced into the organ 50 and the intermediate portion thereof has attained its elastic (martensitic) state, as discussed above, the respective cutting element ( 152 , 176 ) and counter element ( 162 , 186 ) would have to be manually forced into cutting engagement.",
"This would cause the cutting element ( 152 , 176 ), together with the counter element ( 162 , 186 ), to slice out a portion of the tissues located therebetween, the size and shape of the tissue sliced out being similar in size and shape to that of the cylindrical portion ( 158 , 180 ).",
"This slicing out of a portion of the tissue will create initial patency of the gastrointestinal tract.",
"Alternatively, if desired, any of clips 110 , 130 , and 300 may be employed in the surgical procedure discussed above.",
"The use of clip 110 would enable the blade 128 and crossbar 116 to automatically make an incision through the portions of the tissue located therebetween, as the blade 128 is forced into cutting engagement with the crossbar 116 when the clip 110 is in an elastic state, as discussed above with regard to FIGS. 2A-B.",
"The use of either of clips 130 and 300 would require that, after the clip ( 130 , 300 ) has been introduced into the organ 50 and has attained its elastic state, as discussed above, the respective cutting element ( 133 , 310 ) and counter element ( 136 , 316 ) would have to be manually forced into cutting engagement.",
"This would cause the cutting element ( 133 , 310 ), together with the counter element ( 136 , 316 ), to make an incision through the portions of the tissue located therebetween.",
"This incision through a portion of the tissue will create initial patency of the gastrointestinal tract.",
"If desired, after an incision has been made by any of the clips ( 110 , 130 , 300 ), the incision may be widened somewhat, although should not be widened to the entire area of the tissue portions 68 and 70 .",
"It will be appreciated by persons skilled in the art that there is a direct relationship between the size and shape of the clip used in the surgical procedure described above and the size and shape of the resulting hole in the organ.",
"It is thus possible to chose to perform the procedure with a clip of a particular size and shape so as to achieve a hole of a desired size and shape.",
"It will be appreciated by persons skilled in the art that the present invention is not limited by what has been shown and described hereinabove, merely by way of illustrative example.",
"Rather, the scope of the present invention is limited solely by the claims, which follow:"
] |
BACKGROUND OF THE INVENTION
The present invention relates to a buckle pretensioner for a vehicle safety restraint.
Pretensioners are used to rapidly withdraw a length of seat belt webbing in the event of an emergency. This takes up slack in the seat belt which might be caused by bulky clothing or by a vehicle occupant being out of position such as when leaning forward in the seat, or when seated skewed for example when asleep. The purpose of eliminating this slack is to more securely restrain the vehicle occupant at the onset of emergency conditions, and to more correctly position him for maximum effect of any secondary safety restraint such as an airbag.
Pretensioners may be situated at the retractor end of a three-point safety belt to rapidly rewind the belt webbing, or alternatively at the buckle end to rapidly pull back the buckle mounting.
Known buckle pretensioners use a piston-cylinder arrangement in which a piston connected to the buckle mounting is pushed rapidly along a cylinder by the force of a spring or more recently by pyrotechnic means which release a sudden rush of gas. Such arrangements are bulky and difficult to fit unobtrusively in a vehicle, particularly in the smaller models of vehicle which are popular nowadays.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved buckle pretensioner and particularly a more compact design.
According to the present invention there is provided a buckle pretensioner for a vehicle safety restraint comprising a buckle head for receiving a buckle tongue to secure safety restraint webbing about a vehicle occupant in a three-point belt system, the pretensioner comprising; a cable connected to the buckle head and means for rapidly withdrawing the cable in a belt tightening direction, the withdrawing means comprising a force generator or reservoir and driving means and being more compact than hitherto known.
According to a first embodiment of the invention the pretensioner further comprises step-up gearing means for converting a linear movement of a predetermined magnitude, produced by the force generator, into a linear movement of the cable of more than the predetermined magnitude, preferably a multiple of the predetermined magnitude.
Gearing arrangements were not previously considered viable for pretensioners, particularly buckle mounted pretensioners because they increase the torque which must be generated by the driving means, the maximum torque from traditional driving means was limited. However the improvements in pyrotechnic force generators means that sufficient torque can now be generated rapidly enough.
The step-up gearing may comprise a multiple pulley arrangement, such that the withdrawal means operates on a small diameter pulley fixedly connected to rotate with a large diameter pulley about which the cable is wound.
This arrangement allows a relatively simple force reservoir to be used in the pretensioner because the necessary locking devices can be included in the pulley arrangement, for example a simple ratchet and stop, rather than being part of the force generator (for example in the tube of a piston-cylinder pretensioner) as hitherto.
This embodiment can also be adapted relatively easily to incorporate load limiting features.
It is particularly applicable to the use of a piston-cylinder type pretensioner, either with a spring or a pyrotechnic force generator and the cylinder tube can in this case be made much shorter than in previous pretensioners.
However this embodiment is equally applicable to other types of force generator or to other driving means.
According to a second embodiment the driving means comprises a rack and pinion arrangement. The rack may be vertical or horizontal and is driven past the pinion wheel which is connected to rotate a pulley about which the cable is wound, by spring force or by a gas generator.
The pinion wheel may be driven by more than one rack, as for example in a system with two moving racks one on either side of the pinion wheel in opposite directions to reinforce each other's driving force. Their movement may be synchronised or phased depending on the pretensioning characteristics to be achieved.
Force generators such as gas generator may be integral with the racks.
Gearing arrangements may advantageously also be incorporated in this embodiment.
According to a third embodiment, the driving means comprises at least two pulley wheels across which the cable passes and means for extending the distance between the pulley wheels so as to withdraw the cable in the belt tightening direction.
Two pulley wheels may be arranged adjacent the path of the cable and driven in opposite directions across the path of the cable so as to withdraw the buckle head.
Alternatively two or preferably more pulley wheels are arranged with the buckle cable wound around them in an S configuration and one or more pulley wheels are driven parallel to the cable to withdraw the buckle head.
A further alternative is to use an elongate, elliptical or oval, cam pulley, arranged in normal use with the cable passing along both its long sides and round one of its short sides. Under pretensioning conditions this cam pulley is rotated rapidly through approximately 90° so that its long sides are tangential to the path of the cable from the buckle head, thus quickly and easily shortening the effective length of cable from the buckle head to its mounting position. The cam pulley may be driven by a pyrotechnically detonated gas generator or by a spring, or by other force generator means.
A gas generator driven cam faced piston may be used instead. The buckle cable passes over the outer arcuate cam face of the piston. When pretensioning is required the gas generator drives the piston a predetermined distance away from the buckle head and thus shortens the effective length of the cable to the buckle head.
According to a fourth embodiment of the invention the driving means comprises a rotating part with paddles or vanes driven by gas from a gas generator. This may be a wheel connected to the cable pulley, with or without gearing, or a helix coaxial with the cable pulley.
Alternatively a Roots motor or gear pump could be used comprising two camming figure-of-8 drive parts, one driven by a gas generator, the other coaxial with the cable pulley.
For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a compact buckle pretensioner according to one embodiment of the invention.
FIG. 2 is an exploded view of a buckle pretensioner according to a variant of the embodiment of Figure
FIGS. 3 and 4 are exploded views of a second embodiment of the present invention.
FIG. 5 is an exploded view of the buckle pretensioner according to a variation of the second embodiment of the present invention.
FIG. 6 is a schematic cross-sectional view of a buckle pretensioner according to a third embodiment of the present invention.
FIG. 7 is a part cut-away view of a buckle pretensioner according to a variant of the third embodiment.
FIG. 8 is an exploded view of a buckle pretensioner according to another variant of the third embodiment.
FIG. 9 illustrates another variant of a buckle pretensioner according to the third embodiment.
FIG. 10 is an exploded, and part cut-away view of a buckle pretensioner according to a fourth embodiment of the invention.
FIGS. 11, 12 , 13 and 14 show alternative variants of the fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is shown a buckle head 1 connected by a cable 2 to the outer diameter of a large diameter pulley wheel 3 Normally the cable would be covered with a plastic sheath and the buckle head is supported to be upstanding by a relatively stiff stalk but these are not shown in FIG. 1 . The pulley wheel 3 is attached to a smaller diameter pulley wheel 4 and the outer diameter of this is connected by cable 5 to piston 6 of pretensioner 7 . Piston 6 is arranged for sliding movement in the cylinder 8 and a gas generator 9 is arranged to be electrically detonated in the event of a crash being detected by crash sensors to release gas into the cylinder 8 to push piston 6 in the direction of arrow A. This has the advantage over traditional arrangements of providing a step up gearing of a ratio corresponding to the ratios of the circumferences of the two pulley wheels 3 and 4 . Thus movement of the piston a predetermined length along the cylinder 8 will move the buckle head downwards by a larger length depending upon the gearing ratio. Thus a more compact linear pretensioner can be used.
FIG. 2 illustrates a load limiting arrangement in a compact buckle pretensioner. The buckle cable 2 passes from the buckle (not shown) around pulley wheel 10 . One side of the wheel 10 is provided with sloping teeth which face correspondingly shaped sloping teeth 12 on the side of a locking ratchet 13 which has locking teeth 14 on its outer circumference. The locking teeth 14 can be engaged by locking pawl 15 which is rotatably mounted on the casing of a buckle pretensioner 16 . The locking ratchet 13 and pulley wheel 10 are mounted on and coaxial with drive shaft 17 of the compact pretensioner 16 . They are fixed on the drive shaft 17 by a bolt or rivet 18 and a spring clutch arrangement 19 is mounted between the rivet 18 and the pulley wheel 10 . The pretensioner 16 is fired by electrically detonated gas generator 9 . However, other firing means may be used.
Spring 19 acts on pulley wheel 10 to keep it engaged, via the interlocking sloping teeth 11 and 12 , with the locking ratchet 13 up to a predetermined torque. Above the predetermined torque the sloping teeth 11 and 12 slip over each other and allow the pulley wheel 10 to rotate independently of the locking ratchet 13 . Thus a maximum load is applied to the vehicle occupant restrained by this buckle.
FIG. 3 shows an alternative compact buckle pretensioner. The buckle head (not shown) is again connected via cable 2 to a pulley wheel 10 . One section of the pulley wheel 10 has teeth 20 about its outer circumference. These teeth are engaged by corresponding teeth 21 on a horizontal rack 22 which is driven tangential to the pulley wheel 10 by electrically detonated gas generator 9 . The pulley wheel 10 is protected by an outer cover 23 and is mounted for rotation and secured in place by rivet or bolt 18 .
FIG. 4 shows an alternative arrangement to FIG. 3 in which the rack 22 is vertically mounted. Otherwise like parts are denoted by like reference numbers. In FIGS. 3 and 4 a seal 24 is situated between the rack 22 and pretensioner housing wall 25 . This maximises the effect of the gas generator by preventing escape of gas along the side of the rack. In addition a locking means is provided so as to lock the rack and pinion in the pretensioned state after pretensioning to hold the buckle in the retracted position. This may, for example be, in the form of a locking ellipse as is well known in this field and as is shown in GB 1 351 447 and also is described in DE 42 34 132 both of which are incorporated herein by reference.
FIG. 5 shows an alternative compact buckle pretensioner. Again buckle cable 2 is connected to a pulley wheel 10 mounted on shaft 26 . A tooth pinion wheel 27 is mounted on shaft 26 . Two sets of tooth racks are arranged one on either side of the pinion wheel 27 so that when activated they move across the pinion wheel engaging the teeth and rotating it. Single or multiple racks 28 and 29 are mounted on respective support blocks 30 , 31 and the parts are contained within housing parts 32 , 33 . An electrically detonated gas generator 9 acts to push the support blocks 30 , 31 with their respective racks 28 , 29 along the respective channels formed by the two parts of the covers 32 , 33 . The gas from the gas generator 9 pushes support members 30 and 31 by acting on planer surfaces of the support end members 34 , 35 .
FIG. 6 illustrates another embodiment of the invention. In FIG. 6 a the buckle is shown in the normal use condition. In FIG. 6 b the pretensioner has operated and the buckle head 2 has been retracted. This is effected by driving two rods 36 and 37 in opposite directions across the path of the cable 2 as indicated by the arrows.
FIG. 7 shows a similar arrangement in which multiple pulleys are introduced and the rods are pushed in a direction parallel to the buckle cable 2 . This arrangement is even more compact than that of FIGS. 6 a and 6 b . FIG. 7 a is a schematic diagram showing buckle head 1 attached via cable 2 to split cables 38 , 39 which pass over respective pulley wheels 40 , 41 and are fixed at points 42 , 43 to the pretensioner housing 44 . A drive arrangement 45 comprises two pusher fingers 46 and 47 which act on respective split cables 38 , 39 . An electrically detonated gas generator 9 or other drive means acts on the outer planer face of the pusher member 45 to drive it in the direction of the arrow thus pulling in a predetermined length of buckle cable 2 to retract the buckle head 1 . This same arrangement is shown in FIG. 7 b in part cut-away cross-sectional view where like references denote like parts.
FIG. 8 shows a similar arrangement in which the buckle cable 2 passes around an elliptic cam 48 . The pretensioner drive means, such as electrically detonated gas generator 9 , rotates this cam 48 in the direction of the arrow so as to take up a predetermined length of cable 2 and thus retract the buckle head.
FIG. 9 uses a pusher member 49 , driven by gas generator 9 to take up a length of cable 2 .
FIG. 10 shows an embodiment which uses a vane motor 50 as a pretensioning drive force. The vane motor 50 is contained within a housing 51 and is driven by electrically detonated gas generator 9 . An exhaust port 52 is provided in the housing 51 . The vane motor 50 is mounted for rotation via the fixing screw 18 which also passes through the motor drum casing 53 and a cable pulley wheel or winch drum 10 about which the buckle cable 2 passes.
FIG. 11 shows a variation of this vane motor which has a single paddle 54 instead of multiple paddles as in FIG. 10 .
In FIG. 12 another variation is shown using a tri-lobe motor 55 in housing 51 . Again this is driven by electrically detonated gas generator 9 , though the person skilled in the art will see that there are many satisfactory alternative drive means.
FIG. 13 shows a screw driven buckle pretensioner in which a helical drive shaft 56 is rotated by the force from electrically detonated gas generator 9 . Seals 24 assist the gas generator 9 in operating efficiently. Preferably the pulley wheel on winch drum 10 has reverse locking to prevent it from rotating in a cable loosening direction.
FIG. 14 is an embodiment using a rotor drive or a Roots motor. This comprises two figure-of-8 rotors 57 , 58 . The drive rotor 57 is mounted for rotation about fixing screw 18 which also fixes the winch drum 10 about which buckle cable 2 is wound. The idler rotor 58 is driven by gas generator 9 and this drives the drive rotor 57 and consequently winch drum 10 to pull back the buckle cable 2 and thus the buckle head (not shown).
It will be seen in all these examples that the buckle pretensioner is particularly compact and suitable for siting in convenient and unobtrusive positions in a vehicle close to the buckle head, or at a distance as required by the vehicle manufacturer. | A buckle pretensioner for a vehicle safety restraint comprising a buckle head ( 1 ) for receiving a buckle tongue to secure safety restraint webbing about a vehicle occupant in a three-point belt system; a cable ( 2 ) connected to the buckle head ( 1 ); and device ( 7 ) for rapidly withdrawing the cable in a belt tightening direction, the withdrawing device ( 7 ) comprising a force reservoir ( 8 ), and driving mechanism ( 6 ), and being of a compact construction through the use of set-up gearing ( 3,4 ) to magnify linear movement produced by the force reservoir ( 8 ) which may be a pyrotechnic gas generator or a spring. The driving mechanism ( 8 ) may be a piston-cylinder ( 6,8 ) or a rack and pinion. The gearing may comprise a pulley arrangement ( 3,4 ). Alternatively a roots motor or a gear pump could be used. | Identify the most important claim in the given context and summarize it | [
"BACKGROUND OF THE INVENTION The present invention relates to a buckle pretensioner for a vehicle safety restraint.",
"Pretensioners are used to rapidly withdraw a length of seat belt webbing in the event of an emergency.",
"This takes up slack in the seat belt which might be caused by bulky clothing or by a vehicle occupant being out of position such as when leaning forward in the seat, or when seated skewed for example when asleep.",
"The purpose of eliminating this slack is to more securely restrain the vehicle occupant at the onset of emergency conditions, and to more correctly position him for maximum effect of any secondary safety restraint such as an airbag.",
"Pretensioners may be situated at the retractor end of a three-point safety belt to rapidly rewind the belt webbing, or alternatively at the buckle end to rapidly pull back the buckle mounting.",
"Known buckle pretensioners use a piston-cylinder arrangement in which a piston connected to the buckle mounting is pushed rapidly along a cylinder by the force of a spring or more recently by pyrotechnic means which release a sudden rush of gas.",
"Such arrangements are bulky and difficult to fit unobtrusively in a vehicle, particularly in the smaller models of vehicle which are popular nowadays.",
"SUMMARY OF THE INVENTION It is an object of the present invention to provide an improved buckle pretensioner and particularly a more compact design.",
"According to the present invention there is provided a buckle pretensioner for a vehicle safety restraint comprising a buckle head for receiving a buckle tongue to secure safety restraint webbing about a vehicle occupant in a three-point belt system, the pretensioner comprising;",
"a cable connected to the buckle head and means for rapidly withdrawing the cable in a belt tightening direction, the withdrawing means comprising a force generator or reservoir and driving means and being more compact than hitherto known.",
"According to a first embodiment of the invention the pretensioner further comprises step-up gearing means for converting a linear movement of a predetermined magnitude, produced by the force generator, into a linear movement of the cable of more than the predetermined magnitude, preferably a multiple of the predetermined magnitude.",
"Gearing arrangements were not previously considered viable for pretensioners, particularly buckle mounted pretensioners because they increase the torque which must be generated by the driving means, the maximum torque from traditional driving means was limited.",
"However the improvements in pyrotechnic force generators means that sufficient torque can now be generated rapidly enough.",
"The step-up gearing may comprise a multiple pulley arrangement, such that the withdrawal means operates on a small diameter pulley fixedly connected to rotate with a large diameter pulley about which the cable is wound.",
"This arrangement allows a relatively simple force reservoir to be used in the pretensioner because the necessary locking devices can be included in the pulley arrangement, for example a simple ratchet and stop, rather than being part of the force generator (for example in the tube of a piston-cylinder pretensioner) as hitherto.",
"This embodiment can also be adapted relatively easily to incorporate load limiting features.",
"It is particularly applicable to the use of a piston-cylinder type pretensioner, either with a spring or a pyrotechnic force generator and the cylinder tube can in this case be made much shorter than in previous pretensioners.",
"However this embodiment is equally applicable to other types of force generator or to other driving means.",
"According to a second embodiment the driving means comprises a rack and pinion arrangement.",
"The rack may be vertical or horizontal and is driven past the pinion wheel which is connected to rotate a pulley about which the cable is wound, by spring force or by a gas generator.",
"The pinion wheel may be driven by more than one rack, as for example in a system with two moving racks one on either side of the pinion wheel in opposite directions to reinforce each other's driving force.",
"Their movement may be synchronised or phased depending on the pretensioning characteristics to be achieved.",
"Force generators such as gas generator may be integral with the racks.",
"Gearing arrangements may advantageously also be incorporated in this embodiment.",
"According to a third embodiment, the driving means comprises at least two pulley wheels across which the cable passes and means for extending the distance between the pulley wheels so as to withdraw the cable in the belt tightening direction.",
"Two pulley wheels may be arranged adjacent the path of the cable and driven in opposite directions across the path of the cable so as to withdraw the buckle head.",
"Alternatively two or preferably more pulley wheels are arranged with the buckle cable wound around them in an S configuration and one or more pulley wheels are driven parallel to the cable to withdraw the buckle head.",
"A further alternative is to use an elongate, elliptical or oval, cam pulley, arranged in normal use with the cable passing along both its long sides and round one of its short sides.",
"Under pretensioning conditions this cam pulley is rotated rapidly through approximately 90° so that its long sides are tangential to the path of the cable from the buckle head, thus quickly and easily shortening the effective length of cable from the buckle head to its mounting position.",
"The cam pulley may be driven by a pyrotechnically detonated gas generator or by a spring, or by other force generator means.",
"A gas generator driven cam faced piston may be used instead.",
"The buckle cable passes over the outer arcuate cam face of the piston.",
"When pretensioning is required the gas generator drives the piston a predetermined distance away from the buckle head and thus shortens the effective length of the cable to the buckle head.",
"According to a fourth embodiment of the invention the driving means comprises a rotating part with paddles or vanes driven by gas from a gas generator.",
"This may be a wheel connected to the cable pulley, with or without gearing, or a helix coaxial with the cable pulley.",
"Alternatively a Roots motor or gear pump could be used comprising two camming figure-of-8 drive parts, one driven by a gas generator, the other coaxial with the cable pulley.",
"For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made to the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of a compact buckle pretensioner according to one embodiment of the invention.",
"FIG. 2 is an exploded view of a buckle pretensioner according to a variant of the embodiment of Figure FIGS. 3 and 4 are exploded views of a second embodiment of the present invention.",
"FIG. 5 is an exploded view of the buckle pretensioner according to a variation of the second embodiment of the present invention.",
"FIG. 6 is a schematic cross-sectional view of a buckle pretensioner according to a third embodiment of the present invention.",
"FIG. 7 is a part cut-away view of a buckle pretensioner according to a variant of the third embodiment.",
"FIG. 8 is an exploded view of a buckle pretensioner according to another variant of the third embodiment.",
"FIG. 9 illustrates another variant of a buckle pretensioner according to the third embodiment.",
"FIG. 10 is an exploded, and part cut-away view of a buckle pretensioner according to a fourth embodiment of the invention.",
"FIGS. 11, 12 , 13 and 14 show alternative variants of the fourth embodiment of the invention.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1 there is shown a buckle head 1 connected by a cable 2 to the outer diameter of a large diameter pulley wheel 3 Normally the cable would be covered with a plastic sheath and the buckle head is supported to be upstanding by a relatively stiff stalk but these are not shown in FIG. 1 .",
"The pulley wheel 3 is attached to a smaller diameter pulley wheel 4 and the outer diameter of this is connected by cable 5 to piston 6 of pretensioner 7 .",
"Piston 6 is arranged for sliding movement in the cylinder 8 and a gas generator 9 is arranged to be electrically detonated in the event of a crash being detected by crash sensors to release gas into the cylinder 8 to push piston 6 in the direction of arrow A. This has the advantage over traditional arrangements of providing a step up gearing of a ratio corresponding to the ratios of the circumferences of the two pulley wheels 3 and 4 .",
"Thus movement of the piston a predetermined length along the cylinder 8 will move the buckle head downwards by a larger length depending upon the gearing ratio.",
"Thus a more compact linear pretensioner can be used.",
"FIG. 2 illustrates a load limiting arrangement in a compact buckle pretensioner.",
"The buckle cable 2 passes from the buckle (not shown) around pulley wheel 10 .",
"One side of the wheel 10 is provided with sloping teeth which face correspondingly shaped sloping teeth 12 on the side of a locking ratchet 13 which has locking teeth 14 on its outer circumference.",
"The locking teeth 14 can be engaged by locking pawl 15 which is rotatably mounted on the casing of a buckle pretensioner 16 .",
"The locking ratchet 13 and pulley wheel 10 are mounted on and coaxial with drive shaft 17 of the compact pretensioner 16 .",
"They are fixed on the drive shaft 17 by a bolt or rivet 18 and a spring clutch arrangement 19 is mounted between the rivet 18 and the pulley wheel 10 .",
"The pretensioner 16 is fired by electrically detonated gas generator 9 .",
"However, other firing means may be used.",
"Spring 19 acts on pulley wheel 10 to keep it engaged, via the interlocking sloping teeth 11 and 12 , with the locking ratchet 13 up to a predetermined torque.",
"Above the predetermined torque the sloping teeth 11 and 12 slip over each other and allow the pulley wheel 10 to rotate independently of the locking ratchet 13 .",
"Thus a maximum load is applied to the vehicle occupant restrained by this buckle.",
"FIG. 3 shows an alternative compact buckle pretensioner.",
"The buckle head (not shown) is again connected via cable 2 to a pulley wheel 10 .",
"One section of the pulley wheel 10 has teeth 20 about its outer circumference.",
"These teeth are engaged by corresponding teeth 21 on a horizontal rack 22 which is driven tangential to the pulley wheel 10 by electrically detonated gas generator 9 .",
"The pulley wheel 10 is protected by an outer cover 23 and is mounted for rotation and secured in place by rivet or bolt 18 .",
"FIG. 4 shows an alternative arrangement to FIG. 3 in which the rack 22 is vertically mounted.",
"Otherwise like parts are denoted by like reference numbers.",
"In FIGS. 3 and 4 a seal 24 is situated between the rack 22 and pretensioner housing wall 25 .",
"This maximises the effect of the gas generator by preventing escape of gas along the side of the rack.",
"In addition a locking means is provided so as to lock the rack and pinion in the pretensioned state after pretensioning to hold the buckle in the retracted position.",
"This may, for example be, in the form of a locking ellipse as is well known in this field and as is shown in GB 1 351 447 and also is described in DE 42 34 132 both of which are incorporated herein by reference.",
"FIG. 5 shows an alternative compact buckle pretensioner.",
"Again buckle cable 2 is connected to a pulley wheel 10 mounted on shaft 26 .",
"A tooth pinion wheel 27 is mounted on shaft 26 .",
"Two sets of tooth racks are arranged one on either side of the pinion wheel 27 so that when activated they move across the pinion wheel engaging the teeth and rotating it.",
"Single or multiple racks 28 and 29 are mounted on respective support blocks 30 , 31 and the parts are contained within housing parts 32 , 33 .",
"An electrically detonated gas generator 9 acts to push the support blocks 30 , 31 with their respective racks 28 , 29 along the respective channels formed by the two parts of the covers 32 , 33 .",
"The gas from the gas generator 9 pushes support members 30 and 31 by acting on planer surfaces of the support end members 34 , 35 .",
"FIG. 6 illustrates another embodiment of the invention.",
"In FIG. 6 a the buckle is shown in the normal use condition.",
"In FIG. 6 b the pretensioner has operated and the buckle head 2 has been retracted.",
"This is effected by driving two rods 36 and 37 in opposite directions across the path of the cable 2 as indicated by the arrows.",
"FIG. 7 shows a similar arrangement in which multiple pulleys are introduced and the rods are pushed in a direction parallel to the buckle cable 2 .",
"This arrangement is even more compact than that of FIGS. 6 a and 6 b .",
"FIG. 7 a is a schematic diagram showing buckle head 1 attached via cable 2 to split cables 38 , 39 which pass over respective pulley wheels 40 , 41 and are fixed at points 42 , 43 to the pretensioner housing 44 .",
"A drive arrangement 45 comprises two pusher fingers 46 and 47 which act on respective split cables 38 , 39 .",
"An electrically detonated gas generator 9 or other drive means acts on the outer planer face of the pusher member 45 to drive it in the direction of the arrow thus pulling in a predetermined length of buckle cable 2 to retract the buckle head 1 .",
"This same arrangement is shown in FIG. 7 b in part cut-away cross-sectional view where like references denote like parts.",
"FIG. 8 shows a similar arrangement in which the buckle cable 2 passes around an elliptic cam 48 .",
"The pretensioner drive means, such as electrically detonated gas generator 9 , rotates this cam 48 in the direction of the arrow so as to take up a predetermined length of cable 2 and thus retract the buckle head.",
"FIG. 9 uses a pusher member 49 , driven by gas generator 9 to take up a length of cable 2 .",
"FIG. 10 shows an embodiment which uses a vane motor 50 as a pretensioning drive force.",
"The vane motor 50 is contained within a housing 51 and is driven by electrically detonated gas generator 9 .",
"An exhaust port 52 is provided in the housing 51 .",
"The vane motor 50 is mounted for rotation via the fixing screw 18 which also passes through the motor drum casing 53 and a cable pulley wheel or winch drum 10 about which the buckle cable 2 passes.",
"FIG. 11 shows a variation of this vane motor which has a single paddle 54 instead of multiple paddles as in FIG. 10 .",
"In FIG. 12 another variation is shown using a tri-lobe motor 55 in housing 51 .",
"Again this is driven by electrically detonated gas generator 9 , though the person skilled in the art will see that there are many satisfactory alternative drive means.",
"FIG. 13 shows a screw driven buckle pretensioner in which a helical drive shaft 56 is rotated by the force from electrically detonated gas generator 9 .",
"Seals 24 assist the gas generator 9 in operating efficiently.",
"Preferably the pulley wheel on winch drum 10 has reverse locking to prevent it from rotating in a cable loosening direction.",
"FIG. 14 is an embodiment using a rotor drive or a Roots motor.",
"This comprises two figure-of-8 rotors 57 , 58 .",
"The drive rotor 57 is mounted for rotation about fixing screw 18 which also fixes the winch drum 10 about which buckle cable 2 is wound.",
"The idler rotor 58 is driven by gas generator 9 and this drives the drive rotor 57 and consequently winch drum 10 to pull back the buckle cable 2 and thus the buckle head (not shown).",
"It will be seen in all these examples that the buckle pretensioner is particularly compact and suitable for siting in convenient and unobtrusive positions in a vehicle close to the buckle head, or at a distance as required by the vehicle manufacturer."
] |
CLAIM OF PRIORITY
[0001] This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application earlier filed in the Korean Intellectual Property Office on 19 Aug. 2010 and there duly assigned Serial No. 10-2010-0080290.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] One embodiment of the present invention relates to a jelly roll and an electrode assembly having the same, and more particularly, to a jelly roll which facilitates a process and has structural stability and an electrode assembly having the jelly roll.
[0004] 2. Discussion of Related Art
[0005] A secondary battery is a chemical cell which may be repeatedly charged and discharged via reversible conversion between chemical energy and electrical energy. Recently, since telecommunication equipment is widely used and automotive batteries require a higher capacity and a higher output emerge, lithium secondary batteries having a higher voltage and a higher capacity density are required.
[0006] Although various materials may be used to form a battery, materials having a high charging and discharging capacity in a potential range for practical use is generally used in order to obtain a battery having a high capacity. Capacity may be classified into specific capacity that is a weight characteristic and capacity density that is a volume characteristic. A high quality battery generally has both a high specific capacity and a high capacity density and contains high-density materials.
[0007] Meanwhile, a lithium-ion secondary battery mainly includes a positive active material, a negative active material, an electrolyte, and a separator. The positive active material generally includes LiCO 2 , and the negative active material generally includes carbon materials, such as graphite, occluding and emitting lithium as ions.
[0008] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE INVENTION
[0009] An aspect of the present invention provides a jelly roll which is easy to be made by a winding process.
[0010] Another aspect of the present invention provides an electrode assembly including a terminal and a current collector and eliminating unnecessary space within the electrode assembly. The size of such electrode assembly may be advantageously minimized.
[0011] Still another aspect of the present invention provides an electrode assembly in which a jelly roll is securely settled during fabrication, and is thus physically stable after the completion of manufacture in order to minimize deformation occurring during charging and discharging and to have a strong structure against external impact.
[0012] In accordance with an embodiment of the present invention, a jelly roll may include a first auxiliary current collector, a second auxiliary current collector, a mandrel insulating layer, and an electrode plate. The first auxiliary current collector and the second auxiliary current collector are spaced apart from each other and each have a mandrel protrusion on a respective opposite end portion. The mandrel insulating layer insulates the auxiliary current collectors from each other and insulates the auxiliary current collectors from an exterior. The electrode plate is formed by layering a separator, a first electrode plate, a separator and a second electrode plate in sequence and the electrode plate may be wound on an outer surface of the mandrel insulating layer.
[0013] The first electrode plate includes a positive active material layer to which a positive active material is applied and a positive non-applied part to which the positive active material is not applied, and the second electrode plate includes a negative active material layer to which a negative active material is applied and a negative non-applied part to which the negative active material is not applied. Here, the electrode plates may be deposited with the positive non-applied part being exposed to one edge of the separator and the negative non-applied part being exposed to another opposite edge of the separator.
[0014] The first auxiliary current collector may include an alloy of at least one of aluminum, nickel, titanium and plastic carbon.
[0015] The second auxiliary current collector may include an alloy of at least one of copper, stainless steel, aluminum and nickel.
[0016] Two or more mandrel protrusions may be formed on each auxiliary current collector.
[0017] In accordance with another embodiment of the present invention, an electrode assembly may include a first auxiliary current collector, a second auxiliary current collector, a mandrel insulating layer, an electrode plate, a first main current collector, and a second main current collector.
[0018] The first auxiliary current collector and the second auxiliary current collector are spaced apart from each other and each have a mandrel protrusion on a respective opposite end portion. The mandrel insulating layer insulates the auxiliary current collectors from each other and insulates the auxiliary current collectors from an outside. The electrode plate is formed by layering a separator, a first electrode plate, a separator and a second electrode plate in sequence and the electrode plate is wound on an outer surface of the mandrel insulating layer. Each of the first and second main current collectors includes a side plate in which a mandrel protrusion accommodating hole to accommodate the mandrel protrusion is formed and a cap plate extending from an edge of the side plate in a perpendicular direction. An electrode terminal is formed on the cap plate. A current collector insulating part connects the cap plate of the first main current collector with the cap plate of the second main current collector.
[0019] Further, the first main current collector, the second main current collector, and the current collector insulating part may be simultaneously and integrally formed as a single body.
[0020] Further, the first electrode plate may include a positive active material layer to which a positive active material is applied and a positive non-applied part to which the positive active material is not applied, and the second electrode plate comprises a negative active material layer to which a negative active material is applied and a negative non-applied part to which the negative active material is not applied. Here, the electrode plates are deposited with the positive non-applied part being exposed to one edge of the separator and the negative non-applied part being exposed to another opposite edge of the separator.
[0021] In addition, an adhesive inlet injecting an adhesive may be formed in the side plate of the first main current collector and in the side plate of the second main current collector.
[0022] Further, an adhesive injected into the adhesive inlet may be electrically conductive. Also, the adhesive may adhere the first main current collector to the positive non-applied part and may adhere the second main current collector to the negative non-applied part.
[0023] The adhesive may adhere the first auxiliary current collector to the positive non-applied part and may adhere the second auxiliary current collector to the negative non-applied part.
[0024] Further, two or more mandrel protrusions may be formed on each auxiliary current collector.
[0025] In addition, at least one adhesive inlet may be provided between the mandrel protrusions.
[0026] A conductive adhesive may be injected into the adhesive inlet.
[0027] The mandrel protrusion accommodating hole and the mandrel protrusions inserted into the mandrel protrusion accommodating hole may be welded together.
[0028] As described above, according to embodiments of the present invention, an auxiliary current collector functioning as a mandrel in a winding process is provided to facilitate the winding process.
[0029] Moreover, unnecessary space may be eliminated in order to increase a total density of a secondary battery maximally, thereby manufacturing the batter with a high output.
[0030] In addition, an auxiliary current collector is securely fixed to a main current collector, so that deformation of a secondary battery is minimized in charging and discharging and sufficient strength is maintained when dropped.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
[0032] FIG. 1 is an oblique view illustrating an auxiliary current collector constructed as an embodiment;
[0033] FIG. 2 is an oblique view illustrating an auxiliary current collector and a mandrel insulating layer constructed as the embodiment;
[0034] FIG. 3A is an exploded partial plan view illustrating an electrode plate;
[0035] FIG. 3B is a partial cross-sectional view illustrating the electrode plate deposited;
[0036] FIG. 4A is an oblique view illustrating winding a jelly roll according to an embodiment.
[0037] FIG. 4B is an oblique view illustrating a wound jelly roll constructed as an embodiment;
[0038] FIG. 4C is an oblique view illustrating a stack constructed as an embodiment;
[0039] FIG. 5 is an oblique view illustrating a current collector constructed as an embodiment;
[0040] FIG. 6 is an oblique view illustrating a current collector and a jelly roll being connected; and
[0041] FIG. 7 is a schematic view illustrating a process of applying an adhesive.
DETAILED DESCRIPTION OF THE INVENTION
[0042] In the following detailed description, only certain embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. In addition, when an element is referred to as being “on” another element, it can be directly on the other element or be indirectly on the other element with one or more intervening elements interposed therebetween. Also, when an element is referred to as being “connected to” another element, it can be directly connected to the other element or be indirectly connected to the other element with one or more intervening elements interposed therebetween. Hereinafter, like reference numerals refer to like elements.
[0043] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the specification, terms to indicate directions “up,” “down,” “right,” and “left” are based on directions in the drawings unless the context clearly indicates otherwise.
[0044] An electrode assembly may include a jelly roll 100 and a current collector 200 as shown in FIGS. 4B , 5 and 6 . In another embodiment, an electrode assembly may include a stack 100 a and a current collector 200 as shown in FIGS. 4C , 5 and 6 .
[0045] As shown in FIG. 4B , the jelly roll 100 may include an auxiliary current collector 110 , a mandrel insulating layer 120 , and an electrode plate 150 .
[0046] As shown in FIG. 4C , the stack 100 a may include an auxiliary current collector 110 , a mandrel insulating layer 120 , and a stacked type electrode plate 150 a.
[0047] FIG. 1 is an oblique view illustrating an auxiliary current collector constructed as an embodiment. As shown in FIG. 1 , the auxiliary current collector 110 includes a first auxiliary current collector 110 a and a second auxiliary current collector 110 b . In one embodiment, the first auxiliary current collector 110 a may act as a positive auxiliary current collector, and the second auxiliary current collector 110 b may act as a negative auxiliary current collector. In another embodiment, the first auxiliary current collector 110 a may act as a negative auxiliary current collector, and the second auxiliary current collector 110 b may act as a positive auxiliary current collector. For convenience of description, the first auxiliary current collector 110 a is thereafter referred to as a positive auxiliary current collector, and the second auxiliary current collector 110 b is thereafter referred to as a negative auxiliary current collector.
[0048] The positive auxiliary current collector 110 a and the negative auxiliary current collector 110 b may be formed in a rectangular plate shape. The positive auxiliary current collector 110 a and the negative auxiliary current collector 110 b may be disposed spaced apart from each other. In one embodiment, one side Sa 1 of the positive auxiliary current collector 110 a may be disposed to face toward one side Sb 1 of the negative auxiliary current collector 110 b , and the positive auxiliary current collector 110 a may be aligned with the negative auxiliary current collector 110 b in a same plane. A mandrel protrusion 111 is formed on an end portion Sa 2 of the positive auxiliary current collector 110 a opposite to the negative auxiliary current collector 110 b , and another mandrel protrusion 111 is formed on an end portion Sb 2 of the negative auxiliary current collector 110 b disposed opposite to the positive auxiliary current collector 110 a . In one embodiment, the mandrel protrusion 111 formed on the positive auxiliary current collector 110 a protrudes away from the negative auxiliary current collector 110 b ; another mandrel protrusion 111 formed on the negative auxiliary current collector 110 b protrudes away from the positive auxiliary current collector 110 a . The mandrel protrusions 111 function as a mandrel when an electrode plate 150 is wound into a jelly roll (see FIG. 4A ). In one embodiment, a pair of mandrel protrusions 111 may be formed on one side of each of auxiliary current collectors. Here, two or more mandrel protrusions 111 may be formed on a single auxiliary current collector so that the mandrel protrusions 111 may be settled securely in a winder 300 (see FIG. 4A ).
[0049] The positive auxiliary current collector 110 a may include aluminum (Al) or an aluminum alloy, and the negative auxiliary current collector 110 b may include copper (Cu) or a copper alloy.
[0050] FIG. 2 is an oblique view illustrating an auxiliary current collector and a mandrel insulating layer constructed as the embodiment. As shown in FIG. 2 , the mandrel insulating layer 120 includes an insulating material and may be formed via molding in order to encompass an outside of the auxiliary current collectors 110 . The mandrel insulating layer 120 insulates the positive auxiliary current collector 110 a and the negative auxiliary current collector 110 b from each other, and insulates the auxiliary current collectors 110 from an electrode plate 150 which is wounded around the auxiliary current collectors 110 . The mandrel insulating layer 120 may be formed by electrical insulating material.
[0051] Referring to FIGS. 3A and 3B , the electrode plate 150 is described. FIG. 3A is an exploded partial plan view illustrating the electrode plate, and FIG. 3B is a partial cross-sectional view illustrating the electrode plate. The electrode plate 150 includes a first electrode plate 160 , a second electrode plate 170 , and a separator 180 . In one embodiment, the first electrode plate 160 may be a positive electrode plate, and the second electrode plate 170 may be a negative electrode plate. In another embodiment, the first electrode plate 160 may be a negative electrode plate, and the second electrode plate 170 may be a positive electrode plate. For convenience of description, the first electrode plate 160 is thereafter denoted as positive, and a second electrode plate 170 is thereafter denoted as negative.
[0052] The positive plate 160 includes a positive active material layer 161 in which a positive active material is applied to both surfaces or one surface of a positive current collector and a positive non-applied part 162 to which the positive active material is not applied. The positive current collector generally uses material having a high conductivity and a high chemical stability. For example, the positive current collector may include aluminum, nickel, titanium, plastic carbon, and the like. The positive active material layer 161 may be formed by applying slurry to the positive current collector, with the slurry being prepared by mixing a positive active material, a conductive material, and a binder with a solvent.
[0053] The negative plate 170 includes a negative active material layer 171 in which a negative active material is applied to both surfaces or one surface of a negative current collector and a negative non-applied part 172 to which the negative active material is not applied. The negative plate 170 may include conductive metal, for example, copper, stainless steel, aluminum, nickel, and the like. The negative active material layer 171 may be formed by applying slurry to a negative current collector, with the slurry being prepared by mixing a negative active material and a binder to improve coherence of the negative active material with a solvent.
[0054] The separator 180 may be interposed between the positive active material layer 161 and the negative active material layer 171 . The separator 180 functions as a passage of ions and prevents a direct contact between the positive plate 160 and the negative plate 170 . Thus, the separator 180 is formed of an insulating thin film having a high ion permeability and a high mechanical strength. In one embodiment, the separator 180 may be formed of an electrical insulating thin film. For example, the separator 180 may use a porous film including polyethylene, polypropylene or polyvinylidene fluoride, or felt.
[0055] An electrode assembly used for a secondary battery may be classified into a winding-type electrode assembly, a deposition-type electrode assembly, and the like. The winding-type electrode assembly is formed by winding a positive plate and a negative plate being insulated from each other by a separator, and the positive and negative plates are sheets extending longitudinally. In the winding-type electrode assembly, the capacity of a battery may be increased by increasing the number of windings. As the number of windings increases, however, the electrode plates or the separator which constitute the electrode assembly may be detached and be easily deformed. Furthermore, the positive plate may come into a direct contact with the negative plate, so that a short circuit may occur.
[0056] FIG. 3B shows a cross-sectional view of a layered structure of the electrode plate 150 . As shown in FIG. 3B , the electrode plate 150 may be formed by layering the separator 180 , the positive plate 160 , the separator 180 , and the negative plate 170 in order. Here, the positive plate 160 , the separator 180 , the negative plate 170 , and the separator 180 may be layered in order, since the above layered structure is repeated in winding.
[0057] As described above, the positive plate 160 includes the positive active material layer 161 and the positive non-applied part 162 , and the negative plate 170 includes the negative active material layer 171 and the negative non-applied part 172 . When the positive plate 160 is deposited on the separator 180 , the positive non-applied part 162 is exposed to one side (or edge) S 1 of the separator 180 . Likewise, when the negative plate 170 is deposited on the separator 180 , the negative non-applied part 172 is exposed to another side (or edge) S 2 of the separator 180 . When the electrode plate 150 is wound, as shown in FIG. 4B , the positive non-applied part 162 is exposed to one side S 1 of the separator 180 , and the negative non-applied part 172 is exposed to the other side S 2 of the separator 180 . When the electrode plate 150 is wound into a jelly roll, in one embodiment, the positive non-applied part 162 is uncovered by the separator 180 and is exposed at one edge S 1 of the separator 180 ; the negative non-applied part 172 is uncovered by the separator 180 and is exposed at an opposite edge S 2 of the separator 180 .
[0058] FIGS. 4A and 4B show a winding process. FIG. 4A is an oblique view illustrating a process of winding the jelly roll 100 , and FIG. 4B is an oblique view the wound jelly roll 100 .
[0059] The winder 300 is a device for winding the electrode plate 150 on an outside of the mandrel insulating layer 120 . The winder 300 includes a mandrel protrusion fixing unit 310 to accommodate and settle the mandrel protrusions 111 on a rotation shaft of a sub-motor and performs a winding process. Here, the alignment of the positive plate 160 , the separator 180 , and the negative plate 170 is important, and thus winding is uniformly performed.
[0060] The auxiliary current collectors 110 may be wound in a situation where only the mandrel protrusions are exposed to the exterior of the jelly roll in view of risk of a short circuit.
[0061] FIG. 4C is an oblique view illustrating a stack constructed as another embodiment. As shown in FIG. 4C , a stack 100 a may include an auxiliary current collector 110 , a mandrel insulating layer 120 , and a stacked type electrode plate 150 a . The difference between FIG. 4B and FIG. 4C is that FIG. 4C shows a stacked type electrode plate 150 a which is different from the jelly roll type electrode plate 150 of FIG. 4B . The stacked type electrode plate 150 a is formed by stacking layers 1000 . In the stacked type electrode plate 150 a , the positive non-applied part 162 a is uncovered by the separator 180 a and is exposed at one edge of the separator 180 a ; the negative non-applied part 172 a is uncovered by the separator 180 a and is exposed at an opposite edge of the separator 180 a.
[0062] FIG. 5 shows an oblique view of the current collector 200 . A main current collector 210 collectively refers to a positive side plate 210 a , a positive cap plate 210 c , a negative side plate 210 b , and a negative cap plate 210 d . The main current collector 210 may be formed by bending one plate twice at a right angle. As shown in FIG. 5 , two plates, i.e., the side plates 210 a and 210 b , face towards each other and are disposed opposite to each other. Two side plates 210 a and 210 b are physically connected by the cap plates 210 c and 210 d , and the two side plates 210 a and 210 b are electrically insulated from each other by a current collector insulating part 230 . The current collector insulating part 230 may be provided between the two cap plates 210 c and 210 d in order to electrically insulate the cap plate 210 c from the cap plate 210 d . Here, the side plates 210 a and 210 b , the cap plates 210 c and 210 d , and the current collector insulating part 230 may be simultaneously and integrally formed as a single body via double injection molding, or may be manufactured separately and combined via soldering or welding.
[0063] A mandrel protrusion accommodating hole 212 is formed in the side plates 210 a and 210 b . The mandrel protrusion accommodating hole 212 may be a through hole. The mandrel protrusions 111 formed on the auxiliary current collectors 110 a and 110 b may be inserted into the mandrel protrusion accommodating hole 212 . Further, an adhesive inlet 211 may be formed in the side plates 210 a and 210 b . The adhesive inlet 211 may be a through hole. In one embodiment, adhesive inlet 211 may be disposed separately from the mandrel protrusion accommodating hole 212 . When the wound jelly roll 100 is put into the current collector 200 , an adhesive may be injected through the adhesive inlet 211 and the adhesive may be disposed to fill a gap between the wound jelly roll 100 and the current collector 200 . Here, the adhesive inlet 211 may be formed between at least two of the mandrel protrusion accommodating holes 212 . When an electrically conductive adhesive is injected through the adhesive inlet 211 provided between the mandrel protrusion accommodating holes 212 , the conductive adhesive may reach up to the auxiliary current collectors 110 . Here, the side plates 210 a and 210 b and the cap plates 210 c and 210 d may be formed of the same material as the auxiliary current collectors 110 .
[0064] Referring to FIG. 6 , a process of connecting the jelly roll 100 to the current collector 200 is described. FIG. 6 is a perspective view illustrating an assembly where the jelly roll 100 and the current collector 200 are connected to each other. The two mandrel protrusions 111 of the jelly roll 100 may be inserted into the mandrel protrusion accommodating holes 212 formed in the side plates 210 a and 210 b of the current collector 200 , so that the jelly roll 100 and the current collector 200 are connected. Here, a jelly roll guide 215 may be provided to guide the inserted jelly roll 100 and to prevent detachment of the positive and negative non-applied parts 162 and 172 formed on opposite sides of the jelly roll 100 after the jelly roll 100 is connected. The jelly roll guide 215 extends from opposite sides (or edges) S 11 and S 22 of the side plates 210 a and 210 b toward a direction along the extending direction of the cap plates 210 c and 210 d.
[0065] When the connection between the jelly roll 100 and the current collector 200 is completed, as shown in FIG. 6 , the inside positive or negative non-applied part 162 and 172 may be seen through the adhesive inlet 211 , and the mandrel protrusions 111 inserted from the inside may be seen through the mandrel protrusion accommodating holes 212 . The electrode terminals 241 and 242 are designed to be electrically connected to external electrical devices.
[0066] Referring to FIG. 7 , a process of applying an adhesive is described. FIG. 7 is a schematic view illustrating the process of applying the adhesive. First, an auxiliary side plate 400 is provided parallel with one of the side plates 210 a and 210 b side by side. Then, a predetermined amount of an adhesive 420 is applied onto the auxiliary side plate 400 , and the adhesive 420 is spread on up to the side plates 210 a and 210 b using a blade 410 . In this manner, the adhesive 420 is put onto the jelly roll 100 through the mandrel protrusion accommodating holes 212 and the adhesive inlet 211 .
[0067] Here, the adhesive 420 may be an electrically conductive adhesive. The adhesive 420 may attach or adhere the positive side plate 210 a to the positive non-applied part 162 , and attach or adhere the negative side plate 210 b to the negative non-applied part 172 . Separately or simultaneously, the adhesive 420 may attach or adhere the positive auxiliary current collector 110 a to the positive non-applied part 162 and attach or adhere the negative auxiliary current collector 110 b to the negative non-applied part 172 .
[0068] In one embodiment where the adhesive 420 is not electrically conductive, a conductive connection member may be additionally provided to respectively electrically connect the non-applied parts 162 and 172 of the electrode plate 150 with the auxiliary current collectors 110 a and 110 b or to respectively electrically connect the non-applied parts 162 and 172 of the electrode plate 150 with the side plates 210 a and 210 b.
[0069] After applying the conductive adhesive 420 , the conductive adhesive 420 is heated via ultraviolet irradiation or the like so as not to damage a separator of a secondary battery and then the conductive adhesive 420 is hardened at a low temperature.
[0070] Here, in order to improve connection of the jelly roll 100 and the current collector 200 , the mandrel protrusion accommodating holes 212 and the mandrel protrusions 111 inserted into the mandrel protrusion accommodating holes 212 are welded before injecting the adhesive 420 .
[0071] Although the spirit of the present invention was described in detail in accordance with the embodiment, it should be understood that the embodiments are provide to explain the present invention and do not limit the present invention, and various jelly rolls and electrode assemblies having the same may be realized without departing from the scope of the present invention.
[0072] While the present invention has been described in connection with certain embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof. | Embodiments of the present invention facilitate a winding process and enable auxiliary current collectors to be securely fixed to a main current collector, thereby minimizing deformation during battery charging and discharging and maintaining sufficient strength. The jelly roll includes a first auxiliary current collector, a second auxiliary current collector, a mandrel insulating layer, and an electrode plate. The first auxiliary current collector and the second auxiliary current collector are spaced apart from each other and each has a mandrel protrusion on an opposite end portion. The mandrel insulating layer insulates the auxiliary current collectors from each other and insulates the auxiliary current collectors from an exterior. The electrode plate is formed by layering a separator, a first electrode plate, a separator and a second electrode plate and is wound on an external surface of the mandrel insulating layer. | Identify the most important aspect in the document and summarize the concept accordingly. | [
"CLAIM OF PRIORITY [0001] This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application earlier filed in the Korean Intellectual Property Office on 19 Aug. 2010 and there duly assigned Serial No. 10-2010-0080290.",
"BACKGROUND OF THE INVENTION [0002] 1.",
"Field of the Invention [0003] One embodiment of the present invention relates to a jelly roll and an electrode assembly having the same, and more particularly, to a jelly roll which facilitates a process and has structural stability and an electrode assembly having the jelly roll.",
"[0004] 2.",
"Discussion of Related Art [0005] A secondary battery is a chemical cell which may be repeatedly charged and discharged via reversible conversion between chemical energy and electrical energy.",
"Recently, since telecommunication equipment is widely used and automotive batteries require a higher capacity and a higher output emerge, lithium secondary batteries having a higher voltage and a higher capacity density are required.",
"[0006] Although various materials may be used to form a battery, materials having a high charging and discharging capacity in a potential range for practical use is generally used in order to obtain a battery having a high capacity.",
"Capacity may be classified into specific capacity that is a weight characteristic and capacity density that is a volume characteristic.",
"A high quality battery generally has both a high specific capacity and a high capacity density and contains high-density materials.",
"[0007] Meanwhile, a lithium-ion secondary battery mainly includes a positive active material, a negative active material, an electrolyte, and a separator.",
"The positive active material generally includes LiCO 2 , and the negative active material generally includes carbon materials, such as graphite, occluding and emitting lithium as ions.",
"[0008] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.",
"SUMMARY OF THE INVENTION [0009] An aspect of the present invention provides a jelly roll which is easy to be made by a winding process.",
"[0010] Another aspect of the present invention provides an electrode assembly including a terminal and a current collector and eliminating unnecessary space within the electrode assembly.",
"The size of such electrode assembly may be advantageously minimized.",
"[0011] Still another aspect of the present invention provides an electrode assembly in which a jelly roll is securely settled during fabrication, and is thus physically stable after the completion of manufacture in order to minimize deformation occurring during charging and discharging and to have a strong structure against external impact.",
"[0012] In accordance with an embodiment of the present invention, a jelly roll may include a first auxiliary current collector, a second auxiliary current collector, a mandrel insulating layer, and an electrode plate.",
"The first auxiliary current collector and the second auxiliary current collector are spaced apart from each other and each have a mandrel protrusion on a respective opposite end portion.",
"The mandrel insulating layer insulates the auxiliary current collectors from each other and insulates the auxiliary current collectors from an exterior.",
"The electrode plate is formed by layering a separator, a first electrode plate, a separator and a second electrode plate in sequence and the electrode plate may be wound on an outer surface of the mandrel insulating layer.",
"[0013] The first electrode plate includes a positive active material layer to which a positive active material is applied and a positive non-applied part to which the positive active material is not applied, and the second electrode plate includes a negative active material layer to which a negative active material is applied and a negative non-applied part to which the negative active material is not applied.",
"Here, the electrode plates may be deposited with the positive non-applied part being exposed to one edge of the separator and the negative non-applied part being exposed to another opposite edge of the separator.",
"[0014] The first auxiliary current collector may include an alloy of at least one of aluminum, nickel, titanium and plastic carbon.",
"[0015] The second auxiliary current collector may include an alloy of at least one of copper, stainless steel, aluminum and nickel.",
"[0016] Two or more mandrel protrusions may be formed on each auxiliary current collector.",
"[0017] In accordance with another embodiment of the present invention, an electrode assembly may include a first auxiliary current collector, a second auxiliary current collector, a mandrel insulating layer, an electrode plate, a first main current collector, and a second main current collector.",
"[0018] The first auxiliary current collector and the second auxiliary current collector are spaced apart from each other and each have a mandrel protrusion on a respective opposite end portion.",
"The mandrel insulating layer insulates the auxiliary current collectors from each other and insulates the auxiliary current collectors from an outside.",
"The electrode plate is formed by layering a separator, a first electrode plate, a separator and a second electrode plate in sequence and the electrode plate is wound on an outer surface of the mandrel insulating layer.",
"Each of the first and second main current collectors includes a side plate in which a mandrel protrusion accommodating hole to accommodate the mandrel protrusion is formed and a cap plate extending from an edge of the side plate in a perpendicular direction.",
"An electrode terminal is formed on the cap plate.",
"A current collector insulating part connects the cap plate of the first main current collector with the cap plate of the second main current collector.",
"[0019] Further, the first main current collector, the second main current collector, and the current collector insulating part may be simultaneously and integrally formed as a single body.",
"[0020] Further, the first electrode plate may include a positive active material layer to which a positive active material is applied and a positive non-applied part to which the positive active material is not applied, and the second electrode plate comprises a negative active material layer to which a negative active material is applied and a negative non-applied part to which the negative active material is not applied.",
"Here, the electrode plates are deposited with the positive non-applied part being exposed to one edge of the separator and the negative non-applied part being exposed to another opposite edge of the separator.",
"[0021] In addition, an adhesive inlet injecting an adhesive may be formed in the side plate of the first main current collector and in the side plate of the second main current collector.",
"[0022] Further, an adhesive injected into the adhesive inlet may be electrically conductive.",
"Also, the adhesive may adhere the first main current collector to the positive non-applied part and may adhere the second main current collector to the negative non-applied part.",
"[0023] The adhesive may adhere the first auxiliary current collector to the positive non-applied part and may adhere the second auxiliary current collector to the negative non-applied part.",
"[0024] Further, two or more mandrel protrusions may be formed on each auxiliary current collector.",
"[0025] In addition, at least one adhesive inlet may be provided between the mandrel protrusions.",
"[0026] A conductive adhesive may be injected into the adhesive inlet.",
"[0027] The mandrel protrusion accommodating hole and the mandrel protrusions inserted into the mandrel protrusion accommodating hole may be welded together.",
"[0028] As described above, according to embodiments of the present invention, an auxiliary current collector functioning as a mandrel in a winding process is provided to facilitate the winding process.",
"[0029] Moreover, unnecessary space may be eliminated in order to increase a total density of a secondary battery maximally, thereby manufacturing the batter with a high output.",
"[0030] In addition, an auxiliary current collector is securely fixed to a main current collector, so that deformation of a secondary battery is minimized in charging and discharging and sufficient strength is maintained when dropped.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0031] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein: [0032] FIG. 1 is an oblique view illustrating an auxiliary current collector constructed as an embodiment;",
"[0033] FIG. 2 is an oblique view illustrating an auxiliary current collector and a mandrel insulating layer constructed as the embodiment;",
"[0034] FIG. 3A is an exploded partial plan view illustrating an electrode plate;",
"[0035] FIG. 3B is a partial cross-sectional view illustrating the electrode plate deposited;",
"[0036] FIG. 4A is an oblique view illustrating winding a jelly roll according to an embodiment.",
"[0037] FIG. 4B is an oblique view illustrating a wound jelly roll constructed as an embodiment;",
"[0038] FIG. 4C is an oblique view illustrating a stack constructed as an embodiment;",
"[0039] FIG. 5 is an oblique view illustrating a current collector constructed as an embodiment;",
"[0040] FIG. 6 is an oblique view illustrating a current collector and a jelly roll being connected;",
"and [0041] FIG. 7 is a schematic view illustrating a process of applying an adhesive.",
"DETAILED DESCRIPTION OF THE INVENTION [0042] In the following detailed description, only certain embodiments of the present invention have been shown and described, simply by way of illustration.",
"As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention.",
"Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.",
"In addition, when an element is referred to as being “on”",
"another element, it can be directly on the other element or be indirectly on the other element with one or more intervening elements interposed therebetween.",
"Also, when an element is referred to as being “connected to”",
"another element, it can be directly connected to the other element or be indirectly connected to the other element with one or more intervening elements interposed therebetween.",
"Hereinafter, like reference numerals refer to like elements.",
"[0043] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.",
"In the specification, terms to indicate directions “up,” “down,” “right,” and “left”",
"are based on directions in the drawings unless the context clearly indicates otherwise.",
"[0044] An electrode assembly may include a jelly roll 100 and a current collector 200 as shown in FIGS. 4B , 5 and 6 .",
"In another embodiment, an electrode assembly may include a stack 100 a and a current collector 200 as shown in FIGS. 4C , 5 and 6 .",
"[0045] As shown in FIG. 4B , the jelly roll 100 may include an auxiliary current collector 110 , a mandrel insulating layer 120 , and an electrode plate 150 .",
"[0046] As shown in FIG. 4C , the stack 100 a may include an auxiliary current collector 110 , a mandrel insulating layer 120 , and a stacked type electrode plate 150 a. [0047] FIG. 1 is an oblique view illustrating an auxiliary current collector constructed as an embodiment.",
"As shown in FIG. 1 , the auxiliary current collector 110 includes a first auxiliary current collector 110 a and a second auxiliary current collector 110 b .",
"In one embodiment, the first auxiliary current collector 110 a may act as a positive auxiliary current collector, and the second auxiliary current collector 110 b may act as a negative auxiliary current collector.",
"In another embodiment, the first auxiliary current collector 110 a may act as a negative auxiliary current collector, and the second auxiliary current collector 110 b may act as a positive auxiliary current collector.",
"For convenience of description, the first auxiliary current collector 110 a is thereafter referred to as a positive auxiliary current collector, and the second auxiliary current collector 110 b is thereafter referred to as a negative auxiliary current collector.",
"[0048] The positive auxiliary current collector 110 a and the negative auxiliary current collector 110 b may be formed in a rectangular plate shape.",
"The positive auxiliary current collector 110 a and the negative auxiliary current collector 110 b may be disposed spaced apart from each other.",
"In one embodiment, one side Sa 1 of the positive auxiliary current collector 110 a may be disposed to face toward one side Sb 1 of the negative auxiliary current collector 110 b , and the positive auxiliary current collector 110 a may be aligned with the negative auxiliary current collector 110 b in a same plane.",
"A mandrel protrusion 111 is formed on an end portion Sa 2 of the positive auxiliary current collector 110 a opposite to the negative auxiliary current collector 110 b , and another mandrel protrusion 111 is formed on an end portion Sb 2 of the negative auxiliary current collector 110 b disposed opposite to the positive auxiliary current collector 110 a .",
"In one embodiment, the mandrel protrusion 111 formed on the positive auxiliary current collector 110 a protrudes away from the negative auxiliary current collector 110 b ;",
"another mandrel protrusion 111 formed on the negative auxiliary current collector 110 b protrudes away from the positive auxiliary current collector 110 a .",
"The mandrel protrusions 111 function as a mandrel when an electrode plate 150 is wound into a jelly roll (see FIG. 4A ).",
"In one embodiment, a pair of mandrel protrusions 111 may be formed on one side of each of auxiliary current collectors.",
"Here, two or more mandrel protrusions 111 may be formed on a single auxiliary current collector so that the mandrel protrusions 111 may be settled securely in a winder 300 (see FIG. 4A ).",
"[0049] The positive auxiliary current collector 110 a may include aluminum (Al) or an aluminum alloy, and the negative auxiliary current collector 110 b may include copper (Cu) or a copper alloy.",
"[0050] FIG. 2 is an oblique view illustrating an auxiliary current collector and a mandrel insulating layer constructed as the embodiment.",
"As shown in FIG. 2 , the mandrel insulating layer 120 includes an insulating material and may be formed via molding in order to encompass an outside of the auxiliary current collectors 110 .",
"The mandrel insulating layer 120 insulates the positive auxiliary current collector 110 a and the negative auxiliary current collector 110 b from each other, and insulates the auxiliary current collectors 110 from an electrode plate 150 which is wounded around the auxiliary current collectors 110 .",
"The mandrel insulating layer 120 may be formed by electrical insulating material.",
"[0051] Referring to FIGS. 3A and 3B , the electrode plate 150 is described.",
"FIG. 3A is an exploded partial plan view illustrating the electrode plate, and FIG. 3B is a partial cross-sectional view illustrating the electrode plate.",
"The electrode plate 150 includes a first electrode plate 160 , a second electrode plate 170 , and a separator 180 .",
"In one embodiment, the first electrode plate 160 may be a positive electrode plate, and the second electrode plate 170 may be a negative electrode plate.",
"In another embodiment, the first electrode plate 160 may be a negative electrode plate, and the second electrode plate 170 may be a positive electrode plate.",
"For convenience of description, the first electrode plate 160 is thereafter denoted as positive, and a second electrode plate 170 is thereafter denoted as negative.",
"[0052] The positive plate 160 includes a positive active material layer 161 in which a positive active material is applied to both surfaces or one surface of a positive current collector and a positive non-applied part 162 to which the positive active material is not applied.",
"The positive current collector generally uses material having a high conductivity and a high chemical stability.",
"For example, the positive current collector may include aluminum, nickel, titanium, plastic carbon, and the like.",
"The positive active material layer 161 may be formed by applying slurry to the positive current collector, with the slurry being prepared by mixing a positive active material, a conductive material, and a binder with a solvent.",
"[0053] The negative plate 170 includes a negative active material layer 171 in which a negative active material is applied to both surfaces or one surface of a negative current collector and a negative non-applied part 172 to which the negative active material is not applied.",
"The negative plate 170 may include conductive metal, for example, copper, stainless steel, aluminum, nickel, and the like.",
"The negative active material layer 171 may be formed by applying slurry to a negative current collector, with the slurry being prepared by mixing a negative active material and a binder to improve coherence of the negative active material with a solvent.",
"[0054] The separator 180 may be interposed between the positive active material layer 161 and the negative active material layer 171 .",
"The separator 180 functions as a passage of ions and prevents a direct contact between the positive plate 160 and the negative plate 170 .",
"Thus, the separator 180 is formed of an insulating thin film having a high ion permeability and a high mechanical strength.",
"In one embodiment, the separator 180 may be formed of an electrical insulating thin film.",
"For example, the separator 180 may use a porous film including polyethylene, polypropylene or polyvinylidene fluoride, or felt.",
"[0055] An electrode assembly used for a secondary battery may be classified into a winding-type electrode assembly, a deposition-type electrode assembly, and the like.",
"The winding-type electrode assembly is formed by winding a positive plate and a negative plate being insulated from each other by a separator, and the positive and negative plates are sheets extending longitudinally.",
"In the winding-type electrode assembly, the capacity of a battery may be increased by increasing the number of windings.",
"As the number of windings increases, however, the electrode plates or the separator which constitute the electrode assembly may be detached and be easily deformed.",
"Furthermore, the positive plate may come into a direct contact with the negative plate, so that a short circuit may occur.",
"[0056] FIG. 3B shows a cross-sectional view of a layered structure of the electrode plate 150 .",
"As shown in FIG. 3B , the electrode plate 150 may be formed by layering the separator 180 , the positive plate 160 , the separator 180 , and the negative plate 170 in order.",
"Here, the positive plate 160 , the separator 180 , the negative plate 170 , and the separator 180 may be layered in order, since the above layered structure is repeated in winding.",
"[0057] As described above, the positive plate 160 includes the positive active material layer 161 and the positive non-applied part 162 , and the negative plate 170 includes the negative active material layer 171 and the negative non-applied part 172 .",
"When the positive plate 160 is deposited on the separator 180 , the positive non-applied part 162 is exposed to one side (or edge) S 1 of the separator 180 .",
"Likewise, when the negative plate 170 is deposited on the separator 180 , the negative non-applied part 172 is exposed to another side (or edge) S 2 of the separator 180 .",
"When the electrode plate 150 is wound, as shown in FIG. 4B , the positive non-applied part 162 is exposed to one side S 1 of the separator 180 , and the negative non-applied part 172 is exposed to the other side S 2 of the separator 180 .",
"When the electrode plate 150 is wound into a jelly roll, in one embodiment, the positive non-applied part 162 is uncovered by the separator 180 and is exposed at one edge S 1 of the separator 180 ;",
"the negative non-applied part 172 is uncovered by the separator 180 and is exposed at an opposite edge S 2 of the separator 180 .",
"[0058] FIGS. 4A and 4B show a winding process.",
"FIG. 4A is an oblique view illustrating a process of winding the jelly roll 100 , and FIG. 4B is an oblique view the wound jelly roll 100 .",
"[0059] The winder 300 is a device for winding the electrode plate 150 on an outside of the mandrel insulating layer 120 .",
"The winder 300 includes a mandrel protrusion fixing unit 310 to accommodate and settle the mandrel protrusions 111 on a rotation shaft of a sub-motor and performs a winding process.",
"Here, the alignment of the positive plate 160 , the separator 180 , and the negative plate 170 is important, and thus winding is uniformly performed.",
"[0060] The auxiliary current collectors 110 may be wound in a situation where only the mandrel protrusions are exposed to the exterior of the jelly roll in view of risk of a short circuit.",
"[0061] FIG. 4C is an oblique view illustrating a stack constructed as another embodiment.",
"As shown in FIG. 4C , a stack 100 a may include an auxiliary current collector 110 , a mandrel insulating layer 120 , and a stacked type electrode plate 150 a .",
"The difference between FIG. 4B and FIG. 4C is that FIG. 4C shows a stacked type electrode plate 150 a which is different from the jelly roll type electrode plate 150 of FIG. 4B .",
"The stacked type electrode plate 150 a is formed by stacking layers 1000 .",
"In the stacked type electrode plate 150 a , the positive non-applied part 162 a is uncovered by the separator 180 a and is exposed at one edge of the separator 180 a ;",
"the negative non-applied part 172 a is uncovered by the separator 180 a and is exposed at an opposite edge of the separator 180 a. [0062] FIG. 5 shows an oblique view of the current collector 200 .",
"A main current collector 210 collectively refers to a positive side plate 210 a , a positive cap plate 210 c , a negative side plate 210 b , and a negative cap plate 210 d .",
"The main current collector 210 may be formed by bending one plate twice at a right angle.",
"As shown in FIG. 5 , two plates, i.e., the side plates 210 a and 210 b , face towards each other and are disposed opposite to each other.",
"Two side plates 210 a and 210 b are physically connected by the cap plates 210 c and 210 d , and the two side plates 210 a and 210 b are electrically insulated from each other by a current collector insulating part 230 .",
"The current collector insulating part 230 may be provided between the two cap plates 210 c and 210 d in order to electrically insulate the cap plate 210 c from the cap plate 210 d .",
"Here, the side plates 210 a and 210 b , the cap plates 210 c and 210 d , and the current collector insulating part 230 may be simultaneously and integrally formed as a single body via double injection molding, or may be manufactured separately and combined via soldering or welding.",
"[0063] A mandrel protrusion accommodating hole 212 is formed in the side plates 210 a and 210 b .",
"The mandrel protrusion accommodating hole 212 may be a through hole.",
"The mandrel protrusions 111 formed on the auxiliary current collectors 110 a and 110 b may be inserted into the mandrel protrusion accommodating hole 212 .",
"Further, an adhesive inlet 211 may be formed in the side plates 210 a and 210 b .",
"The adhesive inlet 211 may be a through hole.",
"In one embodiment, adhesive inlet 211 may be disposed separately from the mandrel protrusion accommodating hole 212 .",
"When the wound jelly roll 100 is put into the current collector 200 , an adhesive may be injected through the adhesive inlet 211 and the adhesive may be disposed to fill a gap between the wound jelly roll 100 and the current collector 200 .",
"Here, the adhesive inlet 211 may be formed between at least two of the mandrel protrusion accommodating holes 212 .",
"When an electrically conductive adhesive is injected through the adhesive inlet 211 provided between the mandrel protrusion accommodating holes 212 , the conductive adhesive may reach up to the auxiliary current collectors 110 .",
"Here, the side plates 210 a and 210 b and the cap plates 210 c and 210 d may be formed of the same material as the auxiliary current collectors 110 .",
"[0064] Referring to FIG. 6 , a process of connecting the jelly roll 100 to the current collector 200 is described.",
"FIG. 6 is a perspective view illustrating an assembly where the jelly roll 100 and the current collector 200 are connected to each other.",
"The two mandrel protrusions 111 of the jelly roll 100 may be inserted into the mandrel protrusion accommodating holes 212 formed in the side plates 210 a and 210 b of the current collector 200 , so that the jelly roll 100 and the current collector 200 are connected.",
"Here, a jelly roll guide 215 may be provided to guide the inserted jelly roll 100 and to prevent detachment of the positive and negative non-applied parts 162 and 172 formed on opposite sides of the jelly roll 100 after the jelly roll 100 is connected.",
"The jelly roll guide 215 extends from opposite sides (or edges) S 11 and S 22 of the side plates 210 a and 210 b toward a direction along the extending direction of the cap plates 210 c and 210 d. [0065] When the connection between the jelly roll 100 and the current collector 200 is completed, as shown in FIG. 6 , the inside positive or negative non-applied part 162 and 172 may be seen through the adhesive inlet 211 , and the mandrel protrusions 111 inserted from the inside may be seen through the mandrel protrusion accommodating holes 212 .",
"The electrode terminals 241 and 242 are designed to be electrically connected to external electrical devices.",
"[0066] Referring to FIG. 7 , a process of applying an adhesive is described.",
"FIG. 7 is a schematic view illustrating the process of applying the adhesive.",
"First, an auxiliary side plate 400 is provided parallel with one of the side plates 210 a and 210 b side by side.",
"Then, a predetermined amount of an adhesive 420 is applied onto the auxiliary side plate 400 , and the adhesive 420 is spread on up to the side plates 210 a and 210 b using a blade 410 .",
"In this manner, the adhesive 420 is put onto the jelly roll 100 through the mandrel protrusion accommodating holes 212 and the adhesive inlet 211 .",
"[0067] Here, the adhesive 420 may be an electrically conductive adhesive.",
"The adhesive 420 may attach or adhere the positive side plate 210 a to the positive non-applied part 162 , and attach or adhere the negative side plate 210 b to the negative non-applied part 172 .",
"Separately or simultaneously, the adhesive 420 may attach or adhere the positive auxiliary current collector 110 a to the positive non-applied part 162 and attach or adhere the negative auxiliary current collector 110 b to the negative non-applied part 172 .",
"[0068] In one embodiment where the adhesive 420 is not electrically conductive, a conductive connection member may be additionally provided to respectively electrically connect the non-applied parts 162 and 172 of the electrode plate 150 with the auxiliary current collectors 110 a and 110 b or to respectively electrically connect the non-applied parts 162 and 172 of the electrode plate 150 with the side plates 210 a and 210 b. [0069] After applying the conductive adhesive 420 , the conductive adhesive 420 is heated via ultraviolet irradiation or the like so as not to damage a separator of a secondary battery and then the conductive adhesive 420 is hardened at a low temperature.",
"[0070] Here, in order to improve connection of the jelly roll 100 and the current collector 200 , the mandrel protrusion accommodating holes 212 and the mandrel protrusions 111 inserted into the mandrel protrusion accommodating holes 212 are welded before injecting the adhesive 420 .",
"[0071] Although the spirit of the present invention was described in detail in accordance with the embodiment, it should be understood that the embodiments are provide to explain the present invention and do not limit the present invention, and various jelly rolls and electrode assemblies having the same may be realized without departing from the scope of the present invention.",
"[0072] While the present invention has been described in connection with certain embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof."
] |
This application is a continuation of International Application No. PCT/SE96/01035, which was filed on Aug. 21, 1996, which designated the United States, and which is expressly incorporated here by reference.
BACKGROUND
The present invention relates to an arrangement in an electro-optic circuit that comprises optic sender and receiver components for transforming an electric output signal to an outgoing optic signal and for transforming a received optic signal to an electric input signal, respectively, connection means for an opto conductor on which the outgoing and received optic signals are transmitted, a sender for the electric output signal, and a receiver for the electric input signal.
Electro-optic circuits of this kind are used e.g. located on a printed circuit card in a telecommunication switch. Each circuit card carries a plurality of such electro-optic circuits and in the switch one or more cabinets can contain a plurality of shielded card magazines, each of which contains a plurality of such circuit cards. For increasing the insensitivity towards EMC, i.e. electromagnetical disturbance radiation, senders and receivers are conventionally located far in on the card as seen from its edge located at an outer cabinet wall, below denominated card front. On the card front there are seated a number of connection devices for connecting an outer opto conductor to two opto conductors leading to the sender and receiver, respectively, of a corresponding sender/receiver pair. For minimizing the risk for interference between sender and receiver of each sender/receiver pair the sender and the receiver are furthermore located remote from each other on the card.
This distribution of the components of the electro-optic circuit counteracts a striving for a more compact architecture of switches of the just described type, while saving or further improving the insensitiveness for EMC, as well as ESD, i.e. electrostatical discharges.
SUMMARY
One object of the invention is to provide an electro-optic circuit of the kind defined by way of introduction that is characterized by a very compact design and great insensitiveness to EMC and ESD and thereby can be mounted at the card front as a unit.
This object has been achieved in that, in the arrangement of the kind defined by way of introduction, the electro-optic circuit forms a module with an electromagnetically shielded housing that contains said optical sender and receiver components and said connection means, and a two-sided printed circuit arrangement that carries the sender and the receiver located shielded from each other on one side each by means of an electrically conducting shielding that is in connection with the housing for forming three Faraday's cages, one for the sender, one for the receiver and one formed of the housing in its entirety.
Embodiments of the invention have then received the features stated in respective subclaims.
DESCRIPTION OF DRAWINGS
The invention will now be described more closely with reference to the attached drawings, on which
FIG. 1 is a perspective view of a housing for an electro-optic circuit mounted on a mother printed circuit card,
FIG. 2 shows an exploded view of the housing shown in FIG. 1 with the parts thereof as well as components enclosed thereby being shown in perspective,
FIG. 3 shows a perspective view of a contact spring module according to the invention used in the housing and intended to be used between different elements, forming parts of the housing according to FIG. 1, a printed circuit card introduced in the housing and the mother card,
FIGS. 4 and 5 show sections in the direction of arrows IV--IV in FIG. 3 through the contact spring module for illustrating cooperation thereof with the elements shown in FIG. 3,
FIG. 6 shows a perspective view of a housing for a contact means,
FIG. 7 shows an exploded view of the housing shown in FIG. 6 with the parts thereof as well as components enclosed therein in perspective,
FIG. 8 shows a perspective view of a component enclosed in the housing according to FIGS. 6 and 7 and turned 90° anti-clockwise in the same plane as the corresponding perspective view in FIG. 7,
FIG. 9 shows a perspective view of the same component as in FIG. 8, although turned 180° about a length axis with respect to the corresponding perspective view in FIG. 7,
FIG. 10 shows a longitudinal section of another component enclosed in the housing according to FIG. 7.
DETAILED DESCRIPTION
FIG. 1 shows the housing for an electro-optic circuit according to the invention, generally designated 2, and mounted on a mother card 4. The housing 2, the design of which appears more closely from FIG. 2, contains connection means in the form of a housing 6 with a receiving tube 7 for receiving one end of an opto conductor. The opto conductor is kept fixedly by a connection device generally designated 8 and received in an opening in a guiding-in part generally designated 9. The connection device 8 will be described more closely further on.
The housing 6 contains an electro-optic component not shown and comprising optic sender and receiver component parts for transforming an electric output signal to an outgoing optic signal, and for transforming a received opto signal to an electric input signal, respectively. The optic sender and receiver component parts can be combined into a unit, e.g. Duplex-2 from ABB HAFO, that admits use of one single opto fibre for transfer in both directions to and from the electro-optic component.
The housing 2 furthermore encloses a printed circuit card arrangement 10 on which the housing 6 is attached. The printed circuit card arrangement 10 is in the form of a sender/receiver printed circuit card 10 and is henceforth, for the sake of simplicity, denominated "printed circuit card" or, alternatively, "sender/receiver printed circuit card", despite the fact that it, as described below, can consist of a sandwich of two printed circuit cards. The printed circuit card 10 on one side carries a sender circuit for the electric output signal and on the other side a receiver circuit for the electric input signal. The circuits are indicated for the upper side of the card at 12 and for the lower side of the card with an arrow 13, but are not shown more closely for the rest. The card 10 furthermore carries connections, not shown, between inputs and outputs of the sender and receiver circuits, respectively, on the one hand, and connection pins 14 on the other hand, that extend through the housing to the outside thereof for connection to outer circuits on the mother card 4.
The housing 2 has a lower part 16 and an upper part 18, both metallic, comprising each one half 9a and 9b, respectively, of the guiding in part 9. Between the lower part 16 and the upper part 18, the sender/receiver printed circuit card 10 is located, the housing containing contact means, described more closely below, between the parts of the housing and between the housing and grounding parts of the sender/receiver printed circuit card 10 and the outer card 4, respectively. As will appear more clearly below said grounding parts of the mother card form part of a metallic layer applied in the card in parallel with and between the two sides of the printed circuit card. The printed circuit card 10 can then consist of one single printed circuit card in which the metallic layer is formed by an integrated conducting layer between the sides of the card. The printed circuit card 10 can, however, also be sandwich-like composed of two printed circuit cards connected together side to side via the metallic layer. The metallic layer can also include a magnetic material, e.g. in the form of a nickel plate for shielding against inductive cross-induction. By the design of the housing 2 just described it forms three Faraday's cages. Two of the cages each enclose one of the sender and receiver circuits 12 and 13, respectively, one consisting of the lower part 16 of the housing and the metallic layer of the printed circuit card 10, and the other one consisting of the upper part 18 of the housing and the metallic layer of the printed circuit card. The third cage is the housing 2 in its entirety.
The above mentioned contact means consist of a number of longitudinal spring means 20 along the sides of the housing parts 16 and 18. Each spring means 20 is made in one piece and comprises a number of contact points for the sender/receiver printed circuit card 10, a number of contact points for the housing lower part 16, a number of contact points for the housing upper part 18, and a number of contact points for the mother card 4.
Each spring means has a first essentially rib-shaped web part 22 extending along the longitudinal direction of the spring means. A second web part 24 extends along and at a distance from the first web part 22 and is connected thereto by means of arcuate connection pieces 26 extending from a first side edge 28 of the first web part to a nearby first side edge 30 of the second web part. First contact tongues 32 are bent away from the first side edge 30 of the second web part in a direction towards the first web part 22 and end between the planes of the two web parts. Second contact tongues 34 are arcuately bent away from the first side edge 28 of the first web part 22 in a direction towards the second web part 24 and end outside the plane of the second web part. Each one of the first and one of the second contact tongues 32 and 34, respectively, are arranged pairwise in the spaces between the arcuate connection pieces 26. Third contact tongues 36 are bent away from the second side edge of the first web part 22 in a direction outwardly from the two web parts. Each one of the third contact tongues 36 has an inner leg 38 bent away from the first web part 22 and an outer leg 40 connected thereto and bent away from the inner leg for forming an acute angle between the two legs.
The web part 22 extends between the inside of a side wall 42 standing up from the bottom wall of the lower part 16 and an opposite side edge 44 of the sender/receiver printed circuit card 10. The web part 24 extends between the outside of the side wall 42 of the lower part and the inside of a side wall 46 extending downwardly from the upper wall of the upper part 18. The contact tongues 32 are located in contact with the outside of the side wall 42 of the lower part 16. The contact tongues 34 are located in contact with the inside of the side wall 46 of the housing upper part 18.
The contact tongues 36 extend between and abut grounding parts, not shown, on the lower side of the sender/receiver printed circuit card 10 and the upper side of the mother card 4. The inner leg 38 of each contact tongue 36 has an upper side formed with a contact boss 48, making contact with the grounding part of the sender/receiver printed circuit card 10. The outer leg 40 makes contact with the grounding part of the mother card 4. In FIGS. 4 and 5 the earlier mentioned inner metallic layer of the card 10 is indicated at 50, as well as an outer continuation 52 thereof, that extends outwardly on the edge 28 of the card 10 to its lower side for forming said grounding part of the card 10 there.
In FIGS. 6-10 an embodiment of the connection device 8 is illustrated more closely with respect to its design and function, which is intended for connecting one end of a sheathed opto fibre 60 to the electro-opto component enclosed in the housing 6.
The connection device 8 includes, while referring particularly to FIG. 7, a retaining sleeve generally designated 62 for a portion of the fibre connecting to said end of the sheathed opto fibre 60, a supporting structure, generally designated 64, for the retaining sleeve 62 intended to be fixed with respect to the electro-opto component in a way to be disclosed more closely below, and a spring 66 acting between the retaining sleeve 62 and the supporting structure 64. More particularly, the spring 66 shall, at connection to the electro-opto component in the housing 6, compensate for tolerances in the length direction of the retaining sleeve 62 with respect to the electro-opto component.
In a way to be described more closely below, the spring 66 and the supporting structure 64 are mutually shaped to first admit introduction of the retaining sleeve 62 with the sheathed fibre 60 kept thereby in the direction of the arrow 68, before the spring 66 which may thereupon be introduced in the direction of the arrow 70 and according to the dashed lines 72 and 74 sidewardly in the supporting structure.
The spring 66 is made in one piece of two spring legs 76 and 78 bent into a V-shape and arranged in parallel with and joined together at the end of the leg of the respective V by means of ties 80 and 82, respectively. On location in the supporting structure 64 the spring 66 straddles the retaining sleeve 62 with the V-shaped spring legs 76 and 78 on each side thereof and commonly acting between an abutment 84 on the sleeve 62 extending around the circumference of the sleeve 62, and an abutment 86 in the support structure.
The support structure 64 is essentially cage shaped and comprises, while referring to FIGS. 7-9, a passage for the retaining sleeve 62 extending in the direction of the arrow 68. This passage includes in turn, in the direction of the arrow 68, an opening 88 located in an end wall 90, an opening 92 located in an intermediate wall 94, and an end opening 96, that is located at the other end of the supporting structure 64 with respect to the end wall 90. The end wall 90 and the intermediate wall 94 delimit each an upper edge, as seen in FIGS. 7 and 9, together with sidewalls 98 and 100 extending therebetween, a rectangular side opening towards said passage for introducing the spring 66 in the direction of the arrow 70. As appears from FIG. 9 the abutment 86 is located in this side opening on the side of the end wall 90 facing the side opening.
When located in the supporting structure 64, the spring 66 is kept in place by the edge of the V of the respective V-shaped spring parts 76 and 78 snapping under the free end 102 and 104, respectively, of each a tongue 106 and 108, respectively, formed in each one of the side walls 98 and 100, respectively. The legs of the spring parts 76 and 78 facing the wall 94 then abut the abutment 84 of the sleeve 62 on each side of the sleeve, and the tie 82 of the spring 66 abuts the abutment 86. The abutment 84, which accordingly is located between the walls 90 and 94, forms one side of a radial extension from the sleeve, the other side 110 of which by engagement with the intermediate wall 94 delimiting movement of the sleeve 62 in the direction of the arrow 68. Movement of the sleeve 62 in the other direction is limited by the engagement of the spring 66 therewith. In FIG. 10 the locations for the abutment 86 and the intermediate wall 94 with respect to the sleeve 94 are indicated when the sleeve is in its mounted position in the supporting structure 64.
Further referring to FIG. 10, the sleeve is assembled, in the shown embodiment, of two mutually concentric parts, viz. a fibre keeping part 112 and a fibre guiding in part 114. The parts 112 and 114 are both essentially bottle shaped with a neck portion 116 and 118, respectively, and a mantle portion 120 and 122, respectively, with open bottom, the mantle portion 122 carrying the radial extension 84/110. The mantle portion 120 furthermore is surrounded by a collar 124 extending outwardly from its bottom edge and being essentially of the same length as the mantle portion 120 and extending parallel with this so that they delimit a gap 126 between them, the width of which is somewhat greater than the thickness of the mantle portion 122 of the part 114. The parts 112 and 114 are interconnected with the open end portion of the mantle portion 122 extending into the gap 126.
The neck portion 116 of the part 112 serves for clampingly keeping in place the sheathed fibre 60, not shown in FIG. 10, that extends up to the mouth 128 of the neck portion 118. The mouth 128 has a width corresponding to the thickness of the optofibre without sheath.
At mounting the sleeve 62 with the sheathed optofibre 60 sitting fixedly therein, first pulling of a suitable length of the sheathed optofibre through the neck portion 116 and clamping of it in the neck portion 116 by means of a suitable clamping tool is performed. Thereupon the part of the optofibre extending out of the neck portion 116 is cut to a length that is greater than the distance between the outer ends of the neck portions 116 and 118 when the sleeve 62 is ready-assembled. Thereupon the end of the optofibre is uncovered by removing a suitable length of its mantle, glue is applied on a portion of the end of the mantle portion 122 turned away from its neck portion 118, and this end is introduced into the gap 126 to the bottom thereof. This is done while simultaneously securing that the uncovered fibre end is guided into the mouth 128 so that it will at last protrude therefrom. The end thus protruding is then cut along the end surface of the neck portion 118.
A conceivable and advantageous alternative to the embodiment of the sleeve 62 shown in FIG. 10 and described above, is that the part 114 is replaced by a layer directly sprayed onto the part 112 and the sheathed optofibre clamped therein and having the same contours as the part 122 when required. The part 112 is then suitably modified so that the collar 124 disappears.
The parts 62-66 are dimensioned and mutually shaped in a way that in their ready-assembled state the support structure 64 surrounds the sleeve 62 essentially over a portion thereof that extends from the rear end of the sleeve 62 up to the transition between the mantle portion 122 and the neck portion 118.
The parts 62-66 are enclosed in an outer housing with a pipe socket 130 united therewith into one piece, via which the sheathed optofibre 60 is guided into the sleeve 62. The housing is shown in FIG. 7 as divided into an upper housing half 132 and a lower housing half 134, which in FIG. 6 are shown in a state mounted by means of screw connections 136 and 138. In FIGS. 1 and 2 the same view of the connecting device 8 is shown as in FIG. 6. At 140 and 142 ears extending from each of the housing halves 132 and 134, respectively, are shown containing screw holes. Referring also to FIGS. 1 and 2 the upper part 18 and the lower part 16 of the housing 2 have correspondingly extending ears 144 and 146, respectively, provided with screw holes. The ears 140 and 144 provided with holes with a screw passing therethrough, on the one hand, and the ears 142 and 146 provided with holes with a screw passing therethrough, on the other hand, each form a screw joint for joining, according to the dashed lines 148 and 150, respectively, the contact device 8 with the housing 2, with the housing 130/132 guided into the guiding-in part 9. In this position the mouth 128 of the sleeve 62 in the housing 6 is in a correct position with respect to the electro-optic component enclosed therein. The receiving tube 7 then extends into the support structure 64 approximately up to its intermediate wall 94, tolerances of the retaining sleeve 62 in its length direction with respect to the electro-optic component being taken up by the spring 66. | An electro-optical circuit includes optical sending and receiving components for transforming an electrical output signal to an optical output signal, and for transforming a received optical signal to an electrical input signal, respectively. The electro-optical circuit forms a module with an electro magnetically shielded case which contains the optical sending and receiving components and connection devices for an optical conductor on which the outgoing and received optical signals are transmitted. A two-sided printed circuit arrangement carries a sender for the electrical output signal and a receiver for the electrical input signal located shielded from each other on one side each by means of an electrically conducting shielding. The shielding is in connection with the case for forming three Faraday's cages, one for the sender, one for the receiver and one formed of the case in its entirety. | Concisely explain the essential features and purpose of the invention. | [
"This application is a continuation of International Application No. PCT/SE96/01035, which was filed on Aug. 21, 1996, which designated the United States, and which is expressly incorporated here by reference.",
"BACKGROUND The present invention relates to an arrangement in an electro-optic circuit that comprises optic sender and receiver components for transforming an electric output signal to an outgoing optic signal and for transforming a received optic signal to an electric input signal, respectively, connection means for an opto conductor on which the outgoing and received optic signals are transmitted, a sender for the electric output signal, and a receiver for the electric input signal.",
"Electro-optic circuits of this kind are used e.g. located on a printed circuit card in a telecommunication switch.",
"Each circuit card carries a plurality of such electro-optic circuits and in the switch one or more cabinets can contain a plurality of shielded card magazines, each of which contains a plurality of such circuit cards.",
"For increasing the insensitivity towards EMC, i.e. electromagnetical disturbance radiation, senders and receivers are conventionally located far in on the card as seen from its edge located at an outer cabinet wall, below denominated card front.",
"On the card front there are seated a number of connection devices for connecting an outer opto conductor to two opto conductors leading to the sender and receiver, respectively, of a corresponding sender/receiver pair.",
"For minimizing the risk for interference between sender and receiver of each sender/receiver pair the sender and the receiver are furthermore located remote from each other on the card.",
"This distribution of the components of the electro-optic circuit counteracts a striving for a more compact architecture of switches of the just described type, while saving or further improving the insensitiveness for EMC, as well as ESD, i.e. electrostatical discharges.",
"SUMMARY One object of the invention is to provide an electro-optic circuit of the kind defined by way of introduction that is characterized by a very compact design and great insensitiveness to EMC and ESD and thereby can be mounted at the card front as a unit.",
"This object has been achieved in that, in the arrangement of the kind defined by way of introduction, the electro-optic circuit forms a module with an electromagnetically shielded housing that contains said optical sender and receiver components and said connection means, and a two-sided printed circuit arrangement that carries the sender and the receiver located shielded from each other on one side each by means of an electrically conducting shielding that is in connection with the housing for forming three Faraday's cages, one for the sender, one for the receiver and one formed of the housing in its entirety.",
"Embodiments of the invention have then received the features stated in respective subclaims.",
"DESCRIPTION OF DRAWINGS The invention will now be described more closely with reference to the attached drawings, on which FIG. 1 is a perspective view of a housing for an electro-optic circuit mounted on a mother printed circuit card, FIG. 2 shows an exploded view of the housing shown in FIG. 1 with the parts thereof as well as components enclosed thereby being shown in perspective, FIG. 3 shows a perspective view of a contact spring module according to the invention used in the housing and intended to be used between different elements, forming parts of the housing according to FIG. 1, a printed circuit card introduced in the housing and the mother card, FIGS. 4 and 5 show sections in the direction of arrows IV--IV in FIG. 3 through the contact spring module for illustrating cooperation thereof with the elements shown in FIG. 3, FIG. 6 shows a perspective view of a housing for a contact means, FIG. 7 shows an exploded view of the housing shown in FIG. 6 with the parts thereof as well as components enclosed therein in perspective, FIG. 8 shows a perspective view of a component enclosed in the housing according to FIGS. 6 and 7 and turned 90° anti-clockwise in the same plane as the corresponding perspective view in FIG. 7, FIG. 9 shows a perspective view of the same component as in FIG. 8, although turned 180° about a length axis with respect to the corresponding perspective view in FIG. 7, FIG. 10 shows a longitudinal section of another component enclosed in the housing according to FIG. 7. DETAILED DESCRIPTION FIG. 1 shows the housing for an electro-optic circuit according to the invention, generally designated 2, and mounted on a mother card 4.",
"The housing 2, the design of which appears more closely from FIG. 2, contains connection means in the form of a housing 6 with a receiving tube 7 for receiving one end of an opto conductor.",
"The opto conductor is kept fixedly by a connection device generally designated 8 and received in an opening in a guiding-in part generally designated 9.",
"The connection device 8 will be described more closely further on.",
"The housing 6 contains an electro-optic component not shown and comprising optic sender and receiver component parts for transforming an electric output signal to an outgoing optic signal, and for transforming a received opto signal to an electric input signal, respectively.",
"The optic sender and receiver component parts can be combined into a unit, e.g. Duplex-2 from ABB HAFO, that admits use of one single opto fibre for transfer in both directions to and from the electro-optic component.",
"The housing 2 furthermore encloses a printed circuit card arrangement 10 on which the housing 6 is attached.",
"The printed circuit card arrangement 10 is in the form of a sender/receiver printed circuit card 10 and is henceforth, for the sake of simplicity, denominated "printed circuit card"",
"or, alternatively, "sender/receiver printed circuit card", despite the fact that it, as described below, can consist of a sandwich of two printed circuit cards.",
"The printed circuit card 10 on one side carries a sender circuit for the electric output signal and on the other side a receiver circuit for the electric input signal.",
"The circuits are indicated for the upper side of the card at 12 and for the lower side of the card with an arrow 13, but are not shown more closely for the rest.",
"The card 10 furthermore carries connections, not shown, between inputs and outputs of the sender and receiver circuits, respectively, on the one hand, and connection pins 14 on the other hand, that extend through the housing to the outside thereof for connection to outer circuits on the mother card 4.",
"The housing 2 has a lower part 16 and an upper part 18, both metallic, comprising each one half 9a and 9b, respectively, of the guiding in part 9.",
"Between the lower part 16 and the upper part 18, the sender/receiver printed circuit card 10 is located, the housing containing contact means, described more closely below, between the parts of the housing and between the housing and grounding parts of the sender/receiver printed circuit card 10 and the outer card 4, respectively.",
"As will appear more clearly below said grounding parts of the mother card form part of a metallic layer applied in the card in parallel with and between the two sides of the printed circuit card.",
"The printed circuit card 10 can then consist of one single printed circuit card in which the metallic layer is formed by an integrated conducting layer between the sides of the card.",
"The printed circuit card 10 can, however, also be sandwich-like composed of two printed circuit cards connected together side to side via the metallic layer.",
"The metallic layer can also include a magnetic material, e.g. in the form of a nickel plate for shielding against inductive cross-induction.",
"By the design of the housing 2 just described it forms three Faraday's cages.",
"Two of the cages each enclose one of the sender and receiver circuits 12 and 13, respectively, one consisting of the lower part 16 of the housing and the metallic layer of the printed circuit card 10, and the other one consisting of the upper part 18 of the housing and the metallic layer of the printed circuit card.",
"The third cage is the housing 2 in its entirety.",
"The above mentioned contact means consist of a number of longitudinal spring means 20 along the sides of the housing parts 16 and 18.",
"Each spring means 20 is made in one piece and comprises a number of contact points for the sender/receiver printed circuit card 10, a number of contact points for the housing lower part 16, a number of contact points for the housing upper part 18, and a number of contact points for the mother card 4.",
"Each spring means has a first essentially rib-shaped web part 22 extending along the longitudinal direction of the spring means.",
"A second web part 24 extends along and at a distance from the first web part 22 and is connected thereto by means of arcuate connection pieces 26 extending from a first side edge 28 of the first web part to a nearby first side edge 30 of the second web part.",
"First contact tongues 32 are bent away from the first side edge 30 of the second web part in a direction towards the first web part 22 and end between the planes of the two web parts.",
"Second contact tongues 34 are arcuately bent away from the first side edge 28 of the first web part 22 in a direction towards the second web part 24 and end outside the plane of the second web part.",
"Each one of the first and one of the second contact tongues 32 and 34, respectively, are arranged pairwise in the spaces between the arcuate connection pieces 26.",
"Third contact tongues 36 are bent away from the second side edge of the first web part 22 in a direction outwardly from the two web parts.",
"Each one of the third contact tongues 36 has an inner leg 38 bent away from the first web part 22 and an outer leg 40 connected thereto and bent away from the inner leg for forming an acute angle between the two legs.",
"The web part 22 extends between the inside of a side wall 42 standing up from the bottom wall of the lower part 16 and an opposite side edge 44 of the sender/receiver printed circuit card 10.",
"The web part 24 extends between the outside of the side wall 42 of the lower part and the inside of a side wall 46 extending downwardly from the upper wall of the upper part 18.",
"The contact tongues 32 are located in contact with the outside of the side wall 42 of the lower part 16.",
"The contact tongues 34 are located in contact with the inside of the side wall 46 of the housing upper part 18.",
"The contact tongues 36 extend between and abut grounding parts, not shown, on the lower side of the sender/receiver printed circuit card 10 and the upper side of the mother card 4.",
"The inner leg 38 of each contact tongue 36 has an upper side formed with a contact boss 48, making contact with the grounding part of the sender/receiver printed circuit card 10.",
"The outer leg 40 makes contact with the grounding part of the mother card 4.",
"In FIGS. 4 and 5 the earlier mentioned inner metallic layer of the card 10 is indicated at 50, as well as an outer continuation 52 thereof, that extends outwardly on the edge 28 of the card 10 to its lower side for forming said grounding part of the card 10 there.",
"In FIGS. 6-10 an embodiment of the connection device 8 is illustrated more closely with respect to its design and function, which is intended for connecting one end of a sheathed opto fibre 60 to the electro-opto component enclosed in the housing 6.",
"The connection device 8 includes, while referring particularly to FIG. 7, a retaining sleeve generally designated 62 for a portion of the fibre connecting to said end of the sheathed opto fibre 60, a supporting structure, generally designated 64, for the retaining sleeve 62 intended to be fixed with respect to the electro-opto component in a way to be disclosed more closely below, and a spring 66 acting between the retaining sleeve 62 and the supporting structure 64.",
"More particularly, the spring 66 shall, at connection to the electro-opto component in the housing 6, compensate for tolerances in the length direction of the retaining sleeve 62 with respect to the electro-opto component.",
"In a way to be described more closely below, the spring 66 and the supporting structure 64 are mutually shaped to first admit introduction of the retaining sleeve 62 with the sheathed fibre 60 kept thereby in the direction of the arrow 68, before the spring 66 which may thereupon be introduced in the direction of the arrow 70 and according to the dashed lines 72 and 74 sidewardly in the supporting structure.",
"The spring 66 is made in one piece of two spring legs 76 and 78 bent into a V-shape and arranged in parallel with and joined together at the end of the leg of the respective V by means of ties 80 and 82, respectively.",
"On location in the supporting structure 64 the spring 66 straddles the retaining sleeve 62 with the V-shaped spring legs 76 and 78 on each side thereof and commonly acting between an abutment 84 on the sleeve 62 extending around the circumference of the sleeve 62, and an abutment 86 in the support structure.",
"The support structure 64 is essentially cage shaped and comprises, while referring to FIGS. 7-9, a passage for the retaining sleeve 62 extending in the direction of the arrow 68.",
"This passage includes in turn, in the direction of the arrow 68, an opening 88 located in an end wall 90, an opening 92 located in an intermediate wall 94, and an end opening 96, that is located at the other end of the supporting structure 64 with respect to the end wall 90.",
"The end wall 90 and the intermediate wall 94 delimit each an upper edge, as seen in FIGS. 7 and 9, together with sidewalls 98 and 100 extending therebetween, a rectangular side opening towards said passage for introducing the spring 66 in the direction of the arrow 70.",
"As appears from FIG. 9 the abutment 86 is located in this side opening on the side of the end wall 90 facing the side opening.",
"When located in the supporting structure 64, the spring 66 is kept in place by the edge of the V of the respective V-shaped spring parts 76 and 78 snapping under the free end 102 and 104, respectively, of each a tongue 106 and 108, respectively, formed in each one of the side walls 98 and 100, respectively.",
"The legs of the spring parts 76 and 78 facing the wall 94 then abut the abutment 84 of the sleeve 62 on each side of the sleeve, and the tie 82 of the spring 66 abuts the abutment 86.",
"The abutment 84, which accordingly is located between the walls 90 and 94, forms one side of a radial extension from the sleeve, the other side 110 of which by engagement with the intermediate wall 94 delimiting movement of the sleeve 62 in the direction of the arrow 68.",
"Movement of the sleeve 62 in the other direction is limited by the engagement of the spring 66 therewith.",
"In FIG. 10 the locations for the abutment 86 and the intermediate wall 94 with respect to the sleeve 94 are indicated when the sleeve is in its mounted position in the supporting structure 64.",
"Further referring to FIG. 10, the sleeve is assembled, in the shown embodiment, of two mutually concentric parts, viz.",
"a fibre keeping part 112 and a fibre guiding in part 114.",
"The parts 112 and 114 are both essentially bottle shaped with a neck portion 116 and 118, respectively, and a mantle portion 120 and 122, respectively, with open bottom, the mantle portion 122 carrying the radial extension 84/110.",
"The mantle portion 120 furthermore is surrounded by a collar 124 extending outwardly from its bottom edge and being essentially of the same length as the mantle portion 120 and extending parallel with this so that they delimit a gap 126 between them, the width of which is somewhat greater than the thickness of the mantle portion 122 of the part 114.",
"The parts 112 and 114 are interconnected with the open end portion of the mantle portion 122 extending into the gap 126.",
"The neck portion 116 of the part 112 serves for clampingly keeping in place the sheathed fibre 60, not shown in FIG. 10, that extends up to the mouth 128 of the neck portion 118.",
"The mouth 128 has a width corresponding to the thickness of the optofibre without sheath.",
"At mounting the sleeve 62 with the sheathed optofibre 60 sitting fixedly therein, first pulling of a suitable length of the sheathed optofibre through the neck portion 116 and clamping of it in the neck portion 116 by means of a suitable clamping tool is performed.",
"Thereupon the part of the optofibre extending out of the neck portion 116 is cut to a length that is greater than the distance between the outer ends of the neck portions 116 and 118 when the sleeve 62 is ready-assembled.",
"Thereupon the end of the optofibre is uncovered by removing a suitable length of its mantle, glue is applied on a portion of the end of the mantle portion 122 turned away from its neck portion 118, and this end is introduced into the gap 126 to the bottom thereof.",
"This is done while simultaneously securing that the uncovered fibre end is guided into the mouth 128 so that it will at last protrude therefrom.",
"The end thus protruding is then cut along the end surface of the neck portion 118.",
"A conceivable and advantageous alternative to the embodiment of the sleeve 62 shown in FIG. 10 and described above, is that the part 114 is replaced by a layer directly sprayed onto the part 112 and the sheathed optofibre clamped therein and having the same contours as the part 122 when required.",
"The part 112 is then suitably modified so that the collar 124 disappears.",
"The parts 62-66 are dimensioned and mutually shaped in a way that in their ready-assembled state the support structure 64 surrounds the sleeve 62 essentially over a portion thereof that extends from the rear end of the sleeve 62 up to the transition between the mantle portion 122 and the neck portion 118.",
"The parts 62-66 are enclosed in an outer housing with a pipe socket 130 united therewith into one piece, via which the sheathed optofibre 60 is guided into the sleeve 62.",
"The housing is shown in FIG. 7 as divided into an upper housing half 132 and a lower housing half 134, which in FIG. 6 are shown in a state mounted by means of screw connections 136 and 138.",
"In FIGS. 1 and 2 the same view of the connecting device 8 is shown as in FIG. 6. At 140 and 142 ears extending from each of the housing halves 132 and 134, respectively, are shown containing screw holes.",
"Referring also to FIGS. 1 and 2 the upper part 18 and the lower part 16 of the housing 2 have correspondingly extending ears 144 and 146, respectively, provided with screw holes.",
"The ears 140 and 144 provided with holes with a screw passing therethrough, on the one hand, and the ears 142 and 146 provided with holes with a screw passing therethrough, on the other hand, each form a screw joint for joining, according to the dashed lines 148 and 150, respectively, the contact device 8 with the housing 2, with the housing 130/132 guided into the guiding-in part 9.",
"In this position the mouth 128 of the sleeve 62 in the housing 6 is in a correct position with respect to the electro-optic component enclosed therein.",
"The receiving tube 7 then extends into the support structure 64 approximately up to its intermediate wall 94, tolerances of the retaining sleeve 62 in its length direction with respect to the electro-optic component being taken up by the spring 66."
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 35 U.S.C. § 371 national stage filing of international application serial number PCT/US2004/042079, filed on Dec. 15, 2004, which itself claims the benefit of U.S. Provisional application serial number 60/530,957, filed on Dec. 19, 2003.
FIELD OF THE INVENTION
The present invention relates to the field of automotive heat exchangers, and, in particular, to heat exchanger tanks with headers. The present invention further relates to a headering means and a method for providing improved headering means for automotive heat exchangers with plastic tanks and headers, wherein the header inner flange is removed or eliminated.
BACKGROUND OF THE INVENTION
Motor vehicles employ heat exchangers to heat or cool various elements of an automotive engine and its component parts. UK Patent application GB 2166862 A, published May 14, 1986, Gebhard Schwarz, ‘Vehicle radiator’ discloses a radiator constituted by flat tubes and a single water containing header with separating webs in the flat tubes which extend in prolongation of the separating wall in the water container. U.S. Pat. No. 4,023,618 issued on May 17, 1977, Kun et al, ‘Heat exchanger headering arrangement,’ discloses a heat exchanger assembly comprising a stacked array of thin-walled heat exchange channel elements. The headering arrangement includes a resilient gasket disposed around the perimeter of each face against the wall portion ends thereof and header tank means enclosing each face of the array and forms a fluid tight seal between the header tank and the stacked array. U.S. Pat. No. 6,179,049 issued Jan. 30, 2001, Higgins, ‘Head exchanger with an integrated tank and head sheet,’ discloses a heat exchanger having a core of a plurality of cooling tubes with a tank at each end of the core tubes. The tanks are formed with a plurality of cooling tube receiving apertures along a side portion of the tanks which receive the ends of the cooling tubes directly into the tanks and are attached to the tubes by brazing. U.S. Pat. No. 4,183,402 issued Jan. 15, 1980, Cotter, ‘Heat exchanger heardering arrangement,’ discloses a heat assembly comprising a stacked array of heat exchange channel elements. The improved headering arrangement includes sealing members each having a bearing surface with a generally corrugated contour and header tank means joined to the sealing members so as to leak-tightly enclose the associated face of the stacked array of heat exchange channel elements. Heat exchangers employ heat exchanger tanks which typically include a coolant and require a fluid tight seal. Heat exchanger tanks may be made of a variety of materials, depending on the strength and/or temperature requirements imposed upon them in automotive applications. Plastic tanks have been utilized in heat exchangers and have proven to reduce weight while providing good thermal and strength characteristics in a number of applications. In certain commercial heat exchangers and automotive radiators, it has been common practice to employ a tube sheet headering arrangement.
In such systems, the tubes in the heater core assembly are characteristically forced through corresponding size openings in a sheet member and the latter is then joined to suitable tank or shell means to form a ‘header’ or header chamber communication with the tubes of the core assembly for introduction or withdrawal of fluid being passed through the tube members.
In certain state of the art designs for automotive heat exchangers with plastic tanks, headers that are stamped from an aluminum sheet are used. In such designs, tube slots are formed with ‘ferrules’ or ‘collars’ in the header to accept tubes and to provide a mating surface for brazing the tubes to the header.
As described above, such tank-header arrangements require a fluid tight seal. In order to create such a seal, a depression or trough is formed around the periphery of the header to accommodate the ‘edge flange’ or ‘foot’ of the plastic tank; which also serves to retain a header gasket that provides a seal between the tank and header. Correspondingly, the header further includes an oppositely directed ‘depression’ or ‘pan’ within the periphery of the outer trough. In certain prior art heat exchangers, the edges of the plastic tank are molded to the turned flange or foot. During construction of the heat exchanger, the tank is installed in the trough, with the tank foot compressing the gasket. The outer edges of the aluminum header are then bent or ‘crimped’ to capture the edge of the tank foot, thereby joining the tank to the header (See prior art FIG. 1 ). However, due to the strict requirements imposed upon use of such plastic tanks in automotive applications, and the need to provide fluid tight seals, designs for plastic heat exchanger tanks also use ‘flanges’ or ‘feet’ that fit inside the trough formed around the periphery of the header.
In addition, different heat exchanger applications are subjected to different internal pressure and related conditions. Radiators typically have lower operating pressures and temperatures than charge-air-coolers. Radiator tanks can generally be more compact, since the internal fluid is a higher density liquid. Charge air coolers, inter coolers and after coolers typically operate at higher temperatures and pressures, and with more rapid transients than radiators in the same vehicle application. Higher pressures and larger wall surface areas result in greater wall deflection in such applications. Higher temperatures reduce the stiffness and fatigue resistance of the materials. These factors contribute to greater structural integrity and durability problems with more extreme temperatures and pressure conditions.
Reinforcing ribs are also been used on the header of heat exchanger between tube slots (See FIG. 2 ). Recently a so-called all-aluminum heat exchanger has been invented that provides for brazing of the inner flange of the header to the ends of the tube as an option when utilizing plastic tanks. See US Patent application 2003/0217838A1 published Nov. 27, 2003, Dey et al.
Problems identified in the prior art, therefore, include that of a trough (or well) formed in the periphery of the header tends to increase the overall thickness of the heat exchanger, which can result in packaging problems in the vehicle; and, that of a header width also creates a bending moment, as the offset of the gasket (lower) flange from the header plane generates a second bending moment. These bending moments contribute to stress concentrations in the header when internal pressure is applied. Moving the inner flange inward such that it contacts and is brazed to the tube improve packaging. However, the solution of connecting the inner flange to the thin-walled tube can create stress concentrations in the tube under internal pressure which may exceed acceptable limits in some applications. This, in addition to the problem of internal temperature and pressure conditions in heat exchanger applications, require further solutions not yet found in the prior art.
One response to these conditions has been to provide more rigid tanks and headers for extreme temperature and/or pressure heat exchanger applications. Tank and header deflection and corresponding stresses can lead to failure in the tank wall, in the header, or in the tube-to-header joint area.
Even in a case of radiators, in the initial vacuum coolant filling of radiators in the factory, extreme internal environmental conditions, such a low internal pressure is required that may pull the radiator tank walls and gasket inward, must be resisted by a reinforced feature such as a header inner flange, or the like.
Solutions such as a brazed flange design would achieve similar compactness, but brazing the inner flange to the tube can create stress concentrations in the tube under pressure loading.
Headering means employing mechanical attachment and sealing methods have been developed, due to the difficulty of effectively welding, brazing or soldering of unlike materials (such as alloy headers with plastics such as those found on radiator header tanks). One solution is to provide for an inner flange that encloses a gasket and tank foot, reducing the tendency of the latter to rotate under internal pressure. While this design has been found to be adequate for many radiator applications, it has many disadvantages which are accentuated, as described above, when used in more extreme, and, particularly, internal high temperature and pressure conditions, such as those found in charge air coolers and the like. The present invention has even further advantages as it relates to heat exchangers when fluid flow involves lower density liquids or where operating pressures are greater than moderate or even high to very high.
SUMMARY OF THE PRESENT INVENTION
The present invention provides for headering arrangement for a heat exchanger, and, particularly, a heat exchanger headering arrangement comprising a header part and plastic tank part that forms an adequate seal without the need for a header inner flange. Preferably, the present invention provides for a heat exchanger operating at extreme or higher operating pressures and temperatures, such as those found in charge air coolers, inter coolers, after coolers and the like, wherein the offset between the outer flange and the tube is decreased, reducing bending movements in the header caused by internal pressure loading more preferably in inner flange is utilized. Also, surprisingly, the present invention finds advantages in extreme internal lower pressure conditions, such as radiator applications.
The present invention address and solves problems of the prior art. In preferred embodiments of the present invention the headering arrangement is such that there is no header inner flange. The header inner flange is removed or eliminated. The preferred embodiments of the present invention position inside edges of a tank foot and gasket by the collar that forms the tube ferrule, the collar therefore acting as a ‘rib’ between header slots to stiffen the header and strengthen or protect the thin-walled tube. In further preferred embodiments, a gasket-mating surface (‘gasket’ or ‘lower flange’) is provided coplanar with the header, thus eliminating the header pan.
In preferred embodiments in accordance with the present invention, the design is very compact; only about twice the header thickness (less thinning due to forming), plus the tank foot width, extends beyond the end of the tube on each side. The preferred embodiments, therefore, comprise at least one collar-style tube ferrule acts as a rib, with a resultant ‘stiffening’ of the header and ‘bridging’ over the tube-to-header joint or seal to reduce stresses in the thin-walled tube. In preferred methods in accordance with the present invention, embodiments with more rigid headers, the more rigid header designs also have been shown to improve the crimping process.
It is an object of the present invention to provide a headering arrangement whereby there are limited obstructions or restrictions in the gorge space of the header.
It is a further object of the present invention to provide an improved headering means wherein a flat header is formed (the header inner flange is eliminated), and the outer flange, gasket, and gasket sealing surface are moved inward toward the tube. It is a further objective to utilize the collar/tube ferrule for gasket and tank foot location and for reinforcement of the header. Since the header inner flange is eliminated, the total thickness of the header is reduced accordingly. It is further an object of the present invention to provide of making headering arrangement comprising, removing or eliminating the header inner flange; moving the outer flange gasket and gasket sealing surface inward toward the tube; utilizing the collar/tube ferrule for gasket and tank foot location; and, reinforcing the header, thereby minimizing the overall depth of the heat exchanger and reducing structural bending moments by moving the outer header flange inward.
In preferred embodiments of the present invention, the collar/tube ferrule acts as a reinforcing rib, bridging over the critical, i.e. ‘fluid tight’ tube-to-header joint or seal. In accordance with preferred embodiments of the present invention, and headering arrangement, provides for simplified and compact header designs with improved fabrication characteristics and maximally efficient use of materials, meaning, reduced cost and improved manufacturability, durability and packaging.
In another aspect of the present invention, flat pan headers may be used with inverted collars to produce a similar effect.
In more preferred embodiments, molded heat exchanger tanks are preferably utilized. In its preferred embodiments, the present invention provides for an apparatus and method for reducing induced stresses in heat exchangers, and, in particular, in heat exchanger tanks or collectors, by providing a headering assembly that reduces the width of the header and optimizes the pressure counter-force path. In more preferred embodiments of the present invention, the pressure operating limits of heat exchangers, and, in particular, pressure limits related to the headering means between the heat exchanger core part and the heat exchanger tank part, can thereby be increased while utilizing less material in the headering area.
It is also preferred to provide a sealing means between the header part and the core part of the heat exchanger to ensure that any joint or area of contact remains sealed to the maximum extent possible under the operating pressure limits of the heat exchanger (fluid tight seal). In more preferred embodiments in accordance with the present invention, the sealing means is a ‘joint’ or ‘gasket’; the gasket preferably is used between the heat exchanger header part and heat exchanger body part at the area of contact or seal. More preferred are gaskets that can be cured to maintain their sealing effect. Even more preferred are gaskets that can be cured in place, or cured at the site or area of contact or seal. Also even more preferred are gaskets that can be utilized in both high pressure and lower pressure operating limit environments. Also even more preferred embodiments of the present invention wherein the gasket can be cured in place, and, therefore, utilized in either radiator or higher pressure heat exchanger applications, such as charge air coolers, intercoolers and after coolers, and the like.
In preferred aspects of the present invention, the collar height of the header collars are calculated to maximize correct positioning and alignment of the gasket. Surprisingly, in preferred aspects of the present invention gasket retention is maintained at a high level in both lower and higher pressure environments, such as those found in radiators, charge air coolers and the like, and during engine cooling system fill, i.e, vacuum for better filling, conditions. In the preferred embodiments of the present invention, the correct positioning of the gasket during both assembly and during cycled pressure tests is maintained.
In preferred embodiments of the present invention, the tank design provides for a robust or deflection resistant tank, thereby reducing tube fatigue and fractures, and, in particular, tube fatigue or fractures at or just below the braze joint with the header.
In preferred methods of the present invention, no inner header flange is produced, or, eventually, the inner header flange is eliminated or removed to maintain the flatness of the header during the production processes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . Schematic representation of Prior Art design for plastic tank heat exchanger tank and header manifold assembly.
FIG. 2 . Schematic representation of Prior Art design for plastic tank heat exchanger tank and header manifold assembly.
FIG 3 a - d . Schematic representation of design for heat exchanger in accordance with an aspect of the present invention, showing a pan with flat medallions (flat plate collector) and inverted collars.
FIGS. 4 a and 4 b showing increased overall thickness and bending moments found in prior art designs.
FIG. 5 . Schematic elevational representation in accordance with an aspect of the present invention showing flat header where header inner flange not included and offset in gasket flange.
FIG. 6 . Schematic cross-sectional representation of collar ribs in accordance with an aspect of the present invention.
FIG. 7 . Schematic representation of collar rib in accordance with an aspect of the present invention
FIG. 8 . Schematic elevational representation of collar rib in accordance with an aspect of the present invention shows the preferred embodiment of the invention for plastic tank automotive charge-air-cooler applications.
FIGS. 9 a and 9 b Schematic elevational representation of collar rib in accordance with an aspect of the present invention showing gasket and tank foot location.
FIG. 10 . is a cross sectional view of heat exchanger with inverted collar rib and notch in accordance with an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention, in its preferred embodiments, overcomes many problems of the prior art. In preferred embodiments, the offset of the outer flange is decreased relative to the tube, thus reducing bending moments on the header due to internal pressure loads on the tank. In the preferred embodiments of the present invention, elimination the offset between the gasket sealing surface or gasket (lower) flange and the header plane eliminates a second bending moment, simplifies the header design, reduces material required, and maximizes ambient airflow to the core.
Elimination of the inner flange and utilization of the tube collar/ferrule ‘collar’ as a rib structure significantly stiffens the header. Linear FEA of preferred embodiments of the present invention indicates up to about a 40% reduction in stress compared to prior art designs examined. The collar also serves to prevent inward translation of the tank foot during crimping. This can improve durability and the header tab crimping process.
In more preferred embodiment of the present invention, the collar around the tube end radius is revolved and a separation maintained between the tube and the planar area of the header. The collar/rib effectively bridges over the tube, thereby reducing or preventing bending loads in the header from being transmitted to the thin-walled tube. In other preferred embodiments, and, particularly, in radiator applications, gasket retention means on the tank foot may be applied to maintain preferred gasket location and/or placement during vacuum filling.
Referring to the prior art shown in FIGS. 1 , 2 and 4 , therein represented is a plastic tank 1 of a heat exchanger, with header 2 . In FIG. 2 , tube 10 is brazed at braze joint 8 to a shaved tube ferrule 7 which continues to an inner flange 9 and leads to lower or gasket flange 12 wherein the gasket 6 (not shown) sits. An outer flange 5 extends upwards toward a crimp tab 3 which maintains a tank foot 1 in the tank and header manifold assembly 20 . FIGS. 4 a - c show the header 2 continuing onto an inner flange 9 and into a lower flange 12 , prior to turning upward into outer flange 5 before leading to the tab 11 , which, in this depiction, is crimped around the tank foot 4 .
In accordance with an aspect of the present invention, FIGS. 3 a , 3 b , and 3 c and FIG. 10 show a schematic representation of a design for a heat exchanger in accordance with an aspect of the present invention, showing a pan 23 with flat medallions 22 (flat plate collector) and inverted collars, the heat exchanger tube 21 ending in a flat plate collector or ‘pan’ 23 with flat ‘medallions’ 22 maintaining the tank foot in place, with an intervening gasket 25 in the space between the foot and the pan 23 . The pan 23 includes a ferrule (inverted collar shown in FIG. 3 c ) integral to the pan (shown as non-inverted collar 18 in FIG. 9 a ). As shown in FIG. 3 c , the tube 21 and the pan 23 together form a type of a gorge 26 wherein the gasket 25 and tank foot 24 are received.
Referring to prior art FIGS. 4 a, b and c , the depression (trough or header well) formed in the periphery of the header tends to increase the overall thickness 29 of the heat exchanger assembly 20 as shown in prior art FIG. 1 . This representation demonstrates the resultant packaging problems for some vehicle applications. The outer header flange 5 offset creates a bending moment arm (L 1 ) 14 . A second bending moment arm (L 2 ) 15 exists due to the offset of the gasket (lower) flange 12 from the header plane. When internal pressure is applied, resultant forces (F 1 , F 2 ) act through these moment arms to generate bending loads. These loads contribute to stress concentrations in the header when internal pressure is applied. Testing, such as that based linear finite element analysis (FEA), shows stress results for preferred embodiments of the present invention that show stress level reductions up to or equal to about 40% lower compared to prior art designs such as described above.
Referring to FIGS. 5 , 6 and 7 , the outer flange 5 gasket-sealing surface 13 are moved inward toward the tube 10 . This tends to reduce the overall thickness of the heat exchanger for improved packaging. The offset between the outer flange 5 and the tube 10 is also decreased, which reduces bending moments in the header caused by internal pressure loading. The planar connection means that the inner flange found in the prior art is eliminated.
Referring to FIGS. 6 and 7 , braze point 8 is shown and deeply drawn upturned collars 13 form a U-shaped cross-section or rib 15 between tube slots, significantly increases the bending moment of inertia of the header section. The collar profile, which includes a large radius, is revolved around the end radius of the tube, effectively bridging over and shielding the critical tube-to-header interface. This minimizes the transmission of bending loads to the thin wall of the tube. The height of the formed collar is adjusted, as appropriate, to provide optimized height to performance ratios.
In preferred embodiments of the present invention applying reverse or brazed flange concepts, the elimination of the inner flange for plastic tank applications shows further advantage. Referring to FIGS. 5 and 8 , the gasket (lower) flange 12 is made coplanar with the header surface 22 between the tube slots, eliminating the offset of the gasket (lower) flange relative to the header plane.
Referring to FIGS. 9 a and 9 b , Stresses in the tube-to-header region are significantly reduced for the proposed design compared to the prior art. The collar/rib 10 is relied upon for gasket 6 and tank foot 4 location and retention as well as stiffening the header 2 and providing a clad surface for brazing to the tube 10 . Resistance to inward translation of the tank foot by the collar is expected during crimping, which should improve the process. Tank foot 4 and gasket 6 are retained by this collar/rib design.
In one aspect of the present invention the upturned collar of tube ferrule is cladded with braze material on the inside of the collar. By providing inside cladding, an aspect in accordance with the present invention, minimizes the possibility of magnesium diffusion from the sheared surface of the collar from contaminating the braze joint, thereby improving braze quality.
In a preferred embodiment of the present invention, the heat exchanger of the present invention has an headering arrangement having a heat exchanger body part; a heat exchanger tank part; a header; a tube extending from the heat exchanger body part; a header pan at the end of the tube; a tank foot at the end of the heat exchanger tank part; a gasket; wherein the pan is a flat pan comprising at least one collar. In a more preferred embodiment, the tube extending from the heat exchanger body has a length of less than or about twice the thickness of the header plus the tank foot width of the header. Also, in preferred embodiments, the header pan further comprises at least one flat medallion. Also, in a more preferred embodiment, the gasket is basically flat in shape. As shown in FIG. 10 , one particularly preferred embodiment of the present invention, has the at least one collar inverted vis a vis the line of extension of the tube, and preferred embodiments can be used in high or extreme pressure internal operating environments.
In preferred embodiments of the present invention, synthetic resin, plastic or plastic like tanks are you. More preferred are embodiments wherein the synthetic resin, plastic or plastic like materials used in the tanks are used for higher pressure environment applications, such as charge-air-cooler applications and the like. The invention can be applied to any heat exchanger with separate, mechanically assembled (rather than soldered, brazed, welded, or otherwise bonded) tank, gasket, and header components.
In preferred methods of the present invention, no inner header flange is produced, or, eventually, the inner header flange is eliminated or removed to maintain the flatness of the header during the production processes. Particularly preferred are methods employing a stamping step in the process. More particularly preferred methods also involving a brazing step. In the preferred methods of the present invention, the stamping process will employ a stamping tool designed to maintain flatness of the plane of the header, so that the p lane does not become distorted due to residual stamping stress relief. In particularly preferred methods, residual stamping stress relief does not distort the plane of the header during brazing. In particularly preferred methods, a crimping step where the tabs are crimped as described above. Particularly preferred methods wherein the process uses coined or scored ‘tabs’ to aid in bending or provide an initiation point for bending during the crimping step. | The present invention relates to the field of automotive heat exchangers, and, in particular, to heat exchanger tanks with headers. This invention eliminates the need for use of an inner flange on the header using a collar that also acts as a rib, thereby providing a compact foot plus header tank arrangement with lower stress on the gasket mating surface of the header and tank. The present invention also provides a method for providing improved headering means for automotive heat exchangers with plastic tanks and headers. | Briefly summarize the invention's components and working principles as described in the document. | [
"CROSS-REFERENCE TO RELATED APPLICATIONS This application is a 35 U.S.C. § 371 national stage filing of international application serial number PCT/US2004/042079, filed on Dec. 15, 2004, which itself claims the benefit of U.S. Provisional application serial number 60/530,957, filed on Dec. 19, 2003.",
"FIELD OF THE INVENTION The present invention relates to the field of automotive heat exchangers, and, in particular, to heat exchanger tanks with headers.",
"The present invention further relates to a headering means and a method for providing improved headering means for automotive heat exchangers with plastic tanks and headers, wherein the header inner flange is removed or eliminated.",
"BACKGROUND OF THE INVENTION Motor vehicles employ heat exchangers to heat or cool various elements of an automotive engine and its component parts.",
"UK Patent application GB 2166862 A, published May 14, 1986, Gebhard Schwarz, ‘Vehicle radiator’ discloses a radiator constituted by flat tubes and a single water containing header with separating webs in the flat tubes which extend in prolongation of the separating wall in the water container.",
"U.S. Pat. No. 4,023,618 issued on May 17, 1977, Kun et al, ‘Heat exchanger headering arrangement,’ discloses a heat exchanger assembly comprising a stacked array of thin-walled heat exchange channel elements.",
"The headering arrangement includes a resilient gasket disposed around the perimeter of each face against the wall portion ends thereof and header tank means enclosing each face of the array and forms a fluid tight seal between the header tank and the stacked array.",
"U.S. Pat. No. 6,179,049 issued Jan. 30, 2001, Higgins, ‘Head exchanger with an integrated tank and head sheet,’ discloses a heat exchanger having a core of a plurality of cooling tubes with a tank at each end of the core tubes.",
"The tanks are formed with a plurality of cooling tube receiving apertures along a side portion of the tanks which receive the ends of the cooling tubes directly into the tanks and are attached to the tubes by brazing.",
"U.S. Pat. No. 4,183,402 issued Jan. 15, 1980, Cotter, ‘Heat exchanger heardering arrangement,’ discloses a heat assembly comprising a stacked array of heat exchange channel elements.",
"The improved headering arrangement includes sealing members each having a bearing surface with a generally corrugated contour and header tank means joined to the sealing members so as to leak-tightly enclose the associated face of the stacked array of heat exchange channel elements.",
"Heat exchangers employ heat exchanger tanks which typically include a coolant and require a fluid tight seal.",
"Heat exchanger tanks may be made of a variety of materials, depending on the strength and/or temperature requirements imposed upon them in automotive applications.",
"Plastic tanks have been utilized in heat exchangers and have proven to reduce weight while providing good thermal and strength characteristics in a number of applications.",
"In certain commercial heat exchangers and automotive radiators, it has been common practice to employ a tube sheet headering arrangement.",
"In such systems, the tubes in the heater core assembly are characteristically forced through corresponding size openings in a sheet member and the latter is then joined to suitable tank or shell means to form a ‘header’ or header chamber communication with the tubes of the core assembly for introduction or withdrawal of fluid being passed through the tube members.",
"In certain state of the art designs for automotive heat exchangers with plastic tanks, headers that are stamped from an aluminum sheet are used.",
"In such designs, tube slots are formed with ‘ferrules’ or ‘collars’ in the header to accept tubes and to provide a mating surface for brazing the tubes to the header.",
"As described above, such tank-header arrangements require a fluid tight seal.",
"In order to create such a seal, a depression or trough is formed around the periphery of the header to accommodate the ‘edge flange’ or ‘foot’ of the plastic tank;",
"which also serves to retain a header gasket that provides a seal between the tank and header.",
"Correspondingly, the header further includes an oppositely directed ‘depression’ or ‘pan’ within the periphery of the outer trough.",
"In certain prior art heat exchangers, the edges of the plastic tank are molded to the turned flange or foot.",
"During construction of the heat exchanger, the tank is installed in the trough, with the tank foot compressing the gasket.",
"The outer edges of the aluminum header are then bent or ‘crimped’ to capture the edge of the tank foot, thereby joining the tank to the header (See prior art FIG. 1 ).",
"However, due to the strict requirements imposed upon use of such plastic tanks in automotive applications, and the need to provide fluid tight seals, designs for plastic heat exchanger tanks also use ‘flanges’ or ‘feet’ that fit inside the trough formed around the periphery of the header.",
"In addition, different heat exchanger applications are subjected to different internal pressure and related conditions.",
"Radiators typically have lower operating pressures and temperatures than charge-air-coolers.",
"Radiator tanks can generally be more compact, since the internal fluid is a higher density liquid.",
"Charge air coolers, inter coolers and after coolers typically operate at higher temperatures and pressures, and with more rapid transients than radiators in the same vehicle application.",
"Higher pressures and larger wall surface areas result in greater wall deflection in such applications.",
"Higher temperatures reduce the stiffness and fatigue resistance of the materials.",
"These factors contribute to greater structural integrity and durability problems with more extreme temperatures and pressure conditions.",
"Reinforcing ribs are also been used on the header of heat exchanger between tube slots (See FIG. 2 ).",
"Recently a so-called all-aluminum heat exchanger has been invented that provides for brazing of the inner flange of the header to the ends of the tube as an option when utilizing plastic tanks.",
"See US Patent application 2003/0217838A1 published Nov. 27, 2003, Dey et al.",
"Problems identified in the prior art, therefore, include that of a trough (or well) formed in the periphery of the header tends to increase the overall thickness of the heat exchanger, which can result in packaging problems in the vehicle;",
"and, that of a header width also creates a bending moment, as the offset of the gasket (lower) flange from the header plane generates a second bending moment.",
"These bending moments contribute to stress concentrations in the header when internal pressure is applied.",
"Moving the inner flange inward such that it contacts and is brazed to the tube improve packaging.",
"However, the solution of connecting the inner flange to the thin-walled tube can create stress concentrations in the tube under internal pressure which may exceed acceptable limits in some applications.",
"This, in addition to the problem of internal temperature and pressure conditions in heat exchanger applications, require further solutions not yet found in the prior art.",
"One response to these conditions has been to provide more rigid tanks and headers for extreme temperature and/or pressure heat exchanger applications.",
"Tank and header deflection and corresponding stresses can lead to failure in the tank wall, in the header, or in the tube-to-header joint area.",
"Even in a case of radiators, in the initial vacuum coolant filling of radiators in the factory, extreme internal environmental conditions, such a low internal pressure is required that may pull the radiator tank walls and gasket inward, must be resisted by a reinforced feature such as a header inner flange, or the like.",
"Solutions such as a brazed flange design would achieve similar compactness, but brazing the inner flange to the tube can create stress concentrations in the tube under pressure loading.",
"Headering means employing mechanical attachment and sealing methods have been developed, due to the difficulty of effectively welding, brazing or soldering of unlike materials (such as alloy headers with plastics such as those found on radiator header tanks).",
"One solution is to provide for an inner flange that encloses a gasket and tank foot, reducing the tendency of the latter to rotate under internal pressure.",
"While this design has been found to be adequate for many radiator applications, it has many disadvantages which are accentuated, as described above, when used in more extreme, and, particularly, internal high temperature and pressure conditions, such as those found in charge air coolers and the like.",
"The present invention has even further advantages as it relates to heat exchangers when fluid flow involves lower density liquids or where operating pressures are greater than moderate or even high to very high.",
"SUMMARY OF THE PRESENT INVENTION The present invention provides for headering arrangement for a heat exchanger, and, particularly, a heat exchanger headering arrangement comprising a header part and plastic tank part that forms an adequate seal without the need for a header inner flange.",
"Preferably, the present invention provides for a heat exchanger operating at extreme or higher operating pressures and temperatures, such as those found in charge air coolers, inter coolers, after coolers and the like, wherein the offset between the outer flange and the tube is decreased, reducing bending movements in the header caused by internal pressure loading more preferably in inner flange is utilized.",
"Also, surprisingly, the present invention finds advantages in extreme internal lower pressure conditions, such as radiator applications.",
"The present invention address and solves problems of the prior art.",
"In preferred embodiments of the present invention the headering arrangement is such that there is no header inner flange.",
"The header inner flange is removed or eliminated.",
"The preferred embodiments of the present invention position inside edges of a tank foot and gasket by the collar that forms the tube ferrule, the collar therefore acting as a ‘rib’ between header slots to stiffen the header and strengthen or protect the thin-walled tube.",
"In further preferred embodiments, a gasket-mating surface (‘gasket’ or ‘lower flange’) is provided coplanar with the header, thus eliminating the header pan.",
"In preferred embodiments in accordance with the present invention, the design is very compact;",
"only about twice the header thickness (less thinning due to forming), plus the tank foot width, extends beyond the end of the tube on each side.",
"The preferred embodiments, therefore, comprise at least one collar-style tube ferrule acts as a rib, with a resultant ‘stiffening’ of the header and ‘bridging’ over the tube-to-header joint or seal to reduce stresses in the thin-walled tube.",
"In preferred methods in accordance with the present invention, embodiments with more rigid headers, the more rigid header designs also have been shown to improve the crimping process.",
"It is an object of the present invention to provide a headering arrangement whereby there are limited obstructions or restrictions in the gorge space of the header.",
"It is a further object of the present invention to provide an improved headering means wherein a flat header is formed (the header inner flange is eliminated), and the outer flange, gasket, and gasket sealing surface are moved inward toward the tube.",
"It is a further objective to utilize the collar/tube ferrule for gasket and tank foot location and for reinforcement of the header.",
"Since the header inner flange is eliminated, the total thickness of the header is reduced accordingly.",
"It is further an object of the present invention to provide of making headering arrangement comprising, removing or eliminating the header inner flange;",
"moving the outer flange gasket and gasket sealing surface inward toward the tube;",
"utilizing the collar/tube ferrule for gasket and tank foot location;",
"and, reinforcing the header, thereby minimizing the overall depth of the heat exchanger and reducing structural bending moments by moving the outer header flange inward.",
"In preferred embodiments of the present invention, the collar/tube ferrule acts as a reinforcing rib, bridging over the critical, i.e. ‘fluid tight’ tube-to-header joint or seal.",
"In accordance with preferred embodiments of the present invention, and headering arrangement, provides for simplified and compact header designs with improved fabrication characteristics and maximally efficient use of materials, meaning, reduced cost and improved manufacturability, durability and packaging.",
"In another aspect of the present invention, flat pan headers may be used with inverted collars to produce a similar effect.",
"In more preferred embodiments, molded heat exchanger tanks are preferably utilized.",
"In its preferred embodiments, the present invention provides for an apparatus and method for reducing induced stresses in heat exchangers, and, in particular, in heat exchanger tanks or collectors, by providing a headering assembly that reduces the width of the header and optimizes the pressure counter-force path.",
"In more preferred embodiments of the present invention, the pressure operating limits of heat exchangers, and, in particular, pressure limits related to the headering means between the heat exchanger core part and the heat exchanger tank part, can thereby be increased while utilizing less material in the headering area.",
"It is also preferred to provide a sealing means between the header part and the core part of the heat exchanger to ensure that any joint or area of contact remains sealed to the maximum extent possible under the operating pressure limits of the heat exchanger (fluid tight seal).",
"In more preferred embodiments in accordance with the present invention, the sealing means is a ‘joint’ or ‘gasket’;",
"the gasket preferably is used between the heat exchanger header part and heat exchanger body part at the area of contact or seal.",
"More preferred are gaskets that can be cured to maintain their sealing effect.",
"Even more preferred are gaskets that can be cured in place, or cured at the site or area of contact or seal.",
"Also even more preferred are gaskets that can be utilized in both high pressure and lower pressure operating limit environments.",
"Also even more preferred embodiments of the present invention wherein the gasket can be cured in place, and, therefore, utilized in either radiator or higher pressure heat exchanger applications, such as charge air coolers, intercoolers and after coolers, and the like.",
"In preferred aspects of the present invention, the collar height of the header collars are calculated to maximize correct positioning and alignment of the gasket.",
"Surprisingly, in preferred aspects of the present invention gasket retention is maintained at a high level in both lower and higher pressure environments, such as those found in radiators, charge air coolers and the like, and during engine cooling system fill, i.e, vacuum for better filling, conditions.",
"In the preferred embodiments of the present invention, the correct positioning of the gasket during both assembly and during cycled pressure tests is maintained.",
"In preferred embodiments of the present invention, the tank design provides for a robust or deflection resistant tank, thereby reducing tube fatigue and fractures, and, in particular, tube fatigue or fractures at or just below the braze joint with the header.",
"In preferred methods of the present invention, no inner header flange is produced, or, eventually, the inner header flange is eliminated or removed to maintain the flatness of the header during the production processes.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 .",
"Schematic representation of Prior Art design for plastic tank heat exchanger tank and header manifold assembly.",
"FIG. 2 .",
"Schematic representation of Prior Art design for plastic tank heat exchanger tank and header manifold assembly.",
"FIG 3 a - d .",
"Schematic representation of design for heat exchanger in accordance with an aspect of the present invention, showing a pan with flat medallions (flat plate collector) and inverted collars.",
"FIGS. 4 a and 4 b showing increased overall thickness and bending moments found in prior art designs.",
"FIG. 5 .",
"Schematic elevational representation in accordance with an aspect of the present invention showing flat header where header inner flange not included and offset in gasket flange.",
"FIG. 6 .",
"Schematic cross-sectional representation of collar ribs in accordance with an aspect of the present invention.",
"FIG. 7 .",
"Schematic representation of collar rib in accordance with an aspect of the present invention FIG. 8 .",
"Schematic elevational representation of collar rib in accordance with an aspect of the present invention shows the preferred embodiment of the invention for plastic tank automotive charge-air-cooler applications.",
"FIGS. 9 a and 9 b Schematic elevational representation of collar rib in accordance with an aspect of the present invention showing gasket and tank foot location.",
"FIG. 10 .",
"is a cross sectional view of heat exchanger with inverted collar rib and notch in accordance with an aspect of the present invention.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention, in its preferred embodiments, overcomes many problems of the prior art.",
"In preferred embodiments, the offset of the outer flange is decreased relative to the tube, thus reducing bending moments on the header due to internal pressure loads on the tank.",
"In the preferred embodiments of the present invention, elimination the offset between the gasket sealing surface or gasket (lower) flange and the header plane eliminates a second bending moment, simplifies the header design, reduces material required, and maximizes ambient airflow to the core.",
"Elimination of the inner flange and utilization of the tube collar/ferrule ‘collar’ as a rib structure significantly stiffens the header.",
"Linear FEA of preferred embodiments of the present invention indicates up to about a 40% reduction in stress compared to prior art designs examined.",
"The collar also serves to prevent inward translation of the tank foot during crimping.",
"This can improve durability and the header tab crimping process.",
"In more preferred embodiment of the present invention, the collar around the tube end radius is revolved and a separation maintained between the tube and the planar area of the header.",
"The collar/rib effectively bridges over the tube, thereby reducing or preventing bending loads in the header from being transmitted to the thin-walled tube.",
"In other preferred embodiments, and, particularly, in radiator applications, gasket retention means on the tank foot may be applied to maintain preferred gasket location and/or placement during vacuum filling.",
"Referring to the prior art shown in FIGS. 1 , 2 and 4 , therein represented is a plastic tank 1 of a heat exchanger, with header 2 .",
"In FIG. 2 , tube 10 is brazed at braze joint 8 to a shaved tube ferrule 7 which continues to an inner flange 9 and leads to lower or gasket flange 12 wherein the gasket 6 (not shown) sits.",
"An outer flange 5 extends upwards toward a crimp tab 3 which maintains a tank foot 1 in the tank and header manifold assembly 20 .",
"FIGS. 4 a - c show the header 2 continuing onto an inner flange 9 and into a lower flange 12 , prior to turning upward into outer flange 5 before leading to the tab 11 , which, in this depiction, is crimped around the tank foot 4 .",
"In accordance with an aspect of the present invention, FIGS. 3 a , 3 b , and 3 c and FIG. 10 show a schematic representation of a design for a heat exchanger in accordance with an aspect of the present invention, showing a pan 23 with flat medallions 22 (flat plate collector) and inverted collars, the heat exchanger tube 21 ending in a flat plate collector or ‘pan’ 23 with flat ‘medallions’ 22 maintaining the tank foot in place, with an intervening gasket 25 in the space between the foot and the pan 23 .",
"The pan 23 includes a ferrule (inverted collar shown in FIG. 3 c ) integral to the pan (shown as non-inverted collar 18 in FIG. 9 a ).",
"As shown in FIG. 3 c , the tube 21 and the pan 23 together form a type of a gorge 26 wherein the gasket 25 and tank foot 24 are received.",
"Referring to prior art FIGS. 4 a, b and c , the depression (trough or header well) formed in the periphery of the header tends to increase the overall thickness 29 of the heat exchanger assembly 20 as shown in prior art FIG. 1 .",
"This representation demonstrates the resultant packaging problems for some vehicle applications.",
"The outer header flange 5 offset creates a bending moment arm (L 1 ) 14 .",
"A second bending moment arm (L 2 ) 15 exists due to the offset of the gasket (lower) flange 12 from the header plane.",
"When internal pressure is applied, resultant forces (F 1 , F 2 ) act through these moment arms to generate bending loads.",
"These loads contribute to stress concentrations in the header when internal pressure is applied.",
"Testing, such as that based linear finite element analysis (FEA), shows stress results for preferred embodiments of the present invention that show stress level reductions up to or equal to about 40% lower compared to prior art designs such as described above.",
"Referring to FIGS. 5 , 6 and 7 , the outer flange 5 gasket-sealing surface 13 are moved inward toward the tube 10 .",
"This tends to reduce the overall thickness of the heat exchanger for improved packaging.",
"The offset between the outer flange 5 and the tube 10 is also decreased, which reduces bending moments in the header caused by internal pressure loading.",
"The planar connection means that the inner flange found in the prior art is eliminated.",
"Referring to FIGS. 6 and 7 , braze point 8 is shown and deeply drawn upturned collars 13 form a U-shaped cross-section or rib 15 between tube slots, significantly increases the bending moment of inertia of the header section.",
"The collar profile, which includes a large radius, is revolved around the end radius of the tube, effectively bridging over and shielding the critical tube-to-header interface.",
"This minimizes the transmission of bending loads to the thin wall of the tube.",
"The height of the formed collar is adjusted, as appropriate, to provide optimized height to performance ratios.",
"In preferred embodiments of the present invention applying reverse or brazed flange concepts, the elimination of the inner flange for plastic tank applications shows further advantage.",
"Referring to FIGS. 5 and 8 , the gasket (lower) flange 12 is made coplanar with the header surface 22 between the tube slots, eliminating the offset of the gasket (lower) flange relative to the header plane.",
"Referring to FIGS. 9 a and 9 b , Stresses in the tube-to-header region are significantly reduced for the proposed design compared to the prior art.",
"The collar/rib 10 is relied upon for gasket 6 and tank foot 4 location and retention as well as stiffening the header 2 and providing a clad surface for brazing to the tube 10 .",
"Resistance to inward translation of the tank foot by the collar is expected during crimping, which should improve the process.",
"Tank foot 4 and gasket 6 are retained by this collar/rib design.",
"In one aspect of the present invention the upturned collar of tube ferrule is cladded with braze material on the inside of the collar.",
"By providing inside cladding, an aspect in accordance with the present invention, minimizes the possibility of magnesium diffusion from the sheared surface of the collar from contaminating the braze joint, thereby improving braze quality.",
"In a preferred embodiment of the present invention, the heat exchanger of the present invention has an headering arrangement having a heat exchanger body part;",
"a heat exchanger tank part;",
"a header;",
"a tube extending from the heat exchanger body part;",
"a header pan at the end of the tube;",
"a tank foot at the end of the heat exchanger tank part;",
"a gasket;",
"wherein the pan is a flat pan comprising at least one collar.",
"In a more preferred embodiment, the tube extending from the heat exchanger body has a length of less than or about twice the thickness of the header plus the tank foot width of the header.",
"Also, in preferred embodiments, the header pan further comprises at least one flat medallion.",
"Also, in a more preferred embodiment, the gasket is basically flat in shape.",
"As shown in FIG. 10 , one particularly preferred embodiment of the present invention, has the at least one collar inverted vis a vis the line of extension of the tube, and preferred embodiments can be used in high or extreme pressure internal operating environments.",
"In preferred embodiments of the present invention, synthetic resin, plastic or plastic like tanks are you.",
"More preferred are embodiments wherein the synthetic resin, plastic or plastic like materials used in the tanks are used for higher pressure environment applications, such as charge-air-cooler applications and the like.",
"The invention can be applied to any heat exchanger with separate, mechanically assembled (rather than soldered, brazed, welded, or otherwise bonded) tank, gasket, and header components.",
"In preferred methods of the present invention, no inner header flange is produced, or, eventually, the inner header flange is eliminated or removed to maintain the flatness of the header during the production processes.",
"Particularly preferred are methods employing a stamping step in the process.",
"More particularly preferred methods also involving a brazing step.",
"In the preferred methods of the present invention, the stamping process will employ a stamping tool designed to maintain flatness of the plane of the header, so that the p lane does not become distorted due to residual stamping stress relief.",
"In particularly preferred methods, residual stamping stress relief does not distort the plane of the header during brazing.",
"In particularly preferred methods, a crimping step where the tabs are crimped as described above.",
"Particularly preferred methods wherein the process uses coined or scored ‘tabs’ to aid in bending or provide an initiation point for bending during the crimping step."
] |
BACKGROUND
1. Technical Field
The present disclosure relates to a laptop having a touchpad.
2. Description of Related Art
Laptops are usually integrated with a touchpad to facilitate the operation of the laptops. However, sometimes operation by an external mouse is desired. In this situation, the external mouse must be obtained, and then connected to the laptop, which is inconvenient in the extreme.
Therefore, it is desirable to provide a laptop, which can overcome the limitations described.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the views.
FIG. 1 is an isometric, and schematic view of an assembled laptop, according to an embodiment.
FIG. 2 is an isometric, exploded, and schematic view of a portion of the laptop of FIG. 1 .
FIG. 3 is another isometric, exploded, and schematic view of a portion of the laptop of FIG. 1 , viewed from another angle.
FIG. 4 is a cross-sectional view of part of the laptop, taken along a line IV-IV of FIG. 1 .
FIG. 5 is a cross-sectional view of part of the laptop, taken along a line V-V of FIG. 1 .
FIG. 6 is another isometric, schematic view of the assembled laptop of FIG. 1 , in another state.
DETAILED DESCRIPTION
Embodiments of the present disclosure will now be described in detail with reference to the drawings.
Referring to FIGS. 1-3 , a laptop 10 , according to an embodiment, includes a main body 100 , a touchpad 200 , and an ejection mechanism 300 .
The main body 100 is cuboid and includes a housing 102 . The housing 102 includes a rectangular keyboard surface 104 and a body sidewall 106 . The housing 102 defines a receiving groove 108 in the keyboard surface 104 , adjacent to the body sidewall 106 , two circular first through holes 110 in a rectangular bottom surface 114 of the receiving groove 108 , and a rectangular second through hole 112 in the body sidewall 106 between the two first through holes 110 . The second through hole 112 is elongated, extending along a direction substantially parallel to the body sidewall 106 .
The touchpad 200 is shaped so as to be received in the receiving groove 108 but is slidable on the same plane as the keyboard surface 104 . That is to say, the touchpad 200 is also cuboid and while there is a simple fitting clearance between the sides of the touchpad 200 and the sidewalls of the receiving groove 108 , the touchpad 200 has substantial front and rear clearance. The touchpad 200 can be wirelessly connected with the main body 100 by means of Bluetooth or a similar technology.
The ejection mechanism 300 includes two ejection headers 302 , two spiral cams 304 , two racks 306 , and two linkage rods 308 .
Each ejection header 302 includes a circular ejection plate and a pair of connection plates (none labeled). Each ejection plate is shaped so as to be received in the corresponding first through hole 110 and is slidable depthwise in the first through hole 110 . The pair of connection plates are diametrically arranged and extend from the underside (ie. the bottom surface) of the ejection plate. Each connection plate defines a hole, the holes in each pair of connection plates are aligned with each other.
Each spiral cam 304 includes an axle 310 and a toothed side surface 312 . Each axle 310 is a shaft on which the corresponding spiral cam 304 may rotate. Each toothed side surface 312 , viewed parallel to the direction of the corresponding axle 310 , has a spiral contour of which the center is aligned with the corresponding axle 310 .
Each rack 306 is a rectangular strip having one toothed surface, and is configured for engaging with the toothed side surface 312 of the corresponding spiral cam 304 .
Each linkage rod 308 is made of wires and includes a drive wire 314 (e.g., a straight wire) and an operation wire 316 (e.g., a straight wire) connecting to and substantially perpendicular to the drive wire 314 .
Also referring to FIGS. 4 and 5 , in assembly, the ejection mechanism 300 is received in the housing 30 , wherein the linkage rods 308 are located at two sides of the second through hole 112 . The operation wires 316 protrude from the housing 30 through the second through hole 112 along a direction substantially perpendicular to the body sidewall 106 and are slidable in the elongated second through hole 112 (that is, in a direction substantially parallel to the keyboard surface 104 ). The drive wires 314 are arranged lengthwise in the body sidewall 106 . The racks 306 are respectively connected to the ends of the respective drive wires 314 opposing the respective operation wires 316 . The ejection plates are received in the respective first through holes 110 . Each spiral cam 304 is rotatably connected to the corresponding ejection header 302 by inserting the corresponding axle 310 into the corresponding pair of shaft holes and each toothed side surface 312 engages with a corresponding rack 306 , such that, when the operation wires 316 are pushed towards each other, the distance between each axle 310 and a point of the corresponding toothed side surface 312 engaging with the corresponding rack 306 increases.
Thus, in operation, when the operation wires 316 are pushed towards each other, the ejection headers 302 are forced to slide upwards in the first through holes 110 , so ejecting the touchpad 200 up from the receiving groove 108 (see FIG. 6 ). Then the touchpad 200 can be detached from, but remain wirelessly connected to, the main body 100 and may function as an external mouse.
The spiral cams 304 can be inversely arranged. That is, the spiral cams 304 can be arranged such that when the operation wires 316 are pulled away from each other, the distance between each axle 310 and the point of the corresponding toothed side surface 312 engaging with the corresponding rack 306 increases. Thus, by pulling the operation wires 316 away from each other instead of pushing, the touchpad 200 can be ejected up.
In alternative embodiments, the ejection of the touchpad 200 can be accomplished utilizing only one of the headers 302 , one of the cams 304 , one of the racks 306 , and one of the linkage rods 308 . The linkage rod 308 can be employed to apply pressure to only one location on the touchpad 200 .
The shapes of the receiving groove 108 , the first through holes 110 , the second through hole 112 , and the touchpad 200 are not limited to this embodiment, but can take other effective forms in alternative embodiments.
Referring to FIGS. 2-3 , the receiving groove 108 is bounded by, in addition to the bottom surface 114 , a rectangular first inner sidewall 116 opposite to the body sidewall 106 , and a rectangular second inner sidewall 118 facing the first inner sidewall 116 . Both the first inner sidewall 116 and the second inner sidewall 118 are perpendicularly connected to the bottom surface 114 . The housing 100 forms cuboid engaging grooves 120 in the second inner sidewall 118 , adjacent to the surface 114 and extending as wide as the second inner sidewall 118 along the direction parallel to both the bottom surface 114 and the second inner sidewall 118 .
Corresponding to the receiving groove 108 , the touchpad 200 includes a rectangular first outer sidewall 202 corresponding to the first inner sidewall 116 , and a rectangular second outer sidewall 204 corresponding to the second inner sidewall 118 . The touchpad 200 includes a cuboid engaging block 206 extending up from the second outer sidewall 204 and corresponding to the engaging groove 120 . The engaging block 206 is as wide as the touchpad 200 along the direction parallel to both the second outer sidewall 204 and the upper surface of the touchpad 200 .
Therefore, when the touchpad 200 is received in the receiving groove 108 , the engaging block 206 is inserted into the engaging groove 120 to secure the touchpad 200 in the receiving groove 108 .
The engaging groove 120 is bounded by a rectangular third inner sidewall 122 facing the first inner sidewall 116 . The housing 102 further defines two rectangular engaging holes 124 in the third inner sidewall 116 , away from the bottom surface 114 and adjacent to the two ends of the third inner sidewall 116 . The engaging block 206 includes two rectangular engaging pins 208 extending therefrom and corresponding to the respective engaging holes 124 .
Therefore, when the touchpad 200 is received in the receiving groove 108 , the engaging pins 208 are inserted into the respective engaging holes 124 to further secure the touchpad 200 in the receiving groove 108 .
The housing 102 further forms two circular receiving holes 126 in the third inner sidewall 122 , adjacent to the two ends of the third inner sidewall 122 but between the engaging holes 124 . The laptop 10 further includes two first coil springs 400 . The first coil springs 400 are received in the respective receiving holes 126 , and are compressed when installing the touchpad 200 into the receiving groove 108 , and compress the touchpad 200 against the first inner sidewall 116 to further secure the touchpad 200 in the receiving groove 108 .
The shapes of the engaging groove 120 , the engaging block 206 , the engaging holes 124 , the engaging pins 208 , and the receiving holes 126 are not limited to this embodiment, but can take other effective shapes in other embodiments.
The housing 102 can further form a curved cutout 128 in the intersection of the keyboard surface 104 and the body sidewall 106 which corresponds to the second through hole 112 to facilitate manual operations on the operation wires 316 therein.
The second through hole 112 extends through the first inner sidewall 116 . The housing 102 further form two rectangular third through holes 130 in the bottom surface 114 , adjacent to the first inner sidewall 116 and corresponding to the second through hole 112 . Each linkage rod 308 includes a first connection wire 318 and a second connection wire 320 . Each first connection wire 318 connects and is substantially perpendicular to both the corresponding drive wire 314 and the corresponding operation wire 316 . Each second connection wire 320 is parallel to the corresponding drive wire 314 and directly connects and is substantially perpendicular to both the corresponding first connection wire 318 and to the corresponding operation wire 316 .
The touchpad 200 forms a sliding groove 210 in the first outer sidewall 202 , adjacent to the bottom surface of the touchpad 200 and extending the width of the first outer sidewall 202 along a direction parallel to both the first outer sidewall 202 and the upper surface of the touchpad 200 .
In assembly, the first connection wires 318 extend through the respective third through holes 130 , and may slide within the third through holes 130 (i.e., in a direction substantially perpendicular to the bottom surface 114 ). The second connection wires 320 are received in the sliding groove 210 and may slide in a direction parallel to both the bottom surface 114 and the first inner sidewall 116 .
The touchpad 200 may include a pair of guiding plates 212 extending from a sidewall of the sliding groove 210 which cooperatively guide the sliding movement of the second connection wires 320 in the sliding groove 210 .
The ejection mechanism 300 further includes two second coil springs 322 . The second coil springs 322 are received in the sliding groove 210 . Each second spring 322 connects the corresponding second connection wire 320 with the housing 102 . When the touchpad 200 is received in the receiving groove 108 , the second coil springs 322 are their natural length. When operating the operation wires 316 , the second connection wires 320 slide within the sliding groove 210 along with the respective wires 316 and thus cause the second coil springs 322 to stretch or be compressed. Thus, when the operation wires 316 are released, the linkage rods 308 , the racks 306 , the spiral cams 304 , and the ejection headers 302 are all restored to their original respective positions by the second coil springs 322 .
The engaging holes 124 , the engaging pins 208 , the receiving hole 126 , the first coil springs 400 , the first through holes 110 , the third through holes 130 , and the ejection mechanism 300 are symmetrical about a central axis O of the receiving groove 108 which is substantially perpendicular to the body sidewall 106 .
The above particular embodiments are shown and described by way of illustration only. The principles and the features of the present disclosure may be employed in various and numerous embodiments thereof without departing from the scope of the disclosure as claimed. The above-described embodiments illustrate the scope of the disclosure but do not restrict the scope of the disclosure. | A laptop includes a main body and a touchpad. The main body includes a housing which defines a receiving groove. The touchpad is detachably received in the receiving groove. The laptop further includes an ejection mechanism to eject the touchpad up from the receiving groove to allow the touchpad to be used independently as an external mouse. | Identify and summarize the most critical technical features from the given patent document. | [
"BACKGROUND 1.",
"Technical Field The present disclosure relates to a laptop having a touchpad.",
"Description of Related Art Laptops are usually integrated with a touchpad to facilitate the operation of the laptops.",
"However, sometimes operation by an external mouse is desired.",
"In this situation, the external mouse must be obtained, and then connected to the laptop, which is inconvenient in the extreme.",
"Therefore, it is desirable to provide a laptop, which can overcome the limitations described.",
"BRIEF DESCRIPTION OF THE DRAWINGS Many aspects of the present disclosure can be better understood with reference to the following drawings.",
"The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present disclosure.",
"Moreover, in the drawings, like reference numerals designate corresponding parts throughout the views.",
"FIG. 1 is an isometric, and schematic view of an assembled laptop, according to an embodiment.",
"FIG. 2 is an isometric, exploded, and schematic view of a portion of the laptop of FIG. 1 .",
"FIG. 3 is another isometric, exploded, and schematic view of a portion of the laptop of FIG. 1 , viewed from another angle.",
"FIG. 4 is a cross-sectional view of part of the laptop, taken along a line IV-IV of FIG. 1 .",
"FIG. 5 is a cross-sectional view of part of the laptop, taken along a line V-V of FIG. 1 .",
"FIG. 6 is another isometric, schematic view of the assembled laptop of FIG. 1 , in another state.",
"DETAILED DESCRIPTION Embodiments of the present disclosure will now be described in detail with reference to the drawings.",
"Referring to FIGS. 1-3 , a laptop 10 , according to an embodiment, includes a main body 100 , a touchpad 200 , and an ejection mechanism 300 .",
"The main body 100 is cuboid and includes a housing 102 .",
"The housing 102 includes a rectangular keyboard surface 104 and a body sidewall 106 .",
"The housing 102 defines a receiving groove 108 in the keyboard surface 104 , adjacent to the body sidewall 106 , two circular first through holes 110 in a rectangular bottom surface 114 of the receiving groove 108 , and a rectangular second through hole 112 in the body sidewall 106 between the two first through holes 110 .",
"The second through hole 112 is elongated, extending along a direction substantially parallel to the body sidewall 106 .",
"The touchpad 200 is shaped so as to be received in the receiving groove 108 but is slidable on the same plane as the keyboard surface 104 .",
"That is to say, the touchpad 200 is also cuboid and while there is a simple fitting clearance between the sides of the touchpad 200 and the sidewalls of the receiving groove 108 , the touchpad 200 has substantial front and rear clearance.",
"The touchpad 200 can be wirelessly connected with the main body 100 by means of Bluetooth or a similar technology.",
"The ejection mechanism 300 includes two ejection headers 302 , two spiral cams 304 , two racks 306 , and two linkage rods 308 .",
"Each ejection header 302 includes a circular ejection plate and a pair of connection plates (none labeled).",
"Each ejection plate is shaped so as to be received in the corresponding first through hole 110 and is slidable depthwise in the first through hole 110 .",
"The pair of connection plates are diametrically arranged and extend from the underside (ie.",
"the bottom surface) of the ejection plate.",
"Each connection plate defines a hole, the holes in each pair of connection plates are aligned with each other.",
"Each spiral cam 304 includes an axle 310 and a toothed side surface 312 .",
"Each axle 310 is a shaft on which the corresponding spiral cam 304 may rotate.",
"Each toothed side surface 312 , viewed parallel to the direction of the corresponding axle 310 , has a spiral contour of which the center is aligned with the corresponding axle 310 .",
"Each rack 306 is a rectangular strip having one toothed surface, and is configured for engaging with the toothed side surface 312 of the corresponding spiral cam 304 .",
"Each linkage rod 308 is made of wires and includes a drive wire 314 (e.g., a straight wire) and an operation wire 316 (e.g., a straight wire) connecting to and substantially perpendicular to the drive wire 314 .",
"Also referring to FIGS. 4 and 5 , in assembly, the ejection mechanism 300 is received in the housing 30 , wherein the linkage rods 308 are located at two sides of the second through hole 112 .",
"The operation wires 316 protrude from the housing 30 through the second through hole 112 along a direction substantially perpendicular to the body sidewall 106 and are slidable in the elongated second through hole 112 (that is, in a direction substantially parallel to the keyboard surface 104 ).",
"The drive wires 314 are arranged lengthwise in the body sidewall 106 .",
"The racks 306 are respectively connected to the ends of the respective drive wires 314 opposing the respective operation wires 316 .",
"The ejection plates are received in the respective first through holes 110 .",
"Each spiral cam 304 is rotatably connected to the corresponding ejection header 302 by inserting the corresponding axle 310 into the corresponding pair of shaft holes and each toothed side surface 312 engages with a corresponding rack 306 , such that, when the operation wires 316 are pushed towards each other, the distance between each axle 310 and a point of the corresponding toothed side surface 312 engaging with the corresponding rack 306 increases.",
"Thus, in operation, when the operation wires 316 are pushed towards each other, the ejection headers 302 are forced to slide upwards in the first through holes 110 , so ejecting the touchpad 200 up from the receiving groove 108 (see FIG. 6 ).",
"Then the touchpad 200 can be detached from, but remain wirelessly connected to, the main body 100 and may function as an external mouse.",
"The spiral cams 304 can be inversely arranged.",
"That is, the spiral cams 304 can be arranged such that when the operation wires 316 are pulled away from each other, the distance between each axle 310 and the point of the corresponding toothed side surface 312 engaging with the corresponding rack 306 increases.",
"Thus, by pulling the operation wires 316 away from each other instead of pushing, the touchpad 200 can be ejected up.",
"In alternative embodiments, the ejection of the touchpad 200 can be accomplished utilizing only one of the headers 302 , one of the cams 304 , one of the racks 306 , and one of the linkage rods 308 .",
"The linkage rod 308 can be employed to apply pressure to only one location on the touchpad 200 .",
"The shapes of the receiving groove 108 , the first through holes 110 , the second through hole 112 , and the touchpad 200 are not limited to this embodiment, but can take other effective forms in alternative embodiments.",
"Referring to FIGS. 2-3 , the receiving groove 108 is bounded by, in addition to the bottom surface 114 , a rectangular first inner sidewall 116 opposite to the body sidewall 106 , and a rectangular second inner sidewall 118 facing the first inner sidewall 116 .",
"Both the first inner sidewall 116 and the second inner sidewall 118 are perpendicularly connected to the bottom surface 114 .",
"The housing 100 forms cuboid engaging grooves 120 in the second inner sidewall 118 , adjacent to the surface 114 and extending as wide as the second inner sidewall 118 along the direction parallel to both the bottom surface 114 and the second inner sidewall 118 .",
"Corresponding to the receiving groove 108 , the touchpad 200 includes a rectangular first outer sidewall 202 corresponding to the first inner sidewall 116 , and a rectangular second outer sidewall 204 corresponding to the second inner sidewall 118 .",
"The touchpad 200 includes a cuboid engaging block 206 extending up from the second outer sidewall 204 and corresponding to the engaging groove 120 .",
"The engaging block 206 is as wide as the touchpad 200 along the direction parallel to both the second outer sidewall 204 and the upper surface of the touchpad 200 .",
"Therefore, when the touchpad 200 is received in the receiving groove 108 , the engaging block 206 is inserted into the engaging groove 120 to secure the touchpad 200 in the receiving groove 108 .",
"The engaging groove 120 is bounded by a rectangular third inner sidewall 122 facing the first inner sidewall 116 .",
"The housing 102 further defines two rectangular engaging holes 124 in the third inner sidewall 116 , away from the bottom surface 114 and adjacent to the two ends of the third inner sidewall 116 .",
"The engaging block 206 includes two rectangular engaging pins 208 extending therefrom and corresponding to the respective engaging holes 124 .",
"Therefore, when the touchpad 200 is received in the receiving groove 108 , the engaging pins 208 are inserted into the respective engaging holes 124 to further secure the touchpad 200 in the receiving groove 108 .",
"The housing 102 further forms two circular receiving holes 126 in the third inner sidewall 122 , adjacent to the two ends of the third inner sidewall 122 but between the engaging holes 124 .",
"The laptop 10 further includes two first coil springs 400 .",
"The first coil springs 400 are received in the respective receiving holes 126 , and are compressed when installing the touchpad 200 into the receiving groove 108 , and compress the touchpad 200 against the first inner sidewall 116 to further secure the touchpad 200 in the receiving groove 108 .",
"The shapes of the engaging groove 120 , the engaging block 206 , the engaging holes 124 , the engaging pins 208 , and the receiving holes 126 are not limited to this embodiment, but can take other effective shapes in other embodiments.",
"The housing 102 can further form a curved cutout 128 in the intersection of the keyboard surface 104 and the body sidewall 106 which corresponds to the second through hole 112 to facilitate manual operations on the operation wires 316 therein.",
"The second through hole 112 extends through the first inner sidewall 116 .",
"The housing 102 further form two rectangular third through holes 130 in the bottom surface 114 , adjacent to the first inner sidewall 116 and corresponding to the second through hole 112 .",
"Each linkage rod 308 includes a first connection wire 318 and a second connection wire 320 .",
"Each first connection wire 318 connects and is substantially perpendicular to both the corresponding drive wire 314 and the corresponding operation wire 316 .",
"Each second connection wire 320 is parallel to the corresponding drive wire 314 and directly connects and is substantially perpendicular to both the corresponding first connection wire 318 and to the corresponding operation wire 316 .",
"The touchpad 200 forms a sliding groove 210 in the first outer sidewall 202 , adjacent to the bottom surface of the touchpad 200 and extending the width of the first outer sidewall 202 along a direction parallel to both the first outer sidewall 202 and the upper surface of the touchpad 200 .",
"In assembly, the first connection wires 318 extend through the respective third through holes 130 , and may slide within the third through holes 130 (i.e., in a direction substantially perpendicular to the bottom surface 114 ).",
"The second connection wires 320 are received in the sliding groove 210 and may slide in a direction parallel to both the bottom surface 114 and the first inner sidewall 116 .",
"The touchpad 200 may include a pair of guiding plates 212 extending from a sidewall of the sliding groove 210 which cooperatively guide the sliding movement of the second connection wires 320 in the sliding groove 210 .",
"The ejection mechanism 300 further includes two second coil springs 322 .",
"The second coil springs 322 are received in the sliding groove 210 .",
"Each second spring 322 connects the corresponding second connection wire 320 with the housing 102 .",
"When the touchpad 200 is received in the receiving groove 108 , the second coil springs 322 are their natural length.",
"When operating the operation wires 316 , the second connection wires 320 slide within the sliding groove 210 along with the respective wires 316 and thus cause the second coil springs 322 to stretch or be compressed.",
"Thus, when the operation wires 316 are released, the linkage rods 308 , the racks 306 , the spiral cams 304 , and the ejection headers 302 are all restored to their original respective positions by the second coil springs 322 .",
"The engaging holes 124 , the engaging pins 208 , the receiving hole 126 , the first coil springs 400 , the first through holes 110 , the third through holes 130 , and the ejection mechanism 300 are symmetrical about a central axis O of the receiving groove 108 which is substantially perpendicular to the body sidewall 106 .",
"The above particular embodiments are shown and described by way of illustration only.",
"The principles and the features of the present disclosure may be employed in various and numerous embodiments thereof without departing from the scope of the disclosure as claimed.",
"The above-described embodiments illustrate the scope of the disclosure but do not restrict the scope of the disclosure."
] |
TECHNICAL FIELD
[0001] The present disclosure relates to an apparatus and a method for modifying colors of a focal stack of a scene according to a color palette.
BACKGROUND
[0002] Color transfer is a known technic consisting in modifying the COLORs of a source image by applying the COLOR palette of an example image without changing the source image structure.
[0003] A lot of color transfer method are known which consist in transferring colors between two images. One of these methods is disclosed in Frigo et al. “Optimal Transportation for Example-Guided COLOR Transfer”, Asian Conference on Computer Vision, 2014.
[0004] Such a method consists in processing separately the processing of the luminance and the chroma channels of an image. The luminance channel is addressed using a chromatic adaption transform, accounting for the illuminant change, while the chroma channels are transformed using an optimal transportation.
[0005] The chromatic adaptation transform consists in modifying the illuminant of the input image with respect to the example image illuminant. In order to do so, the color of the illuminant of the example image is estimated. The illuminant of the input image is then modified so as to adapt to the estimated illuminant of the example image.
[0006] In order to define the COLOR chroma transfer, set of modes from the input image and example image are extracted. Then, a COLOR transfer based on an optimal mapping between these two sets of modes is performed.
[0007] Such a method does not preserve the quality of the bokeh in areas of an images that are not in focus at a given depth. This results in a navigation in the depth dimension that is not smooth.
[0008] The present invention has been devised with the foregoing in mind.
SUMMARY OF INVENTION
[0009] A first aspect of the invention concerns an apparatus for modifying COLORs of a focal stack of a scene according to a COLOR palette comprising a processor configured to:
applying the COLOR palette to an all-in-focus image generated from said focal stack, estimating the COLOR of a not-in-focus pixel in a layer of a reCOLORed focal stack generated from the obtained reCOLORed all-in-focus image of the scene depending on a COLOR and on a position in said reCOLORed focal stack of at least one pixel in focus in at least one layer of said reCOLORed focal stack.
[0012] According to an embodiment of the apparatus, the processor is configured to apply the COLOR palette of an image of another scene.
[0013] According to an embodiment of the apparatus, the image of the other scene is an all-in-focus image generated from a focal stack of the other scene.
[0014] According to an embodiment of the apparatus, the processor is configured to store, during the generation of the all-in-focus image, a position in the focal stack of a layer wherein a pixel is in focus.
[0015] According to an embodiment of the apparatus, the processor is configured to generate the reCOLORed focal stack by putting a pixel of the reCOLORed all-in-focus image back into the layer of the reCOLORed focal stack wherein said pixel is focus.
[0016] According to an embodiment of the apparatus, the processor is configured to propagate the COLOR of a pixel in focus in a layer of the reCOLORed focal stack to the other layers of the reCOLORed focal stack by computing a convolution of said pixel in focus with a kernel.
[0017] According to an embodiment of the apparatus, a size of the kernel is proportional to the position of a layer in the reCOLORed focal stack.
[0018] According to an embodiment of the apparatus, when a pixel is in focus in a layer of the reCOLORed focal stack, the processor is configured to associate the COLOR of said pixel in the reCOLORed all-in-focus to said pixel in focus in said layer of the reCOLORed focal stack.
[0019] According to an embodiment of the apparatus, the processor is configured to estimate the COLOR of a pixel in a layer of said reCOLORed focal stack wherein said pixel is not in focus by computing a weighted average of the COLORs associated to said pixel in other layers located before said layer in the reCOLORed focal stack.
[0020] According to an embodiment of the apparatus, the weights used in the computation of the weighted average are inversely proportional to a distance in the reCOLORed focal stack between the layer in which the COLOR to be associated to the pixel is computed and the layer wherein said pixel is in focus.
[0021] Another aspect of the invention concerns a method for modifying COLORs of a focal stack of a scene according to a COLOR palette comprising:
applying the COLOR palette to an all-in-focus image generated from said focal stack, estimating the COLOR of a not-in-focus pixel in a layer of a reCOLORed focal stack generated from the obtained reCOLORed all-in-focus image of the scene depending on a COLOR and on a position in said reCOLORed focal stack of at least one pixel in focus in at least one layer of said reCOLORed focal stack.
[0024] According to an embodiment of the method, the applied COLOR palette is the COLOR palette of an image of another scene.
[0025] According to an embodiment of the method, the image of the other scene is an all-in-focus image generated from a focal stack of the other scene.
[0026] According to an embodiment of the method, the method further comprises storing, during the generation of the all-in-focus image, a position in the focal stack of a layer wherein a pixel is in focus.
[0027] According to an embodiment of the method, the method further comprises generating the reCOLORed focal stack by putting a pixel of the reCOLORed all-in-focus image back into the layer of the reCOLORed focal stack wherein said pixel is focus.
[0028] According to an embodiment of the method, the method further comprises propagating the COLOR of a pixel in focus in a layer of the reCOLORed focal stack to the other layers of the reCOLORed focal stack by computing a convolution of said pixel in focus with a kernel.
[0029] According to an embodiment of the method, a size of the kernel is proportional to the position of a layer in the reCOLORed focal stack.
[0030] According to an embodiment of the method, when a pixel is in focus in a layer of the reCOLORed focal stack, the method further comprises associating the COLOR of said pixel in the reCOLORed all-in-focus to said pixel in focus in said layer of the reCOLORed focal stack.
[0031] According to an embodiment of the method, the method further comprises estimating the COLOR of a pixel in a layer of said reCOLORed focal stack wherein said pixel is not in focus by computing a weighted average of the COLORs associated to said pixel in other layers located before said layer in the reCOLORed focal stack.
[0032] According to an embodiment of the method, the weights used in the computation of the weighted average are inversely proportional to a distance in the reCOLORed focal stack between the layer in which the COLOR to be associated to the pixel is computed and the layer wherein said pixel is in focus.
[0033] Some processes implemented by elements of the invention may be computer implemented. Accordingly, such elements may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit”, “module” or “system”. Furthermore, such elements may take the form of a computer program product embodied in any tangible medium of expression having computer usable program code embodied in the medium.
[0034] Since elements of the present invention can be implemented in software, the present invention can be embodied as computer readable code for provision to a programmable apparatus on any suitable carrier medium. A tangible carrier medium may comprise a storage medium such as a floppy disk, a CD-ROM, a hard disk drive, a magnetic tape device or a solid state memory device and the like. A transient carrier medium may include a signal such as an electrical signal, an electronic signal, an optical signal, an acoustic signal, a magnetic signal or an electromagnetic signal, e.g. a microwave or RF signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Embodiments of the invention will now be described, by way of example only, and with reference to the following drawings in which:
[0036] FIG. 1A schematically represents a plenoptic camera,
[0037] FIG. 1B represents a multi-array camera,
[0038] FIG. 2 schematically illustrates a plan view of sensor regions arranged on the sensing surface of an image sensor of a light-field camera,
[0039] FIG. 3 illustrates a schematic light-field camera comprising an ideal, perfect thin lens model,
[0040] FIG. 4 represents a focal stack computed from acquired 4D light-field data,
[0041] FIG. 5 is a schematic block diagram illustrating an example of an apparatus for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present disclosure, and
[0042] FIG. 6 is a flow chart for explaining a process for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0043] As will be appreciated by one skilled in the art, aspects of the present principles can be embodied as a system, method or computer readable medium. Accordingly, aspects of the present principles can take the form of an entirely hardware embodiment, an entirely software embodiment, (including firmware, resident software, micro-code, and so forth) or an embodiment combining software and hardware aspects that can all generally be referred to herein as a “circuit”, “module”, or “system”. Furthermore, aspects of the present principles can take the form of a computer readable storage medium. Any combination of one or more computer readable storage medium (a) may be utilized.
[0044] A plenoptic camera is able to measure the amount of light traveling along each bundle of rays that intersects a sensor, by arranging a microlens array between a main lens and the sensor. The data acquired by such a camera are called light-field data. These light-field data can be post-processed to reconstruct images of a scene from different viewpoints. The light-field data can be used to generate a focal stack which comprises a collection of images each having different re-focusing depth. As a result, a user can change a focal point of the images. Compared to a conventional camera, the plenoptic camera can obtain additional optical information components for achieving the reconstruction of the images of a scene from the different viewpoints and re-focusing depth by post-processing.
[0045] FIG. 1A is a diagram schematically representing a plenoptic camera 100 . Light-field cameras are capable of recording four-dimensional (or 4D) light-field data. The plenoptic camera 100 comprises a main lens 101 , a microlens array 102 and an image sensor 104 .
[0046] FIG. 1B represents a multi-array camera 110 . The multi-array camera 110 comprises a lens array 112 and an image sensor 114 .
[0047] In the example of the plenoptic camera 100 as shown in FIG. 1A , the main lens 101 receives light from an object (not shown on the figure) in an object field of the main lens 101 and passes the light through an image field of the main lens 101 . The microlens array 102 includes a plurality of microlenses 103 arranged in a two-dimensional array.
[0048] Data captured by a light-field camera can be post-processed to reconstruct images of a scene from different points of view. Since a light-field camera is capable of capturing a collection of partial views of a same scene from slightly changed point of views, it is possible to create an image with a customized focus plane by combining those different partial views.
[0049] FIG. 2 is a plan view schematically illustrating an example of sensor regions arranged on the sensing surface of an image sensor of a light-field camera. As illustrated in FIG. 2 , the image sensor 200 includes a plurality of pixels 201 arranged in a two-dimensional array, and receives the light from the object through the microlens array 202 . Each of the microlenses 203 of the microlens array 202 has the lens properties to direct the light to a circular area 204 on the image sensor 200 . An outer contour of the circular area 204 may represent the shape of a microlens image formed and captured on the image sensor 200 , which shape depends on the shape of the microlens 203 . Amongst all of the pixels 201 on the image sensor 200 , only the pixels 201 located substantially inside the circular area 204 contribute to the imaging. In other words, a pixel area (or sensing area) of each pixel 201 that contributes to the imaging is located substantially inside the circular area 204 .
[0050] The image sensor 200 of a light-field camera records an image comprising a collection of two-dimensional (or 2D) microlens images arranged within a 2D image. Each microlens 203 of the microlens array 202 forms a microlens image represented by a circular area 204 . Coordinates of pixels 201 on the sensor 200 are indicated by an ordered pair (x, y) in a x-y coordinate system on the surface of the image sensor 200 as shown in FIG. 2 . A distance p is the distance between two consecutive microlens images. Microlenses 203 are chosen such that the distance p is larger than the size of a pixel 201 . A distance w is the disparity distance between two consecutive microlens images. Microlens images are referred by their respective coordinates (i,j) in a i-j coordinate system on the surface of the image sensor 200 as shown in FIG. 2 .
[0051] As mentioned above, only the pixels 201 located substantially inside the circular area 204 receive the light through a microlens 203 . The inter microlens space may be masked out to prevent photons to pass outside a microlens 203 . If the microlenses 203 have a square shape and the inter microlens space is not formed, such a masking is not needed.
[0052] The center of a microlens image (i,j) is located on the image sensor 200 at the coordinate (x i,j , y i,j ) in the x-y coordinate system. A θ represents an angle between the square lattice of pixels 201 and the square lattice of microlenses 204 . The coordinates (x i,j , y i,j ) of the center of the microlens image can be deduced by the following equation (1) considering (x 0,0 , y 0,0 ) as the pixel coordinate of the microlens image (0,0):
[0000]
[
x
i
,
j
y
i
,
j
]
=
p
[
cos
θ
-
sin
θ
sin
θ
cos
θ
]
[
i
j
]
+
[
x
0
,
0
y
0
,
0
]
(
1
)
[0053] The distances p and w are given in unit of pixel. They are converted into physical unit of distance, for example meters, P and W, respectively, by multiplying the pixel size δ in meters: W=δw and P=δp. These distances depend on the characteristics of the light-field camera.
[0054] Here, exemplary optical properties of a light-field camera will be discussed with reference to FIG. 3 which illustrates a schematic light-field camera comprising an ideal, perfect thin lens model.
[0055] The main lens 301 has a focal length F and an aperture Φ. The microlens array 302 comprises microlenses 303 having a focal length ƒ. The pitch of the microlens array 302 is φ. The microlens array 302 is located at a distance D from the main lens 301 and at a distance d from the sensor 304 . An object (not shown on the figure) is located at a distance z from the main lens 301 . This object is focused by the main lens 301 at a distance z′ from the main lens 301 . FIG. 3 illustrates the case where D>z′. In this case, microlens images can be in-focus on the sensor 304 depending on d and ƒ.
[0056] A major property of a light-field camera is the possibility to compute 2D re-focused images where the re-focalization distance is freely adjustable after the shot of the images.
[0057] A 4D light-field image L of size [N x ,N y ], where N x and N y represent the number of pixels along the x-axis and the y-axis respectively, is projected into a 2D image by shifting and zooming microlens images and then summing them into a 2D image. The amount of shift of the microlens images controls the re-focalization distance. The projection of a pixel of coordinates (x,y,i,j) in the 4D light-field image L into the re-focused 2D image coordinate (X, Y) is defined by:
[0000]
[
X
Y
]
=
sg
(
[
x
y
]
-
[
x
i
,
j
y
i
,
j
]
)
+
s
[
x
i
,
j
y
i
,
j
]
(
2
)
[0000] where s controls the size of the 2D re-focused image, and g controls the focalization distance of the re-focused image. This equation (6) can be rewritten as equation (7) by considering equation (1):
[0000]
[
X
Y
]
=
sg
[
x
y
]
+
sp
(
1
-
g
)
[
cos
θ
-
sin
θ
sin
θ
cos
θ
]
[
i
j
]
+
s
(
1
-
g
)
[
x
0
,
0
y
0
,
0
]
(
3
)
[0058] The parameter g can be expressed as function of p and w as in equation (4). The parameter g represents the zoom that must be performed on the microlens images, using their centers as reference, such that the various zoomed views of the same objects get superposed.
[0000]
g
=
p
p
-
w
(
4
)
[0059] Equation (3) becomes:
[0000]
[
X
Y
]
=
sg
[
x
y
]
-
sgw
[
cos
θ
-
sin
θ
sin
θ
cos
θ
]
[
i
j
]
+
sgw
p
[
x
0
,
0
y
0
,
0
]
(
5
)
[0060] In reference to FIG. 4 , a focal stack 40 is a collection of N re-focused images, or layers, R η (with η∈[1, N]) which define a cube of images, where N is a user selected number of images. The N re-focused images are computed for g varying linearly between g min and g max corresponding to a range of focalization distances between z min and z max defined by equation (4). Another option is to compute the focal stack with w varying linearly from w min and w max corresponding to a range of focalization distances between z min and z max defined by equation (4). The min max boundaries of g or w are defined by the user in order to encompass re-focused images with a focalization distance within z min and z max .
[0061] The computation of the focal stack 40 described in this embodiment is on the assumption that the 4D light-field data are recorded by a single image sensor with a lens array and optionally a main lens. However, the computation of a focal stack 40 is not limited to 4D light-field data recorded by such type of light-field camera, therefore it should be noted that it is possible to compute a focal stack of re-focused images by capturing with a classical camera several images of a same scene with different focus settings.
[0062] FIG. 5 is a schematic block diagram illustrating an example of an apparatus for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present disclosure.
[0063] The apparatus 500 comprises a processor 501 , a storage unit 502 , an input device 503 , a display device 504 , and an interface unit 505 which are connected by a bus 506 . Of course, constituent elements of the computer apparatus 500 may be connected by a connection other than a bus connection.
[0064] The processor 501 controls operations of the apparatus 500 . The storage unit 502 stores at least one program to be executed by the processor 501 , and various data, including data such as focal stacks of different scenes, images or COLOR palettes, parameters used by computations performed by the processor 501 , intermediate data of computations performed by the processor 501 , and so on. The processor 501 may be formed by any known and suitable hardware, or software, or a combination of hardware and software. For example, the processor 501 may be formed by dedicated hardware such as a processing circuit, or by a programmable processing unit such as a CPU (Central Processing Unit) that executes a program stored in a memory thereof.
[0065] The storage unit 502 may be formed by any suitable storage or means capable of storing the program, data, or the like in a computer-readable manner. Examples of the storage unit 502 include non-transitory computer-readable storage media such as semiconductor memory devices, and magnetic, optical, or magneto-optical recording media loaded into a read and write unit. The program causes the processor 501 to perform a process for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present invention as described hereinafter with reference to FIG. 6 .
[0066] The input device 503 may be formed by a keyboard, a pointing device such as a mouse, or the like for use by the user to input commands, to make user's selections of three-dimensional (or 3D) models of an object of interest use to define a re-focusing surface. The output device 504 may be formed by a display device to display, for example, a Graphical User Interface (GUI), images generated according to an embodiment of the present disclosure. The input device 503 and the output device 504 may be formed integrally by a touchscreen panel, for example.
[0067] The interface unit 505 provides an interface between the apparatus 500 and an external apparatus. The interface unit 505 may be communicable with the external apparatus via cable or wireless communication. In an embodiment, the external apparatus may be a light-field camera. In this case, data of 4D light-field images captured by the light-field camera can be input from the light-field camera to the apparatus 500 through the interface unit 505 , then stored in the storage unit 502 .
[0068] In this embodiment the apparatus 500 is exemplary discussed as it is separated from the light-field camera and they are communicable each other via cable or wireless communication, however it should be noted that the apparatus 500 can be integrated with such a light-field camera. In this later case, the apparatus 500 may be for example a portable device such as a tablet or a smartphone embedding a light-field camera.
[0069] FIG. 6 is a flow chart for explaining a process for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present invention.
[0070] During a step 601 , the processor 501 executes a GUI function on the display 504 of the apparatus 500 . This GUI function allows a user of the apparatus 500 to select a focal stack of a first scene from a plurality of focal stacks stored in the storage unit 502 of the apparatus 500 .
[0071] Once the focal stack of the first scene is selected, the processor 501 computes an all-in-focus image of the first scene based on the selected focal stack during a step 602 . An all-in-focus image is an image in which all the points constituting the image are in focus. The processor 601 computes the all-in-focus image of the first scene by selecting in each layers of the focal stack of the first scene the pixels which are in focus this layer and placing them in a same image which is the all-in-focus image of the first scene.
[0072] In a step 603 , the processor 501 stores, in the storage unit 502 of the apparatus 500 , for each pixel constituting the all-in-focus image of the first scene an index of the layer of the focal stack of the first scene in which said pixel is in focus. An index of a layer of the focal stack represents the position of a layer in a focal stack. For example, a layer with an index equal to 1 is for example the foreground layer of the focal stack and a layer with an index equal to N is the background layer of the focal stack.
[0073] In a step 604 , the processor 501 executes a GUI function on the display 504 of the apparatus 500 . This GUI function allows a user of the apparatus 500 to select a COLOR palette a plurality of COLOR palettes stored in the storage unit 502 of the apparatus 500 .
[0074] A COLOR palette is a given, finite set of colors for the management of digital images. In an embodiment of the invention, the selected COLOR palette is the COLOR palette of an image of a second scene stored in the storage unit 502 of the apparatus 500 .
[0075] In another embodiment of the invention the image of the second scene is an all-in-focus image computed based on a focal stack of the second scene. The all-in-focus image of the second scene may be directly stored in the storage unit 502 of the apparatus 500 or may be computed by the processor 501 .
[0076] In a step 605 , the processor 501 applies the selected COLOR palette to the all-in-focus image of the first scene, this is called COLOR transfer. COLOR transfer consists in modifying the COLORs of an original image such that it acquires the COLOR palette of another image. A COLOR transfer technique that may be executed by the processor 501 is disclosed in Frigo et al. “Optimal Transportation for Example-Guided COLOR Transfer”, Asian Conference on Computer Vision, 2014. The result of the transferring of the COLOR palette to the all-in-focus image if the first scene is a reCOLORed all-in-focus image of the first scene.
[0077] During a step 606 , the processor 501 generates a reCOLORed focal stack of the first scene based on the reCOLORed all-in-focus image of the first scene. The reCOLORed focal stack of the first scene is obtained by replacing each pixel of the reCOLORed all-in-focus image in the layer of the reCOLORed focal stack in which said pixel is in focus. This is made possible because the index of the layer of the reCOLORed focal stack of the first scene in which a pixel is in focus is stored in the storage unit 502 of the apparatus 500 for each pixel constituting the reCOLORed all-in-focus image of the first scene.
[0078] In a step 607 , the processor 501 propagates the COLOR of the pixels in focus to the different layers of the reCOLORed focal stack. In order to propagate the COLOR of a pixel in focus to the other layers of the reCOLORed focal stack, the processor 501 computes a convolution of a pixel in focus with a kernel. In image processing, a kernel, or convolution matrix, is a small matrix used for blurring, or sharpening, etc. an image by computing the convolution between the kernel and an image.
[0079] This computation is done for each layer of the reCOLORed focal stack other than the layer wherein the pixel considered for the computation is in focus. In an embodiment of the invention, the kernel is a Gaussian kernel. In another embodiment of the invention, the kernel is a crenel kernel. The type of the kernel, i.e. Gaussian or crenel, gives the geometry of the bokeh of the reCOLORed focal stack.
[0080] In order to preserve the quality of the bokeh in the reCOLORed focal stack and to allow a smooth navigation between the different layers of the reCOLORed focal stack, the size of the kernel is proportional to the absolute value of the difference between the index of the layer wherein the pixel considered for the computation is in focus and the index of the layer in the reCOLORed focal stack. That is to say, the greater the absolute value of the index difference the greater the size of the kernel used in the convulsion. Thus, the farther a layer of the reCOLORed focal stack is from the layer wherein the pixel considered for the computation is in focus, the greater the number of pixels of said layer the COLOR of the pixel in focus is associated to.
[0081] In an embodiment of the invention, the characteristic of a point spread function of the optical system with which the focal stack was captured are determined by the processor 501 from the focal stack and used for propagating the COLORs in the reCOLORed focal stack. This enables the reproduction of the optical effects found in the focal stack in the reCOLORed focal stack.
[0082] As a consequence of the propagation of the COLORs of the different pixels in focus in the reCOLORed focal stack, several COLORs are available for a given pixel in a given layer of the reCOLORed focal stack. In order to estimate the COLOR of a given pixel in a given layer of the reCOLORed focal stack, the processor 501 determines if the considered pixel is in focus in said layer of the reCOLORed focal stack during a step 608 .
[0083] If the considered pixel is in focus in said layer, then the processor 501 associate to said pixel the COLOR of the considered pixel in the reCOLORed all-in-focus image in a step 609 .
[0084] If the considered pixel is not in focus in said layer, then the processor 501 determines if there is at least one layer in the reCOLORed focal stack having an index smaller than the index of the considered layer in a step 610 . That is to say, the processor 501 determines if there is at least one layer in the reCOLORed focal stack located before the considered layer, for example the layer of the reCOLORed focal stack which index is 3 is located before the layer of the reCOLORed focal stack which index is 4. In the same way, the layer of the reCOLORed focal stack which index is 5 is located behind the layer of the reCOLORed focal stack which index is 4. The smaller the index of the layer in the focal stack the smaller the depth of field of the layer of the focal stack.
[0085] In a step 611 , the processor 501 estimates the COLOR of the considered pixel by computing a weighted average of the COLORs associated to said pixel in all the layers of the reCOLORed focal stack which have a smaller index than the layer of the reCOLORed focal stack to which the considered pixel belongs.
[0086] If the considered pixel is not in focus in said layer and there is no layer in the reCOLORed focal stack having an index smaller than the index of layer to which the considered pixel belongs, then the processor 501 estimates, in a step 612 , the COLOR of the considered pixel by computing a weighted average of the COLORs associated to said pixel in all the layers of the reCOLORed focal stack which have a greater index than the layer of the reCOLORed focal stack to which the considered pixel belongs. That is to say, the processor 501 considers the layers located behind the layer to which the considered pixel belongs.
[0087] The weights used by the processor 501 during the computation of the weighted averages in steps 611 and 612 are inversely proportional to the distance in the reCOLORed focal stack between the layer in which the COLOR to be associated to the pixel is computed and the layer wherein said pixel is in focus, i.e. the greater the absolute value of the difference between the indexes of the layers the smaller the weight.
[0088] Steps 607 to 612 are executed by the processor 501 for each pixel of each layer of the reCOLORed focal stack.
[0089] Although the present invention has been described hereinabove with reference to specific embodiments, the present invention is not limited to the specific embodiments, and modifications will be apparent to a skilled person in the art which lie within the scope of the present invention.
[0090] Many further modifications and variations will suggest themselves to those versed in the art upon making reference to the foregoing illustrative embodiments, which are given by way of example only and which are not intended to limit the scope of the invention, that being determined solely by the appended claims. In particular the different features from different embodiments may be interchanged, where appropriate. | The present invention generally relates to COLOR transfer between two images. COLOR transfer is a known technic consisting in modifying the COLORs of a source image by applying the COLOR palette of an example image without changing the source image structure. A lot of COLOR transfer method are known which consist in transferring COLORs between two images, however, those methods do not preserve the quality of the bokeh in areas of an images that are not in focus at a given depth. This results in a navigation in the depth dimension that is not smooth. It is proposed to modify the COLORs of a focal stack of a scene according to a COLOR palette by propagating the COLORs of the pixels in focus in different layers of the reCOLORed focal stack to the layers of the reCOLORed focal stack located behind the layer wherein a considered pixel is in focus. | Briefly summarize the main idea's components and working principles as described in the context. | [
"TECHNICAL FIELD [0001] The present disclosure relates to an apparatus and a method for modifying colors of a focal stack of a scene according to a color palette.",
"BACKGROUND [0002] Color transfer is a known technic consisting in modifying the COLORs of a source image by applying the COLOR palette of an example image without changing the source image structure.",
"[0003] A lot of color transfer method are known which consist in transferring colors between two images.",
"One of these methods is disclosed in Frigo et al.",
"“Optimal Transportation for Example-Guided COLOR Transfer”, Asian Conference on Computer Vision, 2014.",
"[0004] Such a method consists in processing separately the processing of the luminance and the chroma channels of an image.",
"The luminance channel is addressed using a chromatic adaption transform, accounting for the illuminant change, while the chroma channels are transformed using an optimal transportation.",
"[0005] The chromatic adaptation transform consists in modifying the illuminant of the input image with respect to the example image illuminant.",
"In order to do so, the color of the illuminant of the example image is estimated.",
"The illuminant of the input image is then modified so as to adapt to the estimated illuminant of the example image.",
"[0006] In order to define the COLOR chroma transfer, set of modes from the input image and example image are extracted.",
"Then, a COLOR transfer based on an optimal mapping between these two sets of modes is performed.",
"[0007] Such a method does not preserve the quality of the bokeh in areas of an images that are not in focus at a given depth.",
"This results in a navigation in the depth dimension that is not smooth.",
"[0008] The present invention has been devised with the foregoing in mind.",
"SUMMARY OF INVENTION [0009] A first aspect of the invention concerns an apparatus for modifying COLORs of a focal stack of a scene according to a COLOR palette comprising a processor configured to: applying the COLOR palette to an all-in-focus image generated from said focal stack, estimating the COLOR of a not-in-focus pixel in a layer of a reCOLORed focal stack generated from the obtained reCOLORed all-in-focus image of the scene depending on a COLOR and on a position in said reCOLORed focal stack of at least one pixel in focus in at least one layer of said reCOLORed focal stack.",
"[0012] According to an embodiment of the apparatus, the processor is configured to apply the COLOR palette of an image of another scene.",
"[0013] According to an embodiment of the apparatus, the image of the other scene is an all-in-focus image generated from a focal stack of the other scene.",
"[0014] According to an embodiment of the apparatus, the processor is configured to store, during the generation of the all-in-focus image, a position in the focal stack of a layer wherein a pixel is in focus.",
"[0015] According to an embodiment of the apparatus, the processor is configured to generate the reCOLORed focal stack by putting a pixel of the reCOLORed all-in-focus image back into the layer of the reCOLORed focal stack wherein said pixel is focus.",
"[0016] According to an embodiment of the apparatus, the processor is configured to propagate the COLOR of a pixel in focus in a layer of the reCOLORed focal stack to the other layers of the reCOLORed focal stack by computing a convolution of said pixel in focus with a kernel.",
"[0017] According to an embodiment of the apparatus, a size of the kernel is proportional to the position of a layer in the reCOLORed focal stack.",
"[0018] According to an embodiment of the apparatus, when a pixel is in focus in a layer of the reCOLORed focal stack, the processor is configured to associate the COLOR of said pixel in the reCOLORed all-in-focus to said pixel in focus in said layer of the reCOLORed focal stack.",
"[0019] According to an embodiment of the apparatus, the processor is configured to estimate the COLOR of a pixel in a layer of said reCOLORed focal stack wherein said pixel is not in focus by computing a weighted average of the COLORs associated to said pixel in other layers located before said layer in the reCOLORed focal stack.",
"[0020] According to an embodiment of the apparatus, the weights used in the computation of the weighted average are inversely proportional to a distance in the reCOLORed focal stack between the layer in which the COLOR to be associated to the pixel is computed and the layer wherein said pixel is in focus.",
"[0021] Another aspect of the invention concerns a method for modifying COLORs of a focal stack of a scene according to a COLOR palette comprising: applying the COLOR palette to an all-in-focus image generated from said focal stack, estimating the COLOR of a not-in-focus pixel in a layer of a reCOLORed focal stack generated from the obtained reCOLORed all-in-focus image of the scene depending on a COLOR and on a position in said reCOLORed focal stack of at least one pixel in focus in at least one layer of said reCOLORed focal stack.",
"[0024] According to an embodiment of the method, the applied COLOR palette is the COLOR palette of an image of another scene.",
"[0025] According to an embodiment of the method, the image of the other scene is an all-in-focus image generated from a focal stack of the other scene.",
"[0026] According to an embodiment of the method, the method further comprises storing, during the generation of the all-in-focus image, a position in the focal stack of a layer wherein a pixel is in focus.",
"[0027] According to an embodiment of the method, the method further comprises generating the reCOLORed focal stack by putting a pixel of the reCOLORed all-in-focus image back into the layer of the reCOLORed focal stack wherein said pixel is focus.",
"[0028] According to an embodiment of the method, the method further comprises propagating the COLOR of a pixel in focus in a layer of the reCOLORed focal stack to the other layers of the reCOLORed focal stack by computing a convolution of said pixel in focus with a kernel.",
"[0029] According to an embodiment of the method, a size of the kernel is proportional to the position of a layer in the reCOLORed focal stack.",
"[0030] According to an embodiment of the method, when a pixel is in focus in a layer of the reCOLORed focal stack, the method further comprises associating the COLOR of said pixel in the reCOLORed all-in-focus to said pixel in focus in said layer of the reCOLORed focal stack.",
"[0031] According to an embodiment of the method, the method further comprises estimating the COLOR of a pixel in a layer of said reCOLORed focal stack wherein said pixel is not in focus by computing a weighted average of the COLORs associated to said pixel in other layers located before said layer in the reCOLORed focal stack.",
"[0032] According to an embodiment of the method, the weights used in the computation of the weighted average are inversely proportional to a distance in the reCOLORed focal stack between the layer in which the COLOR to be associated to the pixel is computed and the layer wherein said pixel is in focus.",
"[0033] Some processes implemented by elements of the invention may be computer implemented.",
"Accordingly, such elements may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit”, “module”",
"or “system.”",
"Furthermore, such elements may take the form of a computer program product embodied in any tangible medium of expression having computer usable program code embodied in the medium.",
"[0034] Since elements of the present invention can be implemented in software, the present invention can be embodied as computer readable code for provision to a programmable apparatus on any suitable carrier medium.",
"A tangible carrier medium may comprise a storage medium such as a floppy disk, a CD-ROM, a hard disk drive, a magnetic tape device or a solid state memory device and the like.",
"A transient carrier medium may include a signal such as an electrical signal, an electronic signal, an optical signal, an acoustic signal, a magnetic signal or an electromagnetic signal, e.g. a microwave or RF signal.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0035] Embodiments of the invention will now be described, by way of example only, and with reference to the following drawings in which: [0036] FIG. 1A schematically represents a plenoptic camera, [0037] FIG. 1B represents a multi-array camera, [0038] FIG. 2 schematically illustrates a plan view of sensor regions arranged on the sensing surface of an image sensor of a light-field camera, [0039] FIG. 3 illustrates a schematic light-field camera comprising an ideal, perfect thin lens model, [0040] FIG. 4 represents a focal stack computed from acquired 4D light-field data, [0041] FIG. 5 is a schematic block diagram illustrating an example of an apparatus for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present disclosure, and [0042] FIG. 6 is a flow chart for explaining a process for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present invention.",
"DETAILED DESCRIPTION [0043] As will be appreciated by one skilled in the art, aspects of the present principles can be embodied as a system, method or computer readable medium.",
"Accordingly, aspects of the present principles can take the form of an entirely hardware embodiment, an entirely software embodiment, (including firmware, resident software, micro-code, and so forth) or an embodiment combining software and hardware aspects that can all generally be referred to herein as a “circuit”, “module”, or “system.”",
"Furthermore, aspects of the present principles can take the form of a computer readable storage medium.",
"Any combination of one or more computer readable storage medium (a) may be utilized.",
"[0044] A plenoptic camera is able to measure the amount of light traveling along each bundle of rays that intersects a sensor, by arranging a microlens array between a main lens and the sensor.",
"The data acquired by such a camera are called light-field data.",
"These light-field data can be post-processed to reconstruct images of a scene from different viewpoints.",
"The light-field data can be used to generate a focal stack which comprises a collection of images each having different re-focusing depth.",
"As a result, a user can change a focal point of the images.",
"Compared to a conventional camera, the plenoptic camera can obtain additional optical information components for achieving the reconstruction of the images of a scene from the different viewpoints and re-focusing depth by post-processing.",
"[0045] FIG. 1A is a diagram schematically representing a plenoptic camera 100 .",
"Light-field cameras are capable of recording four-dimensional (or 4D) light-field data.",
"The plenoptic camera 100 comprises a main lens 101 , a microlens array 102 and an image sensor 104 .",
"[0046] FIG. 1B represents a multi-array camera 110 .",
"The multi-array camera 110 comprises a lens array 112 and an image sensor 114 .",
"[0047] In the example of the plenoptic camera 100 as shown in FIG. 1A , the main lens 101 receives light from an object (not shown on the figure) in an object field of the main lens 101 and passes the light through an image field of the main lens 101 .",
"The microlens array 102 includes a plurality of microlenses 103 arranged in a two-dimensional array.",
"[0048] Data captured by a light-field camera can be post-processed to reconstruct images of a scene from different points of view.",
"Since a light-field camera is capable of capturing a collection of partial views of a same scene from slightly changed point of views, it is possible to create an image with a customized focus plane by combining those different partial views.",
"[0049] FIG. 2 is a plan view schematically illustrating an example of sensor regions arranged on the sensing surface of an image sensor of a light-field camera.",
"As illustrated in FIG. 2 , the image sensor 200 includes a plurality of pixels 201 arranged in a two-dimensional array, and receives the light from the object through the microlens array 202 .",
"Each of the microlenses 203 of the microlens array 202 has the lens properties to direct the light to a circular area 204 on the image sensor 200 .",
"An outer contour of the circular area 204 may represent the shape of a microlens image formed and captured on the image sensor 200 , which shape depends on the shape of the microlens 203 .",
"Amongst all of the pixels 201 on the image sensor 200 , only the pixels 201 located substantially inside the circular area 204 contribute to the imaging.",
"In other words, a pixel area (or sensing area) of each pixel 201 that contributes to the imaging is located substantially inside the circular area 204 .",
"[0050] The image sensor 200 of a light-field camera records an image comprising a collection of two-dimensional (or 2D) microlens images arranged within a 2D image.",
"Each microlens 203 of the microlens array 202 forms a microlens image represented by a circular area 204 .",
"Coordinates of pixels 201 on the sensor 200 are indicated by an ordered pair (x, y) in a x-y coordinate system on the surface of the image sensor 200 as shown in FIG. 2 .",
"A distance p is the distance between two consecutive microlens images.",
"Microlenses 203 are chosen such that the distance p is larger than the size of a pixel 201 .",
"A distance w is the disparity distance between two consecutive microlens images.",
"Microlens images are referred by their respective coordinates (i,j) in a i-j coordinate system on the surface of the image sensor 200 as shown in FIG. 2 .",
"[0051] As mentioned above, only the pixels 201 located substantially inside the circular area 204 receive the light through a microlens 203 .",
"The inter microlens space may be masked out to prevent photons to pass outside a microlens 203 .",
"If the microlenses 203 have a square shape and the inter microlens space is not formed, such a masking is not needed.",
"[0052] The center of a microlens image (i,j) is located on the image sensor 200 at the coordinate (x i,j , y i,j ) in the x-y coordinate system.",
"A θ represents an angle between the square lattice of pixels 201 and the square lattice of microlenses 204 .",
"The coordinates (x i,j , y i,j ) of the center of the microlens image can be deduced by the following equation (1) considering (x 0,0 , y 0,0 ) as the pixel coordinate of the microlens image (0,0): [0000] [ x i , j y i , j ] = p [ cos θ - sin θ sin θ cos θ ] [ i j ] + [ x 0 , 0 y 0 , 0 ] ( 1 ) [0053] The distances p and w are given in unit of pixel.",
"They are converted into physical unit of distance, for example meters, P and W, respectively, by multiplying the pixel size δ in meters: W=δw and P=δp.",
"These distances depend on the characteristics of the light-field camera.",
"[0054] Here, exemplary optical properties of a light-field camera will be discussed with reference to FIG. 3 which illustrates a schematic light-field camera comprising an ideal, perfect thin lens model.",
"[0055] The main lens 301 has a focal length F and an aperture Φ.",
"The microlens array 302 comprises microlenses 303 having a focal length ƒ.",
"The pitch of the microlens array 302 is φ.",
"The microlens array 302 is located at a distance D from the main lens 301 and at a distance d from the sensor 304 .",
"An object (not shown on the figure) is located at a distance z from the main lens 301 .",
"This object is focused by the main lens 301 at a distance z′ from the main lens 301 .",
"FIG. 3 illustrates the case where D>z′.",
"In this case, microlens images can be in-focus on the sensor 304 depending on d and ƒ.",
"[0056] A major property of a light-field camera is the possibility to compute 2D re-focused images where the re-focalization distance is freely adjustable after the shot of the images.",
"[0057] A 4D light-field image L of size [N x ,N y ], where N x and N y represent the number of pixels along the x-axis and the y-axis respectively, is projected into a 2D image by shifting and zooming microlens images and then summing them into a 2D image.",
"The amount of shift of the microlens images controls the re-focalization distance.",
"The projection of a pixel of coordinates (x,y,i,j) in the 4D light-field image L into the re-focused 2D image coordinate (X, Y) is defined by: [0000] [ X Y ] = sg ( [ x y ] - [ x i , j y i , j ] ) + s [ x i , j y i , j ] ( 2 ) [0000] where s controls the size of the 2D re-focused image, and g controls the focalization distance of the re-focused image.",
"This equation (6) can be rewritten as equation (7) by considering equation (1): [0000] [ X Y ] = sg [ x y ] + sp ( 1 - g ) [ cos θ - sin θ sin θ cos θ ] [ i j ] + s ( 1 - g ) [ x 0 , 0 y 0 , 0 ] ( 3 ) [0058] The parameter g can be expressed as function of p and w as in equation (4).",
"The parameter g represents the zoom that must be performed on the microlens images, using their centers as reference, such that the various zoomed views of the same objects get superposed.",
"[0000] g = p p - w ( 4 ) [0059] Equation (3) becomes: [0000] [ X Y ] = sg [ x y ] - sgw [ cos θ - sin θ sin θ cos θ ] [ i j ] + sgw p [ x 0 , 0 y 0 , 0 ] ( 5 ) [0060] In reference to FIG. 4 , a focal stack 40 is a collection of N re-focused images, or layers, R η (with η∈[1, N]) which define a cube of images, where N is a user selected number of images.",
"The N re-focused images are computed for g varying linearly between g min and g max corresponding to a range of focalization distances between z min and z max defined by equation (4).",
"Another option is to compute the focal stack with w varying linearly from w min and w max corresponding to a range of focalization distances between z min and z max defined by equation (4).",
"The min max boundaries of g or w are defined by the user in order to encompass re-focused images with a focalization distance within z min and z max .",
"[0061] The computation of the focal stack 40 described in this embodiment is on the assumption that the 4D light-field data are recorded by a single image sensor with a lens array and optionally a main lens.",
"However, the computation of a focal stack 40 is not limited to 4D light-field data recorded by such type of light-field camera, therefore it should be noted that it is possible to compute a focal stack of re-focused images by capturing with a classical camera several images of a same scene with different focus settings.",
"[0062] FIG. 5 is a schematic block diagram illustrating an example of an apparatus for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present disclosure.",
"[0063] The apparatus 500 comprises a processor 501 , a storage unit 502 , an input device 503 , a display device 504 , and an interface unit 505 which are connected by a bus 506 .",
"Of course, constituent elements of the computer apparatus 500 may be connected by a connection other than a bus connection.",
"[0064] The processor 501 controls operations of the apparatus 500 .",
"The storage unit 502 stores at least one program to be executed by the processor 501 , and various data, including data such as focal stacks of different scenes, images or COLOR palettes, parameters used by computations performed by the processor 501 , intermediate data of computations performed by the processor 501 , and so on.",
"The processor 501 may be formed by any known and suitable hardware, or software, or a combination of hardware and software.",
"For example, the processor 501 may be formed by dedicated hardware such as a processing circuit, or by a programmable processing unit such as a CPU (Central Processing Unit) that executes a program stored in a memory thereof.",
"[0065] The storage unit 502 may be formed by any suitable storage or means capable of storing the program, data, or the like in a computer-readable manner.",
"Examples of the storage unit 502 include non-transitory computer-readable storage media such as semiconductor memory devices, and magnetic, optical, or magneto-optical recording media loaded into a read and write unit.",
"The program causes the processor 501 to perform a process for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present invention as described hereinafter with reference to FIG. 6 .",
"[0066] The input device 503 may be formed by a keyboard, a pointing device such as a mouse, or the like for use by the user to input commands, to make user's selections of three-dimensional (or 3D) models of an object of interest use to define a re-focusing surface.",
"The output device 504 may be formed by a display device to display, for example, a Graphical User Interface (GUI), images generated according to an embodiment of the present disclosure.",
"The input device 503 and the output device 504 may be formed integrally by a touchscreen panel, for example.",
"[0067] The interface unit 505 provides an interface between the apparatus 500 and an external apparatus.",
"The interface unit 505 may be communicable with the external apparatus via cable or wireless communication.",
"In an embodiment, the external apparatus may be a light-field camera.",
"In this case, data of 4D light-field images captured by the light-field camera can be input from the light-field camera to the apparatus 500 through the interface unit 505 , then stored in the storage unit 502 .",
"[0068] In this embodiment the apparatus 500 is exemplary discussed as it is separated from the light-field camera and they are communicable each other via cable or wireless communication, however it should be noted that the apparatus 500 can be integrated with such a light-field camera.",
"In this later case, the apparatus 500 may be for example a portable device such as a tablet or a smartphone embedding a light-field camera.",
"[0069] FIG. 6 is a flow chart for explaining a process for modifying COLORs of a focal stack of a scene according to a COLOR palette according to an embodiment of the present invention.",
"[0070] During a step 601 , the processor 501 executes a GUI function on the display 504 of the apparatus 500 .",
"This GUI function allows a user of the apparatus 500 to select a focal stack of a first scene from a plurality of focal stacks stored in the storage unit 502 of the apparatus 500 .",
"[0071] Once the focal stack of the first scene is selected, the processor 501 computes an all-in-focus image of the first scene based on the selected focal stack during a step 602 .",
"An all-in-focus image is an image in which all the points constituting the image are in focus.",
"The processor 601 computes the all-in-focus image of the first scene by selecting in each layers of the focal stack of the first scene the pixels which are in focus this layer and placing them in a same image which is the all-in-focus image of the first scene.",
"[0072] In a step 603 , the processor 501 stores, in the storage unit 502 of the apparatus 500 , for each pixel constituting the all-in-focus image of the first scene an index of the layer of the focal stack of the first scene in which said pixel is in focus.",
"An index of a layer of the focal stack represents the position of a layer in a focal stack.",
"For example, a layer with an index equal to 1 is for example the foreground layer of the focal stack and a layer with an index equal to N is the background layer of the focal stack.",
"[0073] In a step 604 , the processor 501 executes a GUI function on the display 504 of the apparatus 500 .",
"This GUI function allows a user of the apparatus 500 to select a COLOR palette a plurality of COLOR palettes stored in the storage unit 502 of the apparatus 500 .",
"[0074] A COLOR palette is a given, finite set of colors for the management of digital images.",
"In an embodiment of the invention, the selected COLOR palette is the COLOR palette of an image of a second scene stored in the storage unit 502 of the apparatus 500 .",
"[0075] In another embodiment of the invention the image of the second scene is an all-in-focus image computed based on a focal stack of the second scene.",
"The all-in-focus image of the second scene may be directly stored in the storage unit 502 of the apparatus 500 or may be computed by the processor 501 .",
"[0076] In a step 605 , the processor 501 applies the selected COLOR palette to the all-in-focus image of the first scene, this is called COLOR transfer.",
"COLOR transfer consists in modifying the COLORs of an original image such that it acquires the COLOR palette of another image.",
"A COLOR transfer technique that may be executed by the processor 501 is disclosed in Frigo et al.",
"“Optimal Transportation for Example-Guided COLOR Transfer”, Asian Conference on Computer Vision, 2014.",
"The result of the transferring of the COLOR palette to the all-in-focus image if the first scene is a reCOLORed all-in-focus image of the first scene.",
"[0077] During a step 606 , the processor 501 generates a reCOLORed focal stack of the first scene based on the reCOLORed all-in-focus image of the first scene.",
"The reCOLORed focal stack of the first scene is obtained by replacing each pixel of the reCOLORed all-in-focus image in the layer of the reCOLORed focal stack in which said pixel is in focus.",
"This is made possible because the index of the layer of the reCOLORed focal stack of the first scene in which a pixel is in focus is stored in the storage unit 502 of the apparatus 500 for each pixel constituting the reCOLORed all-in-focus image of the first scene.",
"[0078] In a step 607 , the processor 501 propagates the COLOR of the pixels in focus to the different layers of the reCOLORed focal stack.",
"In order to propagate the COLOR of a pixel in focus to the other layers of the reCOLORed focal stack, the processor 501 computes a convolution of a pixel in focus with a kernel.",
"In image processing, a kernel, or convolution matrix, is a small matrix used for blurring, or sharpening, etc.",
"an image by computing the convolution between the kernel and an image.",
"[0079] This computation is done for each layer of the reCOLORed focal stack other than the layer wherein the pixel considered for the computation is in focus.",
"In an embodiment of the invention, the kernel is a Gaussian kernel.",
"In another embodiment of the invention, the kernel is a crenel kernel.",
"The type of the kernel, i.e. Gaussian or crenel, gives the geometry of the bokeh of the reCOLORed focal stack.",
"[0080] In order to preserve the quality of the bokeh in the reCOLORed focal stack and to allow a smooth navigation between the different layers of the reCOLORed focal stack, the size of the kernel is proportional to the absolute value of the difference between the index of the layer wherein the pixel considered for the computation is in focus and the index of the layer in the reCOLORed focal stack.",
"That is to say, the greater the absolute value of the index difference the greater the size of the kernel used in the convulsion.",
"Thus, the farther a layer of the reCOLORed focal stack is from the layer wherein the pixel considered for the computation is in focus, the greater the number of pixels of said layer the COLOR of the pixel in focus is associated to.",
"[0081] In an embodiment of the invention, the characteristic of a point spread function of the optical system with which the focal stack was captured are determined by the processor 501 from the focal stack and used for propagating the COLORs in the reCOLORed focal stack.",
"This enables the reproduction of the optical effects found in the focal stack in the reCOLORed focal stack.",
"[0082] As a consequence of the propagation of the COLORs of the different pixels in focus in the reCOLORed focal stack, several COLORs are available for a given pixel in a given layer of the reCOLORed focal stack.",
"In order to estimate the COLOR of a given pixel in a given layer of the reCOLORed focal stack, the processor 501 determines if the considered pixel is in focus in said layer of the reCOLORed focal stack during a step 608 .",
"[0083] If the considered pixel is in focus in said layer, then the processor 501 associate to said pixel the COLOR of the considered pixel in the reCOLORed all-in-focus image in a step 609 .",
"[0084] If the considered pixel is not in focus in said layer, then the processor 501 determines if there is at least one layer in the reCOLORed focal stack having an index smaller than the index of the considered layer in a step 610 .",
"That is to say, the processor 501 determines if there is at least one layer in the reCOLORed focal stack located before the considered layer, for example the layer of the reCOLORed focal stack which index is 3 is located before the layer of the reCOLORed focal stack which index is 4.",
"In the same way, the layer of the reCOLORed focal stack which index is 5 is located behind the layer of the reCOLORed focal stack which index is 4.",
"The smaller the index of the layer in the focal stack the smaller the depth of field of the layer of the focal stack.",
"[0085] In a step 611 , the processor 501 estimates the COLOR of the considered pixel by computing a weighted average of the COLORs associated to said pixel in all the layers of the reCOLORed focal stack which have a smaller index than the layer of the reCOLORed focal stack to which the considered pixel belongs.",
"[0086] If the considered pixel is not in focus in said layer and there is no layer in the reCOLORed focal stack having an index smaller than the index of layer to which the considered pixel belongs, then the processor 501 estimates, in a step 612 , the COLOR of the considered pixel by computing a weighted average of the COLORs associated to said pixel in all the layers of the reCOLORed focal stack which have a greater index than the layer of the reCOLORed focal stack to which the considered pixel belongs.",
"That is to say, the processor 501 considers the layers located behind the layer to which the considered pixel belongs.",
"[0087] The weights used by the processor 501 during the computation of the weighted averages in steps 611 and 612 are inversely proportional to the distance in the reCOLORed focal stack between the layer in which the COLOR to be associated to the pixel is computed and the layer wherein said pixel is in focus, i.e. the greater the absolute value of the difference between the indexes of the layers the smaller the weight.",
"[0088] Steps 607 to 612 are executed by the processor 501 for each pixel of each layer of the reCOLORed focal stack.",
"[0089] Although the present invention has been described hereinabove with reference to specific embodiments, the present invention is not limited to the specific embodiments, and modifications will be apparent to a skilled person in the art which lie within the scope of the present invention.",
"[0090] Many further modifications and variations will suggest themselves to those versed in the art upon making reference to the foregoing illustrative embodiments, which are given by way of example only and which are not intended to limit the scope of the invention, that being determined solely by the appended claims.",
"In particular the different features from different embodiments may be interchanged, where appropriate."
] |
BACKGROUND
[0001] The present invention relates to a method and to an apparatus for determining the anatomic condition of components of the body of a human or of an animal and also to an exercise machine, in particular an adjustable exercise machine and to a computer program stored on a storage medium.
[0002] Although the present invention is principally concerned with diseases of the joints and soft tissues, or their therapeutic treatment and rehabilitation and also with corresponding apparatuses, the term “osteoporosis” and the significance of the illness should be briefly explained in order to be better able to explain the invention.
[0003] In accordance with various sources there are in Germany about 6-8 million people suffering from osteoporosis. As a result of the ¼ million fractures, in particular fractures of the neck of the femur, the cost of treating osteoporosis and the consequence of osteoporosis reach a sum in the tens of billions.
[0004] The bone substance undergoes a physiological restructuring. The cells which build up the bone mass and for example repair it after fracture are osteoblasts. They take calcium and other minerals from the blood and bind it in the bones. In this manner the bone substance becomes stronger. The other type of cells which break down bone substance and prevent excess bone growth are named osteoclasts.
[0005] In the physiological condition equilibrium exists between the two processes. With increasing age the decomposition of bones takes the upper hand. Some sources state that from the 25 th year of life onwards there is an increased break down of the bones, both in men and also in women.
[0006] Stated simply one understands under the term osteoporosis a porous fragile bone. Medically one has to distinguish it however from a relatively rare illness, osteomalacia. Both osteoporosis and also osteomalacia fall medically beneath the generic term osteopenie.
[0007] Independently of the causes of osteoporosis in women and men the same picture generating measures are used. The bone density is most frequently investigated by means of computer tomography. This method has however many disadvantages, such as exposure to radiation and influencing of the measurement results in the lower LWS by changes such as spondylophytes, osteochondrosis etc.
[0008] The increasingly most frequent method is the measurement with ultra sound. The patients are however here forced into orthopaedic and gynaecological practices in order to undergo an ultrasonic investigation. The precision of this measurement is, however, hitherto very unreliable as is known from the literature and from daily practice. The bone densitometry by means of ultra sound takes place in a frequency range from 200 kHz to 1 MHz and is additionally restricted by the legally prescribed health insurers. This is done for two reasons: on the one hand, as a result of the relatively high costs amounting to an average of 80-130 DM per investigation and, on the other hand, as a result of the above discussed unreliability of this method.
[0009] X-ray diagnosis only reliably shows osteoporotic changes when the reduction in bone density has passed about 30 percent. Densitometrie is in such cases no longer useful. Appropriate treatment is commenced even without this investigation.
[0010] The object of the invention is to set forth a new method and a new apparatus with which one can reliably carry out a series of investigations and diagnoses in connection with the anatomic condition of components of the body of an human or of an animal at favourable cost and indeed without having to carry out medical surgery or to take samples.
SUMMARY
[0011] In order to satisfy this object the method of the invention is characterized in that one produces a sound signal in the selected component by passive or active movements of at least one joint and records a sound signal at a point adjacent to the component and evaluates it.
[0012] An apparatus for carrying out the method of the invention consists of a sound recording device, a device which carries out a signal analysis and which preferably includes a low pass filter or a low pass function, and an output device for outputting the results of the signal analysis.
[0013] The invention is based on the recognition that sound signals, which are caused by movement of a joint in components of the body of an human or of an animal, enable, on appropriate evaluation, conclusions to be drawn on the condition of the respective components. For example the evaluation allows statements to be made concerning the material characteristics, the degree of mineralization, the ultra structure, the collagen structure, the micro structure and the geometry of the bone. Above all, however, the evaluation allows statements to be made concerning the anatomic condition of joints and of the soft tissues associated with them.
[0014] The evaluation can take place in accordance with the invention by filtration and spectral analysis and also includes in many cases a comparison with the reference values or reference patterns. In this connection the filtering that is used is normally understood as low pass filtering, for example in the range up to about 10 kHz. In this way the bandwidth is restricted. The analysis and evaluation is advantageously carried out by means of a computer program.
[0015] Under active movements one understands that the patient himself moves a selected joint. In contrast, for passive movements, a device is used which forces the movement of a selected joint. Advantageous in the use of active movements is that the patient is not made insecure or anxious by technical apparatus.
[0016] On the other hand, with passive movements, the speed and amplitude of the movement can be precisely and repeatedly preset so that the results from different patients can be better compared to one another here.
[0017] A special case of the passive generation of movement lies in the situation in which the doctor or another person moves the joint manually.
[0018] The invention is however not restricted to this. Examples for further possible applications are:
[0019] 1. Checking the bone consolidation (callus formation following fractures). With conservative therapy, i.e., without operational treatment, this measure can certainly be used.
[0020] For osteosynthetically treated bone fractures certain problems result with reliable references as a result of the diversity of the methods and the different types of metal implants.
[0021] Advantage: X-ray checks can be reduced to a minimum with conservatively treated fractures.
[0022] 2. Signal analysis of both legs with diffuse complaints, for example lower legs with young patients. It is known that primary bone lesions (tumours) statistically arise frequently in this group of patients.
[0023] An advantage lies in the fact that the measurement result can be used as an aid to a decision, as to whether further investigations are appropriate. For example, the absence of a difference between the two lower extremities can count as a reason for dispensing with further image forming processes.
[0024] When a difference of the signal analyses is present further investigations such as X-ray investigations or scintigraphic imaging must be carried out.
[0025] 3. For many other bone diseases, for example plasmozytoma (malignant tumour) the scull is frequently afflicted (“moth holes”). The tapping and signal analysis of the skull can preclude or confirm plastic and lytic bone changes. The consequences are further investigations such as X-ray investigations or computer tomography.
[0026] 4. The above named method can be used above all with diseases of the joints and soft tissue lesions. These include arthrosis (cartilage loss). Every person is effected by this in the course of life. The possibility of attaching a plurality of sensors at different positions is of advantage. In this way osteoarthroses of the knee (wear of the knee joint) can be precisely differentiated. It is assumed that a determination can be made on the basis of the signal analysis whether this is wear of the inner joint gap or of the outer joint gap. Wear of the rear of the patella could also be diagnosed.
[0027] With respect to the patella (knee cap) there are always diagnostic problems and indeed both clinical and also with image giving methods such as NMR. By means of the signal analysis carried out in accordance with the invention it can be determined whether problems are present at all at the rear side of the patella. The corresponding noises (spectra) can be associated with specific diseases from chondropathic patella, chondromalacic patella to retropatella arthrosis (cartilage loss at the rear side of the patella or of the sliding support for the patella).
[0028] 5. The method can also be used for various soft tissue diseases, for example:
[0029] pathology of the meniscus,
[0030] extent of achillodynia (the grating of the “paratenon”) in addition to sono-graphic estimation of the pathological situation.
[0031] coxa saltans (snapping hips).
[0032] labrum lesion of the shoulder joints.
[0033] rotator cuff lesions of the shoulder for example narrowing ( M. supraspinatus )
[0034] discus triangularis lesion—hitherto the biggest diagnostic problem even by means of NMR of the hand joint.
[0035] Possibly, one can obtain additional diagnostic advantages through the signal analysis carried out in accordance with the invention.
[0036] 6. A further conceivable application would be the portrayal of the carpal tunnel syndrome (very frequent disease—narrowing of the N. medianus in the carpal tunnel of the hand joint). This illness causes thousands of operations per year in Germany.
[0037] The diagnosis is normally made by means of nerve speed measurements of the N. medianus. Theoretically diagnosis appears to be possible with analysis of, for example, the tapping sound of the carpal tunnel (the tapping of the carpal tunnel is termed Hoffmann-Tinel-Test in orthopedics. In this test the result of the tapping is however not evaluated acoustically but rather through the subjective sense of pain of the patient). Appropriate references can possibly be found here.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The invention will be explained in more detail with reference to embodiments and to the accompanying drawings in which FIGS. 1 to 3 show a method for the diagnosis of osteoporosis whereas the further FIGS. 4 to 10 show examples of the invention. There are shown:
[0039] [0039]FIG. 1 a schematic diagram for the explanation of the method of the invention,
[0040] [0040]FIG. 2 a schematic diagram for the explanation of a possible variant of the signal evaluation in the method of FIG. 1,
[0041] [0041]FIG. 3A the result of a measurement in accordance with the invention on a healthy male patient of 42 years of age,
[0042] [0042]FIG. 3B the result of a measurement in accordance with the invention of a male patient suffering from osteoporosis and aged 44,
[0043] [0043]FIG. 3C the result of a measurement in accordance with the invention on a female patient suffering from osteoporosis and aged 64,
[0044] [0044]FIG. 3D the result of a measurement in accordance with the invention on an older female patient suffering from pronounced osteoporosis and aged 72,
[0045] [0045]FIG. 3E the recorded sound signal from the same patient as considered in FIG. 3A and
[0046] [0046]FIG. 3F the recorded sound signal from the same patient as considered in FIG. 3C,
[0047] [0047]FIGS. 4A to 4 C schematic representations of a healthy human knee joint,
[0048] [0048]FIG. 4D a schematic illustration of a human knee joint suffering under medial osteoarthrosis,
[0049] [0049]FIG. 5 a schematic illustration of a sound recording device in accordance with the invention,
[0050] [0050]FIG. 6A an orthosis for the knee joint,
[0051] [0051]FIG. 6B a modification of the orthosis of FIG. 6A in accordance with the invention,
[0052] [0052]FIG. 7A a spectral analysis of sound signals of a healthy human knee joint in accordance with the FIGS. 4A to 4 C,
[0053] [0053]FIG. 7B a histogram corresponding to FIG. 7A,
[0054] [0054]FIG. 8A a spectral analysis of sound signals of a human knee joint in accordance with FIG. 4D suffering medial osteoarthrosis,
[0055] [0055]FIG. 8B a histogram corresponding to FIG. 8A,
[0056] [0056]FIG. 9A a schematic representation of an exercise machine usable for the invention,
[0057] [0057]FIG. 9B a schematic diagram to explain an inventive setting of an exercise machine in accordance with FIG. 9A and
[0058] [0058]FIG. 10 a schematic representation of an apparatus with animation in accordance with the invention.
DETAILED DESCRIPTION
[0059] Noises arise in the human body through movements and internal friction. These noises can say something concerning the inner condition of the body. In the description attention is particularly directed to bone and joint noises. First of all a principle methodology for the determination and evaluation of these noises will be described, which has been investigated in the practice of the applicant in the diagnosis of osteoporosis. Then—building on this description—the present invention will be further explained with reference to FIGS. 4 to 10 . In diagnosing osteoporosis one is concerned primarily with the evaluation of the tapping noises (longitudinal vibrations) which are initiated with a device which always delivers the same pulses. One taps the selected measurement position (tibia head anatomically hardly any soft tissue cover) about 5 cm caudal.
[0060] Noises are basically longitudinal air vibrations which can be perceived by our ears. After reception they can be analyzed by the brain into a very broad spectrum. The human brain is able to recognize certain patterns from a sound—pattern recognition—or to sort out specific tones from it (filtering).
[0061] All these abilities are in reality very complicated mechanisms which first become aware to us on attempting to realize these abilities artificially.
[0062] Precisely these problems have occupied scientists from all fields for decades. In the course of the years ever more powerful tools (systems) have arisen for the analysis or pattern recognition of sound signals. One can see this in the performance of modern speech recognition programs which have improved dramatically.
[0063] Before the discussion of the analysis of the signal starts the obtaining of the signals and the correct preparation of the signals should be described.
[0064] The sounds which are of interest to us can arise in two ways.
[0065] The one possibility is through movement. If one moves a joint in a specific direction, this leads to an internal friction in the joint which one can hear.
[0066] The second possibility assumes there is an outer impact on the bone which brings it to oscillation which can again be listened to.
[0067] In addition reference should be made to noises of the soft tissues, for example the musculature in the shoulder region, the special anatomic structure in the hand joint, etc. Such noises can likewise be evaluated in accordance with the invention and lead to improve diagnoses of the corresponding components.
[0068] The processing of the sounds in accordance with the invention is schematically illustrated in FIG. 1 and can be used for all anatomic sounds or sound signals independently of how they arose.
[0069] The first step in the signal processing is the detection of the sound signals. These are converted into electrically measurable values.
[0070] Sensors are generally used for such tasks. A sensor is a component which records a mechanical parameter and converts it after appropriate transformation into an electrical signal. This electrical parameter can be both the voltage and also the current or indeed the capacity. The sensor is however an analog component which signifies that it transmits time continuous signals which can have all desired values. For the signal analysis these must however first be digitized. This is brought about with an analog to digital converter ADW. However, during the conversion, the signal spectrum must be restricted with the aid of a low pass filter so that the Nyquist sampling condition remains satisfied.
[0071] One can also imagine under an ADW a sampler which samples or reads the analog signal in fixed time intervals and subsequently converts the analog value into a digital value by a quantizer. The precondition for this process is given by the Nyquist sampling condition which requires a minimum sample Rate Ts of twice the bandwidth W of the signal.
T s ≤ 1 2 W .
[0072] It should be furthermore pointed out that one can accommodate a plurality of sensors at different locations during the investigation.
[0073] After the preparation of the digital signal the actual signal analysis can be started.
[0074] For this a plurality of possibilities is available which, depending on the circumstances, can lead to the desired result. It should be emphasized that these tools are very different with regard to the complexity and the time required for the computation. When selecting the correct method a compromise must accordingly be found.
[0075] At this point two methods of signal analysis should be presented which are frequently used in practice.
[0076] The first method, which is simultaneously the simpler method consists in carrying out a fast Fourier transform (FFT) and subsequently comparing the frequency spectrum which is obtained in this way with other reference spectra (see FIG. 2).
[0077] Thereafter the signal which was originally set forth in the time zone is transformed in accordance with the equations into the frequency range. For this reason the method is also termed spectral analysis.
[0078] The advantage of this method lies in the fact that the intensity of all spectra or frequencies of a time interval can be observed very quickly and simply.
[0079] The Fourier analysis (FFT) is frequently used in the field of electrical communication
[0080] technology and is concerned with a mathematic method for the analysis of complex wave forms or signals into a sequence of simple harmonic functions the frequencies of each are each an integral multiple of the basic frequency. The following applies:
Fn ( f ) = ∫ - α + α f ( t ) - wt · t ,
[0081] In the equation given above f(t) is the sound signal which is recorded as a function of the time (t). w signifies the basic frequency and Fn(f) signifies the Fourier transformation, i.e., the result of the Fourier analysis in the form of a sequence of the basic wave of the sound signal and its harmonics, with the respective amplitudes and phase shifts. α corresponds to infinity and the other symbols have the usual meaning.
[0082] If the information which is sought is embodied in the spectral distribution of the signal then one can best read out this information with FFT. The example of an osteoporotic bone is such a case. One can, by detailing the spectrum of the signals, rapidly determine whether this is a muffled sound or not.
[0083] The second method is the method of the neural networks which is very powerful and very informative and has many different variations. One should adopt this method for the investigation of the more complex patterns in the signal and for the recognition of incomprehensible patterns in the time zone.
[0084] Neural networks are logical circuits which can be compared with the functionality of our brain. As is the case with the brain they are capable of learning and can first be used after a learning phase. This has a role to play for the selection of the suitable learning patterns.
[0085] For the evaluation of the analysis one requires a reference with which one can compare the appropriate signal and then make a decision. This type of reference can be very different from case to case. It must however correspond with the method analysis.
[0086] Now that two possibilities for the signal analysis have been presented, a practical example should be set out with reference to the FIGS. 1 to 3 and with reference to the determination of osteoporosis which represents a relatively simple and practical application, as is shown in FIG. 1. The sound signal to be investigated is caused by an external action 10 on a bone 12 , for example on the tibia or on the head of the tibia by the blow of a doctors hammer. Through this, the bone 12 starts vibrating and transmits a sound signal 14 . This sound signal 14 is picked up by a microphone 16 and is passed on as an electrical signal to a low pass filter 20 . After the low pass filter the signal runs into an analog to digital converter 22 consisting of a sampler 24 and a quantizer 26 . The output signal of the analog to digital converter 22 is a digital signal which is supplied to a device 30 which carries out an FFT analysis which provides particulars of the frequency spectrum of the sound signal 14 , i.e. the base frequency which is present, its harmonics and the respective amplitudes.
[0087] The microphone itself is a type of a sensor. Other sensors, for example piezosensors can be considered and a plurality of sensors for example 16 and 16 ′ can be used. When other sensors such as 16 , 16 ′ are used their respective digitized signals can be fed with appropriate identification into the input channel 28 of the device 30 which carries out the Fourier transformation. For some investigations it can also be advantageous to evaluate the signals of a plurality of sensors in order to make special diagnoses, for example at a knee joint. The identification makes it possible for the subsequent device 30 to respectively associate the signals of the various sensors with the latter.
[0088] The low pass filter restricts the bandwidth to a desired range, for example from 0 to 10 kHz.
[0089] The device 30 is moreover laid out in order to compare the frequency spectrum of the digital signal with a reference pattern or with a plurality of reference patterns which are stored in a memory 32 termed a “library”. These reference patterns in the library 32 are based on earlier measurements, for example from the same patient, or from a patient of the same sex, same age, same weight or same body type. They can alternatively consist of reference patterns which are formed from measured values which originate from a group of patients who are comparable to the respective patient, for example with the criteria of same sex, same age, same weight or same body type, with such reference patterns also being subdivided into different classes depending on the degree of the osteoporosis.
[0090] In order to carry out the comparison it is advantageous to compress the data, for which purpose one of the known data compression processes can be used. The carrying out of the comparison is schematically illustrated in FIG. 2. As a result of the comparison that is carried out one succeeds in determining whether the respective patient has osteoporosis and if so the degree of the illness.
[0091] The devices 20 , 22 , 24 , 26 , 28 , 30 and 32 an be formed by a computer 34 as is indicated by the box in FIG. 1 with the same reference numeral. The computer can for example have available a keyboard 36 for the inputting of patient data, time details and commands, a screen 38 for showing the result of the measurements and the reference pattern which is considered, or the reference patterns which have been considered, and also a printer 40 for printing out the results.
[0092] In a practical version of the invention the sound signal can be passed on to the sound card of the computer which directly takes care of the filtering and digitalisation tasks and subsequently the analysis.
[0093] The basic idea of this acoustic investigation of the osteoporosis is based on the concept that the human bone, just as any other object, should sound different depending on the enclosed content. That is to say the more porous the bone is the more muffled it should sound when tapped. This characteristic can be very well observed by way of a spectral analysis. This corresponds to an accumulation of the low frequency components of the spectrum. After the FFT of the signal the shift of the spectrum in the low frequency range can be made visible.
[0094] As a result of the investigations on previously and precisely diagnosed patients and healthy patients some examples will now be given which show that the above named method operates in a problem-free manner with osteoporosis.
[0095] Thereafter the plausibiity of the method which has been presented will be shown with reference to healthy probands and osteoporosis patients pre-diagnosed by means of, for example, osteodensitometry.
[0096] In addition, the theoretical possibilities of the diagnostic signal analysis will be shown with respect to the large joints.
[0097] Furthermore, references will be made to the theoretical possibilities of the diagnosis of soft tissue diseases.
[0098] [0098]FIG. 3A shows the result of the measurement at a healthy bone of a 42 year old man.
[0099] The x-axis specifies the frequency in Hz whereas the y-axis delivers a potential value in V. The height of the base line, i.e. the start at the y-axis in V depends on the sound strength and does not appear to be dependent on the patient, it is thus probably unimportant for the evaluation. However the amplitudes at the individual frequencies, i.e. the relative amplitudes of the frequency peaks, compared to one another, deliver important information.
[0100] In order to receive a clean signal the tibia is tapped several times. The signal was evaluated at the tenth time. As described above, the impulses were made with the doctors hammer on the ventral tibia approximately 5 cm below the knee joint gap, with the measurement being made at the tibia head.
[0101] [0101]FIG. 3B shows the bone of an osteoporotic male patient (44 years). The measurement was recorded as described above in connection with FIG. 3A but here for the first tap. Although the patient is of a similar age to the healthy patient on which the measurement of FIG. 3A was carried out there are visible shifts of the spectrum into the low frequency ranges. The difference can be seen clearly: the 44 year old patient was previously diagnosed by means of osteodensitometry. The standard deviation amounted to 1.75.
[0102] One can classify the osteoporosis as manifest.
[0103] [0103]FIG. 3C shows the bone of a 64 year old patient with an average degree of osteoporosis.
[0104] According to the finding by densitometry the bone density reduction amounts to 10-15 percent. In this case the knocking sound was evaluated at the fourth time.
[0105] [0105]FIG. 3D shows the measurement of a 72 year old patient with serious osteoporosis and having undergone several fractures, including compression fractures of the spine. In this case the sound was measured at the second time. The visible result is very impressive.
[0106] [0106]FIGS. 3E and 3F show the difference of the amplitude between a healthy bone (patient in FIG. 3A) and an osteoporotic bone (patient in FIG. 3C) even before the computer evaluation.
[0107] Notable is the width of the amplitude for a person with osteoporosis. For a healthy person the amplitude appears to be reduced in time (if anything) and peak-like.
[0108] The above named examples were investigated or recorded by means of a normal microphone. It is to be assumed that when using the special sensors the results would appear even more impressive and more precise. That is to say the method presented functions in principle.
[0109] Further investigations of joints and bones have shown that in fact many noises can be associated with a number of specific illnesses.
[0110] An important part of the work is the generation of reliable references, since the reliability of the decisions that are made depends strongly on the correct choice of references.
[0111] It is however already certain, even without references, that a distinction can be made between healthy and osteoporotic bones. Simply for this reason this method should find broad acceptance. By reliably excluding osteoporosis unnecessary X-ray investigations and diverse densitometric investigations can be avoided.
[0112] The savings in expenses of the patient and of the health insurer can be enormous.
[0113] The above named concept of the bone density measurement (osteodensitometry by means of measurement of the longitudinal wave sound) will also be able to be transferred to software without problem in the future. This relates also to the development of special programs with investigation of the joints and soft tissues as named above. The future of software manufacture will presumably enable in a short period of time osteoporosis investigation in every practice which is equipped with a computer. Merely the simple confirmation or preclusion of osteoporosis without significant cost and work is to be regarded as an enormous step for the daily activity of the doctor in the practice. An internet transmission can also be involved in the investigation. For example a doctor's practice can call up reference patterns from other sources (doctor's practices and the like) via the internet. As an alternative the computer 34 can send the result of an actual measurement (with or without prior evaluation) via the internet to an evaluation center or computer center where the evaluation is carried out. The results of the evaluation can then be supplied online to the computer 34 to be displayed and/or to be printed out. In this manner the measurements of a large member of practices are available to form high quality reference patterns, above all when they are linked with the result of further measurements, such as osteodensitometry measurements on the same patient.
[0114] It is also entirely conceivable for the reference patterns to be made available to individual doctors practices and other institutions stored on a storage medium, for example on a CD.
[0115] The attached reference list contains details of literature sources which deliver information concerning signal analysis in general and which can be used for assistance if required. Although the previous description is concerned with measurements on humans, the method of the invention and the apparatus of the invention can also be used in connection with animals, above all with race horses, for diagnoses, for example with respect to their suitability for racing and the danger of fracture.
[0116] [0116]FIG. 4 shows a schematic representation of the right hand knee joint of a human with FIG. 4A showing the illustration from the front with the femur bone 100 , the tibia 102 with the tibia head 104 and the fibula 106 . The reference numerals 108 and 110 point to the outer meniscus and the inner meniscus respectively.
[0117] [0117]FIG. 4B shows the same representation seen from the outer side of the knee and additionally shows the knee cap or patella 112 .
[0118] [0118]FIG. 4C likewise shows the knee cap 112 here in a representation corresponding to the longitudinal axis of the femur bone 100 , with the knee being shown axially in the bent position and with the femur sliding roll 107 being visible. This representation is a representation of a physiologically “ideal” knee joint, i.e. a joint in a good condition. The double arrow 114 indicates the movements which occur during bending and stretching of the knee joints.
[0119] In contrast FIG. 4D shows a similar joint in which the condition of a medial osteoarthrosis is present, i.e. a wear of the inner joint gap which is shown at 116 . This arthrosis 116 makes itself notable in the noise spectrum when bending at the knee joint in accordance with the arrow 114 , which is also evident in the schematic illustration of FIG. 4D.
[0120] An apparatus for recording the noises which arise on bending at the knee joint is shown in FIG. 5. This is an elastic stocking 120 which is drawn over the knee joint and which is equipped in this example with three microphones 122 which are coupled via lines 124 to a computer such as 34 . Instead of using three microphones one can also operate with a single microphone and other sensors which pickup acoustic signals can also be used. It is also not necessary to connect the microphone to the computer via signal lines 124 but rather a wireless transmission could be selected. For this purpose a transmitter unit with appropriate batteries is incorporated into the stocking so that the signal transmission to the computer takes place by means of infrared signals or using another wireless transmission, with it naturally being necessary for a corresponding receiving unit to be associated with the computer 34 . In this example the knee joint is either (actively) moved by the patient himself or which is moved manually by a doctor or an assistant, i.e., passively.
[0121] It is however, best of all when the microphones are installed into an auxiliary device or orthosis which can be secured to the knee joint independently of the anatomic circumstances of the joint. The stocking 120 can form a part of this auxiliary device or the microphones can be mounted onto the auxiliary device in another way or means. The sense of the auxiliary device is to ensure that the sound pickup always takes place with a like movement of the knee joint so that the recorded sound signals are reproducible; whereby, on the one hand, a comparison of the recorded signals of the respective patient or program with reference values on which were recorded under the same conditions is made possible, and, on the other hand, the comparison is also possible with other recordings for the same patient or proband, i.e. a comparison between recordings made at different times.
[0122] One form of the auxiliary device would be a splint or brace which follows or forces the natural movement of the joint. For example, a splint can be used for the knee joint such as is used in hospitals for the post-operative movement of the knee joint of a patient who has, for example, suffered ripping of the cruciate ligaments which was cured surgically. With an apparatus of this kind the upper leg of the patient lies on a first splint whereas his lower leg lies on a second splint which is connected to the first splint via a polycentric joint and is driven relative to the first splint by a motor in order to force movements about the polycentric joint and to carry out corresponding movements of the knee joint of the patient. This splint can be operated for the purpose of the invention and also without any motor when the second splint is (actively) moved by the patient himself or (passively) moved by an assistant about the polycentric joint. An apparatus of this kind could be termed a CAPM orthosis (Continuous Active/Passive Motion orthosis).
[0123] Another possible design of the auxiliary device resembles a knee orthosis known per se such as for example shown in FIG. 6A. This is a knee orthosis such as is available from the company Medi Bayreuth in Germany and is sold under the designation “Monarch GA”. This orthosis consists of a fixing band 130 which is secured around the upper leg 132 of the proband, for example with the aid of a hook and loop fastener and also of two lower bandages 134 and 136 which are secured to the lower limb 138 and can likewise be provided, as an example, with a hoop and loop fastener. Arms 140 and 142 which are in principle rigid and which are secured to one another at a joint 144 extend from the upper fastening band 130 , or from the upper fastening bands 130 if two are provided, which is also possible and from the lower two bands 134 and 136 . The joint executes a polycentric movement in accordance with the movement of the human knee joint and is aligned with the knee joint of the patient or of the proband. This arrangement of the two arms 140 and 142 can also be repeated at the left hand side of the lower leg in FIG. 6A, which is not shown here. In order to force passive movements of the knee joint a motor 150 can be secured to this orthosis as shown in FIG. 6B. This motor 150 drives a threaded spindle 152 in two alternative directions of rotation which are shown by the double arrow 145 . In this connection the threaded spindle extends, as shown in FIG. 6B, through a nut 156 , which is pivotally secured about the axis 158 to an arm 160 which is rigidly connected to the arm 142 .
[0124] The motor 150 itself is pivotally hinged about the axis 162 to a further arm 164 which is firmly connected to the arm 140 . The motor can be controlled from the computer 34 via the lines 166 in order to turn the spindle 152 alternatively in the one or other arrow direction 154 . In this way a polycentric movement of the knee joint is forced in accordance with the design of the joint 144 and this movement is also precisely predeterminable via a computer 34 with respect to its amplitude, speed and frequency, so that the same movement is ensured for all probands or patients. For patients with knee problems a different amplitude of the movement of the knee joint can be preset optionally via the computer 34 or a special motor control so that they do not suffer unnecessary pain or indeed damage. The speed of the movements and the repetition frequency can also be selected correspondingly differently if required. The motor 150 , the spindle 152 and also the arms 160 , 164 which carry the spindle and the associated parts 156 , 158 , 162 are preferably so designed that they are easily removable. For example they can be secured to the orthosis by clipping them in place so that they can be removed “with one click”. In this manner the auxiliary device can easily be converted into a normal orthosis.
[0125] [0125]FIG. 7A now shows in a three-dimensional representation the result of a recording of knee joint noises in a proband with a knee joint in good condition in accordance with FIGS. 4A to 4 C.
[0126] This recording was made using a program for acoustic signal analysis which is commercially available as a tool for the most diverse acoustic signal analyses. This is the Wave Lab program which is obtainable from Herrn Steinberg or from Miro Computer Products AG, Cham, Germany.
[0127] The investigation is carried out with a special microphone connected to the computer. The sounds are recorded at specific joint positions. For the precise investigation it is, however, as already mentioned, necessary to use a special splint device or orthosis.
[0128] The evaluation now takes place with a standard program for the frequency analysis, for example Wave Lab Steinberg (see above). Both mathematical data is stored, such as sound level, loudness, peak, and also a schematic representation is used. A totally inconspicuous joint without pathological noises of the soft tissues, of the cartilage and others is shown schematically in three dimensions in the form of a frequency analysis.
[0129] Three parameters are shown: frequency in Hertz, amplitude and the time from 0 to the end of the investigation (here after 8 seconds). The joint is moved several times, on average five times. After fast Fourier analysis the computer processes the acoustic joint situation. For an inconspicuous joint, as in this example, the levels marked in color are very regular, as schematically illustrated. The amplitude of the frequencies between 20 Hz to about 30 Hz is the highest (the first three-dimensional structure on the left, i.e. with the signal color brown). The next structure from about 40 Hz to about 50 Hz is on average smaller by half, i.e. with the signal color red. Then follows again a structure which is smaller by one third at about 50 Hz to about 80 Hz, i.e. at the signal color orange. The next levels from 150 Hz onwards are extremely low and are only indicated i.e. at the signal color yellow. At the frequency of about 3600 Hz there is again a small rise, which is indicated with the signal color blue.
[0130] The time plot on the levels is symmetrical, no differences from about 0 to 1 second and from about 0 to about 8 seconds (depending on the length of the investigation).
[0131] The pathological joint shows itself to be different, independently of a specific diagnosis. An example is set out in FIG. 8A for a knee joint which has a medial osteoarthrosis. There is a very precise correlation between functional diagnosis and the schematic representation and the mathematical data. For example, with a medial osteoarthrosis significantly lower levels at 20 Hz to 40 Hz can be seen as in FIG. 8A, in contrast individual partly high and irregular peaks 171 are present at 115 Hz. The determining factor is the frequency and the height of the levels between 200 Hz to about 1000 Hz (here marked yellow). The seriousness of the arthrosis, i.e. of the frictional processes of the damaged cartilage/bone structures is shown in this region. Of less significance are, in this case, the structures at 3500 Hz, 8000 Hz and about 18000 Hz. With relief of the joint parts (effected either manually and with the already described rail) or with the known orthosis (Monarch GA) these parameters change. With this program the levels (amplitudes) at the frequencies between 200 Hz to 650 Hz are significantly smaller. The amplitudes of the lower frequencies are in contrast higher. From this diagnostic conclusions can be drawn (as already described).
[0132] The computer shows a quite different picture and quite different but specific mathematical parameters for soft tissue diseases. For example for tendovaginitis stenosans of the thumb (jerking thumbs) the levels at 20 Hz or 40 Hz are extremely low. The yellow levels are also not present. The noise is very loud and has quite different characteristics from the joint noise.
[0133] [0133]FIG. 7B shows how this three-dimensional frequency analysis can be reproduced, for example in form of a bar diagram. With a computer representation one can for example, call up the histogram or the three-dimensional representation as in FIG. 7A (or both at the same time) and these representations can also be shown in color so that the different colors are associated with the respective frequency ranges, as is indicated in FIGS. 7A and 8A.
[0134] Thus the present invention enables, by evaluation of the noises which originate from a joint an unambiguous diagnosis of the condition of the joint and it is to be expected that the different signal evaluations will turn out so differently that one can diagnose all important medical problems in the region of the knee joint, also in connection with the soft tissues, such as the meniscuses, by different frequency spectra of the recorded signals. Not only the frequency subdivision delivers useful information concerning the respectively present disease or change of condition of the knee. It is for example evident from FIG. 8A that the frequencies in the range of about 150 to about 1000 Hz again have discrete peaks which are also characteristic for a knee with arthrosis in accordance with FIG. 4D.
[0135] Investigations in the practice of the applicant have shown that a justified hope really does exist of being able to make a diagnosis for all relevant knee joint diseases and indeed in a way and means which is not in principle painful for the patient and which can in any event under some circumstances prevent some unnecessary medical operations. The same also applies for all other joints of the human where movements of bones or soft tissues occur.
[0136] The invention can however not only be used for diagnoses as described in connection with the FIGS. 4 to 8 but rather it can also be useful for therapeutic treatment of the respective joint. In order to give an example for this reference will once again be made to the representation of FIG. 6A.
[0137] It has already been brought out above that this is an orthosis of the company Medi from Bayreuth. With an orthosis of this kind air chambers are built into the bands 130 , 136 , 124 and in the region of the joint 144 which can be pumped up by means of an air pump. It is possible in this manner or with a screw arranged in the region of the joint 144 to exert a lateral pressure onto the knee joint so that, for example, with wear effects of the joint in the region of an inner meniscus 108 , the knee joint gap at this position can be opened slightly and for this the knee joint gap in the region of the outer meniscus is if anything loaded more. Through this relief of this damage point of the knee joint, by opening of the knee joint gap, a relief arises here which is reflected in the noise signal. Thus the doctor, or an orthopaedic technician, can move the knee joint, optionally with the aid of the apparatus of FIG. 6B, but also without using the motor and can consider the frequency analysis until this shows that noises no longer occur in the region of the inner meniscus 108 . As soon as this is achieved he knows that an adequate relief of the knee joint has been achieved and the patient can move with the apparatus in the intended way and means while the effected joint portion recovers or is brought into a better condition by special medication or treatments. After the setting of the joint gap the motor 150 and the associated parts can be removed from the orthosis, as previously indicated. During the therapy the patient walks around, i.e. carries out his daily work with the attached orthosis, but without the motor 150 .
[0138] When it is stated that the joint is moved without using the motor 150 then this is to be understood in the sense that the patient himself bends his knee, for example in that he carries out easy knee bends or walks, this would then be active movements of the knee joint. Alternatively the patient can allow his knee joint to be moved manually by another person while sitting down or reclining, this would then be passive movements.
[0139] When the therapy is ended, i.e. an initial improvement of the condition of a knee joint has arisen, the phase of the rehabilitation then begins. Here the patient is either in the care of a physiotherapist or can himself go to a fitness studio and use the exercise machines which can be used there which are intended for a strengthening of the knee joint and the muscles associated with it. An apparatus of this kind is schematically shown in FIG. 9. Here the patient 170 sits on a seat part 172 of an apparatus with a fixedly arranged but rotatable roller 174 which is arranged in the back of the knee of the patient and supports his knee. In this the feet of the patient engage beneath a cylindrical bar-like part 176 which is rotatable via a chassis or a frame 178 about the axis 180 of the roller 714 . The patient has to attempt to lift the part 176 with his foot, so that the chassis 178 pivots about the axis of rotation 180 ; in this arrangement a pivotal movement in the range between 0° and 90° would be usual, as is evident from FIG. 9B. Such apparatus are designed so that the resistance to this rotary movement can be set. One can now imagine that the patient again pulls on the stocking of FIG. 5 and that the acoustic signals are again recorded during this movement on the exercise machine. For example, it will then turn out, for example as a result of arthrosis in the region of the knee, that an unpleasant friction occurs in the knee joint in the angular range from, for example, 60° to 80°, so that precisely in this region of the movement a resistance which originates from the exercise machine should be kept as small as possible. In contrast, in the range of movement between 90° and 80° and between 60° and 0° no poor points of the knee joint are loaded, so that one can operate here with an increased resistance so that the desired condition is achieved. In other words the resistance characteristic of the exercise machine is specifically set in accordance with the respective patient. The rehabilitation of the knee joint by building up the muscles then progresses as desired without the damaged portion of the knee joint, which has to be rehabilitated, being loaded. The exercise machines which are laid out in this way are not only to be used for rehabilitation but can also be used in leisure time for fitness training.
[0140] Here the example has also been given with reference to a knee joint. It is, however, self-evident that any other type of exercise machine which is intended to train special muscle regions can be designed accordingly in order to rehabilitate or to train the respective associated joint of the patient.
[0141] Instead of installing the sensors in a knee stocking they could also eventually be incorporated into the exercise machine itself and indeed the exercise machine could also be so designed that it automatically adjusts itself while evaluating the recorded sound of signals, so that damaged joint positions are protected and can be more quickly rehabilitated. Once a specific setting of the exercise machine has been found for a specific patient then the setting can be stored specifically for the patient and can be retained for future exercises on the machine, so that it is not necessary for each renewed use of the exercise machine to determine the settings anew, or for the patient to again pull on a knee stocking with microphone.
[0142] The invention however goes even further. One can imagine that the invention is used for the setting of ski boots or other devices used in the most diverse types of sport. This will be explained with reference to new ski boots.
[0143] It is known that good skiers, such as for example Hermann Maier, can move far into the forward knee position, i.e. can bend the knee to an extreme degree without suffering pain or deterioration of the joint to a pronounced degree. In contrast there are other skiers who are older or who have a weaker musculature or have already damaged knees who could not practice such an extreme forward knee position as Hermann Maier. It will be good if in this case this ski boot could be designed so that, in a specific forward knee region, it either blocks or exerts a resistance against a further forwardly disposed position, i.e. further knee bending. For example this could take place by special spring arrangements in the boot or by swapping shin pads which are differently supported at the front part of the boot and thus restrict the forward knee position of the skier. One can now imagine that the skier who wishes to procure a new pair of boots goes into a shop, pulls on a stocking in accordance with FIG. 5 and carries out knee bends, i.e. active movements under load (for example with weights on the shoulders). Passive movements would also enter into question, i.e. the apparatus of FIGS. 6A and 6B could also be used here. If now the acoustic signal analysis shows that the respective skier can easily achieve a forward knee position up to 30° but that a further going forward knee position beyond this angle leads to an undesired loading of the knee joint—determined by the changing knee sounds—then the respective sport shop knows that the boots suitable for him must be set or selected such that they block a forward knee position of 30° or make a movement beyond 30° substantially more difficult. This prevents the skier skiing in a forward knee position which is damaging for him.
[0144] In order to realize this it is naturally necessary, which is also sensible with the embodiments described here, for the joint noises to be evaluated in an angle specific manner in accordance with the degree of bending of the joint, which also requires a device to be provided which measures the degree of bending.
[0145] If the signals are recorded using an orthosis in accordance with FIG. 6B then an angular measuring device can for example be incorporated in the joint 144 , or the control signals for the motor 150 , can be used for this purpose. For example, the motor could be turned in one direction until the spindle 152 has been almost screwed out of the nut 156 so that the joint is located in its extended position. When the stop is achieved here this is assumed to be 0° of bending. If the motor 150 is for example designed as a stepping motor then a precise determination of the respective bending angle of the apparatus for each movement on the stepping motor and of the spindle can be found from the particulars of the pitch of the thread of the threaded spindle 152 and the geometry of the orthosis.
[0146] A special feature of the present invention lies in the fact that an animation is possible which facilitates the diagnosis of the respectively present problem and is also easily comprehended by the patient or proband. With reference to the knee joint one can now imagine that the pictures which are shown in FIGS. 4A to 4 C appear schematically in the screen of the computer 34 , as shown in FIG. 10, and on the movement of the knee joint the corresponding movement of the joint parts is shown on the screen by an appropriate animation. Here the angle signals which are discussed above can be useful for the purpose of the animation. In any event the signal evaluation can be used in order to indicate on the screen animation the regions where problem positions are to be found as a result of the signal evaluation. For example, the corresponding positions could be emphasized on the screen by a flushing representation or by a special coloring, so that the doctor can for example say to a patient “Look at that, your inner meniscus is damaged” or “You are suffering from arthrosis”. This emphasizing of the damaged positions can either take place by a static representation of the joint images according to FIGS. 4A to 4 C or with a simultaneous movement of the joint members or, if the problem only occurs in a specific angular range in a representation which corresponds to this angular range, for example with an angular bending of the knee of 30°, which could above all be indicated in accordance with the illustration of FIG. 4B. One possibility of realizing such representation is shown schematically in FIG. 10. Here we see the above discussed computer 34 and it is illustrated schematically that the computer communicates via a data line 200 with two memory areas 202 and 204 .
[0147] These memory areas 202 and 204 can be present in the computer itself or they can for example be realized in the external memories, for example remote memories. The data line 200 could for example also be understood as an internet connection so that the computer 34 stands in the doctor's practice, whereas the memory regions which can be accessed by the computer 34 stand at a remote location.
[0148] In the memory 202 there are then, for example, stored a series of histograms corresponding to FIGS. 7B and 8B whereas in the region 204 corresponding representations of the knee are contained illustrating the respective problem. i.e. the computer 34 carries out a spectral analysis as a result of the respective recordings by the doctor, which are supplied to the computer via the line 18 , and accesses the correspondingly stored reference histograms or patterns from the region 202 and the matching pictures from the memory 204 and shows them on the screen. When the joint shown on the screen is moved in the context of the animation in accordance with the movement of the joint being investigated then this movement in the screen can take place substantially more slowly so that the problem areas can be more easily recognized by the viewer of the screen. Although only four memory regions for frequency analysis and animation possibilities ( 202 A, 202 B, 202 C and 202 D and 204 A, 204 B, 204 C and 204 D) are shown in FIG. 10, in practice a large number of different frequency analyses and animation possibilities or diagnoses is stored. FIG. 10 is to be understood purely by way of example and applies not only for knee joints but rather for all other joints which come into question.
[0149] Summarizing it is emphasized that a computer program with a specific representation of the joint that is investigated will be relatively simple to produce. One can schematically represent every joint analogously to the above described scheme. Problem zones such as, for example, frictional processes, trapping of soft tissues, trapping of meniscuses etc. could be shown schematically. In this way a particular person can observe his joint during the movement. In similar manner one can show soft tissues such as the point of trapping in the cause of the tendon. This would be a very important aspect in rehabilitation, performance sports etc. The bio feedback roll should also not be forgotten. For example, with pathological pressure of the patella on the upper limb sliding roll between, for example, 60° and 80° an exercise machine could be especially set (analogously to the Cybex 2-apparatus). In this way one could avoid the pathological friction processes in this range. A further example for the use of this method (data bank, corresponding apparatus, corresponding joint splint with sensors or microphones) would be the adaptation of the ski shoes with respect to the knee joint. A majority of skiers suffer retropatellar pain, such as for example chondropathic patella. The acoustic determination of the forward knee position of the shoe could take place depending on the pathological signals from the knee joint. It would be of great importance both for the performance skier and also for the recreational skier. With a physiological, non-damaged joint a very wide/soft forward knee position is naturally possible without restriction. With pathology a difficult forward knee position should be used in dependence on the acoustic signal. This is the only method where a picture yielding method comes about in orthopaedics from an acoustic signal. The advantage of this method is an active representation—for example bending and extension, which can be repeated as desired.
[0150] An animation (computer animation) of the joint model controlled by acoustic waves from the real joint is realized, with this animation being capable of being used both in investigations, in therapy, in rehabilitation and/or during training.
[0151] The possibility of diverse attachment of an auxiliary device to the whole or to part of the extremity should also be pointed out, with the auxiliary device being able to have one joint or several joints. Moreover, the possibility of adjustable and measurable movements (and force distribution) in all planes should be pointed out coupled to adjustable main movement; for example the possibility of additional distractions, compressions and rotations, for example of physiological end rotations also with knee extension, additional compression with fractures or after operations and utilization of the distraction relief or action on the whole joint, not just one sided pivoting opening or distraction, analogous to the methods of Ilisarow, for example with bone extension. | A method for determining the anatomic condition of components of the body of a human or of an animal is disclosed comprising producing a sound signal in a selected component of the body by at least one of passive and active movements of at least one joint. The method includes recording a sound signal at a point adjacent to the selected component of the body and evaluating the sound signal. An auxiliary device selected from the group consisting of a splint, an orthosis and an exercise machine is used which ensures a repeatable movement determined by the design of the auxiliary device. The sound signal caused by the movement is recorded and evaluated by a spectral analysis of frequencies and amplitudes contained in the sound signal. A comparison is made with reference patterns of the spectral analyses for the diagnosis of the anatomic condition. The result of a diagnosis is indicated as at least one of a print out and a screen display and wherein the joint investigated is schematically illustrated on the screen display, optionally with associated soft tissues, tendons and ligaments. The diagnosis is indicated visually, by at least one of coloring, lighting up of and flashing of damaged positions. | Briefly summarize the invention's components and working principles as described in the document. | [
"BACKGROUND [0001] The present invention relates to a method and to an apparatus for determining the anatomic condition of components of the body of a human or of an animal and also to an exercise machine, in particular an adjustable exercise machine and to a computer program stored on a storage medium.",
"[0002] Although the present invention is principally concerned with diseases of the joints and soft tissues, or their therapeutic treatment and rehabilitation and also with corresponding apparatuses, the term “osteoporosis”",
"and the significance of the illness should be briefly explained in order to be better able to explain the invention.",
"[0003] In accordance with various sources there are in Germany about 6-8 million people suffering from osteoporosis.",
"As a result of the ¼ million fractures, in particular fractures of the neck of the femur, the cost of treating osteoporosis and the consequence of osteoporosis reach a sum in the tens of billions.",
"[0004] The bone substance undergoes a physiological restructuring.",
"The cells which build up the bone mass and for example repair it after fracture are osteoblasts.",
"They take calcium and other minerals from the blood and bind it in the bones.",
"In this manner the bone substance becomes stronger.",
"The other type of cells which break down bone substance and prevent excess bone growth are named osteoclasts.",
"[0005] In the physiological condition equilibrium exists between the two processes.",
"With increasing age the decomposition of bones takes the upper hand.",
"Some sources state that from the 25 th year of life onwards there is an increased break down of the bones, both in men and also in women.",
"[0006] Stated simply one understands under the term osteoporosis a porous fragile bone.",
"Medically one has to distinguish it however from a relatively rare illness, osteomalacia.",
"Both osteoporosis and also osteomalacia fall medically beneath the generic term osteopenie.",
"[0007] Independently of the causes of osteoporosis in women and men the same picture generating measures are used.",
"The bone density is most frequently investigated by means of computer tomography.",
"This method has however many disadvantages, such as exposure to radiation and influencing of the measurement results in the lower LWS by changes such as spondylophytes, osteochondrosis etc.",
"[0008] The increasingly most frequent method is the measurement with ultra sound.",
"The patients are however here forced into orthopaedic and gynaecological practices in order to undergo an ultrasonic investigation.",
"The precision of this measurement is, however, hitherto very unreliable as is known from the literature and from daily practice.",
"The bone densitometry by means of ultra sound takes place in a frequency range from 200 kHz to 1 MHz and is additionally restricted by the legally prescribed health insurers.",
"This is done for two reasons: on the one hand, as a result of the relatively high costs amounting to an average of 80-130 DM per investigation and, on the other hand, as a result of the above discussed unreliability of this method.",
"[0009] X-ray diagnosis only reliably shows osteoporotic changes when the reduction in bone density has passed about 30 percent.",
"Densitometrie is in such cases no longer useful.",
"Appropriate treatment is commenced even without this investigation.",
"[0010] The object of the invention is to set forth a new method and a new apparatus with which one can reliably carry out a series of investigations and diagnoses in connection with the anatomic condition of components of the body of an human or of an animal at favourable cost and indeed without having to carry out medical surgery or to take samples.",
"SUMMARY [0011] In order to satisfy this object the method of the invention is characterized in that one produces a sound signal in the selected component by passive or active movements of at least one joint and records a sound signal at a point adjacent to the component and evaluates it.",
"[0012] An apparatus for carrying out the method of the invention consists of a sound recording device, a device which carries out a signal analysis and which preferably includes a low pass filter or a low pass function, and an output device for outputting the results of the signal analysis.",
"[0013] The invention is based on the recognition that sound signals, which are caused by movement of a joint in components of the body of an human or of an animal, enable, on appropriate evaluation, conclusions to be drawn on the condition of the respective components.",
"For example the evaluation allows statements to be made concerning the material characteristics, the degree of mineralization, the ultra structure, the collagen structure, the micro structure and the geometry of the bone.",
"Above all, however, the evaluation allows statements to be made concerning the anatomic condition of joints and of the soft tissues associated with them.",
"[0014] The evaluation can take place in accordance with the invention by filtration and spectral analysis and also includes in many cases a comparison with the reference values or reference patterns.",
"In this connection the filtering that is used is normally understood as low pass filtering, for example in the range up to about 10 kHz.",
"In this way the bandwidth is restricted.",
"The analysis and evaluation is advantageously carried out by means of a computer program.",
"[0015] Under active movements one understands that the patient himself moves a selected joint.",
"In contrast, for passive movements, a device is used which forces the movement of a selected joint.",
"Advantageous in the use of active movements is that the patient is not made insecure or anxious by technical apparatus.",
"[0016] On the other hand, with passive movements, the speed and amplitude of the movement can be precisely and repeatedly preset so that the results from different patients can be better compared to one another here.",
"[0017] A special case of the passive generation of movement lies in the situation in which the doctor or another person moves the joint manually.",
"[0018] The invention is however not restricted to this.",
"Examples for further possible applications are: [0019] 1.",
"Checking the bone consolidation (callus formation following fractures).",
"With conservative therapy, i.e., without operational treatment, this measure can certainly be used.",
"[0020] For osteosynthetically treated bone fractures certain problems result with reliable references as a result of the diversity of the methods and the different types of metal implants.",
"[0021] Advantage: X-ray checks can be reduced to a minimum with conservatively treated fractures.",
"[0022] 2.",
"Signal analysis of both legs with diffuse complaints, for example lower legs with young patients.",
"It is known that primary bone lesions (tumours) statistically arise frequently in this group of patients.",
"[0023] An advantage lies in the fact that the measurement result can be used as an aid to a decision, as to whether further investigations are appropriate.",
"For example, the absence of a difference between the two lower extremities can count as a reason for dispensing with further image forming processes.",
"[0024] When a difference of the signal analyses is present further investigations such as X-ray investigations or scintigraphic imaging must be carried out.",
"[0025] 3.",
"For many other bone diseases, for example plasmozytoma (malignant tumour) the scull is frequently afflicted (“moth holes”).",
"The tapping and signal analysis of the skull can preclude or confirm plastic and lytic bone changes.",
"The consequences are further investigations such as X-ray investigations or computer tomography.",
"[0026] 4.",
"The above named method can be used above all with diseases of the joints and soft tissue lesions.",
"These include arthrosis (cartilage loss).",
"Every person is effected by this in the course of life.",
"The possibility of attaching a plurality of sensors at different positions is of advantage.",
"In this way osteoarthroses of the knee (wear of the knee joint) can be precisely differentiated.",
"It is assumed that a determination can be made on the basis of the signal analysis whether this is wear of the inner joint gap or of the outer joint gap.",
"Wear of the rear of the patella could also be diagnosed.",
"[0027] With respect to the patella (knee cap) there are always diagnostic problems and indeed both clinical and also with image giving methods such as NMR.",
"By means of the signal analysis carried out in accordance with the invention it can be determined whether problems are present at all at the rear side of the patella.",
"The corresponding noises (spectra) can be associated with specific diseases from chondropathic patella, chondromalacic patella to retropatella arthrosis (cartilage loss at the rear side of the patella or of the sliding support for the patella).",
"[0028] 5.",
"The method can also be used for various soft tissue diseases, for example: [0029] pathology of the meniscus, [0030] extent of achillodynia (the grating of the “paratenon”) in addition to sono-graphic estimation of the pathological situation.",
"[0031] coxa saltans (snapping hips).",
"[0032] labrum lesion of the shoulder joints.",
"[0033] rotator cuff lesions of the shoulder for example narrowing ( M. supraspinatus ) [0034] discus triangularis lesion—hitherto the biggest diagnostic problem even by means of NMR of the hand joint.",
"[0035] Possibly, one can obtain additional diagnostic advantages through the signal analysis carried out in accordance with the invention.",
"[0036] 6.",
"A further conceivable application would be the portrayal of the carpal tunnel syndrome (very frequent disease—narrowing of the N. medianus in the carpal tunnel of the hand joint).",
"This illness causes thousands of operations per year in Germany.",
"[0037] The diagnosis is normally made by means of nerve speed measurements of the N. medianus.",
"Theoretically diagnosis appears to be possible with analysis of, for example, the tapping sound of the carpal tunnel (the tapping of the carpal tunnel is termed Hoffmann-Tinel-Test in orthopedics.",
"In this test the result of the tapping is however not evaluated acoustically but rather through the subjective sense of pain of the patient).",
"Appropriate references can possibly be found here.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0038] The invention will be explained in more detail with reference to embodiments and to the accompanying drawings in which FIGS. 1 to 3 show a method for the diagnosis of osteoporosis whereas the further FIGS. 4 to 10 show examples of the invention.",
"There are shown: [0039] [0039 ]FIG. 1 a schematic diagram for the explanation of the method of the invention, [0040] [0040 ]FIG. 2 a schematic diagram for the explanation of a possible variant of the signal evaluation in the method of FIG. 1, [0041] [0041 ]FIG. 3A the result of a measurement in accordance with the invention on a healthy male patient of 42 years of age, [0042] [0042 ]FIG. 3B the result of a measurement in accordance with the invention of a male patient suffering from osteoporosis and aged 44, [0043] [0043 ]FIG. 3C the result of a measurement in accordance with the invention on a female patient suffering from osteoporosis and aged 64, [0044] [0044 ]FIG. 3D the result of a measurement in accordance with the invention on an older female patient suffering from pronounced osteoporosis and aged 72, [0045] [0045 ]FIG. 3E the recorded sound signal from the same patient as considered in FIG. 3A and [0046] [0046 ]FIG. 3F the recorded sound signal from the same patient as considered in FIG. 3C, [0047] [0047 ]FIGS. 4A to 4 C schematic representations of a healthy human knee joint, [0048] [0048 ]FIG. 4D a schematic illustration of a human knee joint suffering under medial osteoarthrosis, [0049] [0049 ]FIG. 5 a schematic illustration of a sound recording device in accordance with the invention, [0050] [0050 ]FIG. 6A an orthosis for the knee joint, [0051] [0051 ]FIG. 6B a modification of the orthosis of FIG. 6A in accordance with the invention, [0052] [0052 ]FIG. 7A a spectral analysis of sound signals of a healthy human knee joint in accordance with the FIGS. 4A to 4 C, [0053] [0053 ]FIG. 7B a histogram corresponding to FIG. 7A, [0054] [0054 ]FIG. 8A a spectral analysis of sound signals of a human knee joint in accordance with FIG. 4D suffering medial osteoarthrosis, [0055] [0055 ]FIG. 8B a histogram corresponding to FIG. 8A, [0056] [0056 ]FIG. 9A a schematic representation of an exercise machine usable for the invention, [0057] [0057 ]FIG. 9B a schematic diagram to explain an inventive setting of an exercise machine in accordance with FIG. 9A and [0058] [0058 ]FIG. 10 a schematic representation of an apparatus with animation in accordance with the invention.",
"DETAILED DESCRIPTION [0059] Noises arise in the human body through movements and internal friction.",
"These noises can say something concerning the inner condition of the body.",
"In the description attention is particularly directed to bone and joint noises.",
"First of all a principle methodology for the determination and evaluation of these noises will be described, which has been investigated in the practice of the applicant in the diagnosis of osteoporosis.",
"Then—building on this description—the present invention will be further explained with reference to FIGS. 4 to 10 .",
"In diagnosing osteoporosis one is concerned primarily with the evaluation of the tapping noises (longitudinal vibrations) which are initiated with a device which always delivers the same pulses.",
"One taps the selected measurement position (tibia head anatomically hardly any soft tissue cover) about 5 cm caudal.",
"[0060] Noises are basically longitudinal air vibrations which can be perceived by our ears.",
"After reception they can be analyzed by the brain into a very broad spectrum.",
"The human brain is able to recognize certain patterns from a sound—pattern recognition—or to sort out specific tones from it (filtering).",
"[0061] All these abilities are in reality very complicated mechanisms which first become aware to us on attempting to realize these abilities artificially.",
"[0062] Precisely these problems have occupied scientists from all fields for decades.",
"In the course of the years ever more powerful tools (systems) have arisen for the analysis or pattern recognition of sound signals.",
"One can see this in the performance of modern speech recognition programs which have improved dramatically.",
"[0063] Before the discussion of the analysis of the signal starts the obtaining of the signals and the correct preparation of the signals should be described.",
"[0064] The sounds which are of interest to us can arise in two ways.",
"[0065] The one possibility is through movement.",
"If one moves a joint in a specific direction, this leads to an internal friction in the joint which one can hear.",
"[0066] The second possibility assumes there is an outer impact on the bone which brings it to oscillation which can again be listened to.",
"[0067] In addition reference should be made to noises of the soft tissues, for example the musculature in the shoulder region, the special anatomic structure in the hand joint, etc.",
"Such noises can likewise be evaluated in accordance with the invention and lead to improve diagnoses of the corresponding components.",
"[0068] The processing of the sounds in accordance with the invention is schematically illustrated in FIG. 1 and can be used for all anatomic sounds or sound signals independently of how they arose.",
"[0069] The first step in the signal processing is the detection of the sound signals.",
"These are converted into electrically measurable values.",
"[0070] Sensors are generally used for such tasks.",
"A sensor is a component which records a mechanical parameter and converts it after appropriate transformation into an electrical signal.",
"This electrical parameter can be both the voltage and also the current or indeed the capacity.",
"The sensor is however an analog component which signifies that it transmits time continuous signals which can have all desired values.",
"For the signal analysis these must however first be digitized.",
"This is brought about with an analog to digital converter ADW.",
"However, during the conversion, the signal spectrum must be restricted with the aid of a low pass filter so that the Nyquist sampling condition remains satisfied.",
"[0071] One can also imagine under an ADW a sampler which samples or reads the analog signal in fixed time intervals and subsequently converts the analog value into a digital value by a quantizer.",
"The precondition for this process is given by the Nyquist sampling condition which requires a minimum sample Rate Ts of twice the bandwidth W of the signal.",
"T s ≤ 1 2 W .",
"[0072] It should be furthermore pointed out that one can accommodate a plurality of sensors at different locations during the investigation.",
"[0073] After the preparation of the digital signal the actual signal analysis can be started.",
"[0074] For this a plurality of possibilities is available which, depending on the circumstances, can lead to the desired result.",
"It should be emphasized that these tools are very different with regard to the complexity and the time required for the computation.",
"When selecting the correct method a compromise must accordingly be found.",
"[0075] At this point two methods of signal analysis should be presented which are frequently used in practice.",
"[0076] The first method, which is simultaneously the simpler method consists in carrying out a fast Fourier transform (FFT) and subsequently comparing the frequency spectrum which is obtained in this way with other reference spectra (see FIG. 2).",
"[0077] Thereafter the signal which was originally set forth in the time zone is transformed in accordance with the equations into the frequency range.",
"For this reason the method is also termed spectral analysis.",
"[0078] The advantage of this method lies in the fact that the intensity of all spectra or frequencies of a time interval can be observed very quickly and simply.",
"[0079] The Fourier analysis (FFT) is frequently used in the field of electrical communication [0080] technology and is concerned with a mathematic method for the analysis of complex wave forms or signals into a sequence of simple harmonic functions the frequencies of each are each an integral multiple of the basic frequency.",
"The following applies: Fn ( f ) = ∫ - α + α f ( t ) - wt · t , [0081] In the equation given above f(t) is the sound signal which is recorded as a function of the time (t).",
"w signifies the basic frequency and Fn(f) signifies the Fourier transformation, i.e., the result of the Fourier analysis in the form of a sequence of the basic wave of the sound signal and its harmonics, with the respective amplitudes and phase shifts.",
"α corresponds to infinity and the other symbols have the usual meaning.",
"[0082] If the information which is sought is embodied in the spectral distribution of the signal then one can best read out this information with FFT.",
"The example of an osteoporotic bone is such a case.",
"One can, by detailing the spectrum of the signals, rapidly determine whether this is a muffled sound or not.",
"[0083] The second method is the method of the neural networks which is very powerful and very informative and has many different variations.",
"One should adopt this method for the investigation of the more complex patterns in the signal and for the recognition of incomprehensible patterns in the time zone.",
"[0084] Neural networks are logical circuits which can be compared with the functionality of our brain.",
"As is the case with the brain they are capable of learning and can first be used after a learning phase.",
"This has a role to play for the selection of the suitable learning patterns.",
"[0085] For the evaluation of the analysis one requires a reference with which one can compare the appropriate signal and then make a decision.",
"This type of reference can be very different from case to case.",
"It must however correspond with the method analysis.",
"[0086] Now that two possibilities for the signal analysis have been presented, a practical example should be set out with reference to the FIGS. 1 to 3 and with reference to the determination of osteoporosis which represents a relatively simple and practical application, as is shown in FIG. 1. The sound signal to be investigated is caused by an external action 10 on a bone 12 , for example on the tibia or on the head of the tibia by the blow of a doctors hammer.",
"Through this, the bone 12 starts vibrating and transmits a sound signal 14 .",
"This sound signal 14 is picked up by a microphone 16 and is passed on as an electrical signal to a low pass filter 20 .",
"After the low pass filter the signal runs into an analog to digital converter 22 consisting of a sampler 24 and a quantizer 26 .",
"The output signal of the analog to digital converter 22 is a digital signal which is supplied to a device 30 which carries out an FFT analysis which provides particulars of the frequency spectrum of the sound signal 14 , i.e. the base frequency which is present, its harmonics and the respective amplitudes.",
"[0087] The microphone itself is a type of a sensor.",
"Other sensors, for example piezosensors can be considered and a plurality of sensors for example 16 and 16 ′ can be used.",
"When other sensors such as 16 , 16 ′ are used their respective digitized signals can be fed with appropriate identification into the input channel 28 of the device 30 which carries out the Fourier transformation.",
"For some investigations it can also be advantageous to evaluate the signals of a plurality of sensors in order to make special diagnoses, for example at a knee joint.",
"The identification makes it possible for the subsequent device 30 to respectively associate the signals of the various sensors with the latter.",
"[0088] The low pass filter restricts the bandwidth to a desired range, for example from 0 to 10 kHz.",
"[0089] The device 30 is moreover laid out in order to compare the frequency spectrum of the digital signal with a reference pattern or with a plurality of reference patterns which are stored in a memory 32 termed a “library.”",
"These reference patterns in the library 32 are based on earlier measurements, for example from the same patient, or from a patient of the same sex, same age, same weight or same body type.",
"They can alternatively consist of reference patterns which are formed from measured values which originate from a group of patients who are comparable to the respective patient, for example with the criteria of same sex, same age, same weight or same body type, with such reference patterns also being subdivided into different classes depending on the degree of the osteoporosis.",
"[0090] In order to carry out the comparison it is advantageous to compress the data, for which purpose one of the known data compression processes can be used.",
"The carrying out of the comparison is schematically illustrated in FIG. 2. As a result of the comparison that is carried out one succeeds in determining whether the respective patient has osteoporosis and if so the degree of the illness.",
"[0091] The devices 20 , 22 , 24 , 26 , 28 , 30 and 32 an be formed by a computer 34 as is indicated by the box in FIG. 1 with the same reference numeral.",
"The computer can for example have available a keyboard 36 for the inputting of patient data, time details and commands, a screen 38 for showing the result of the measurements and the reference pattern which is considered, or the reference patterns which have been considered, and also a printer 40 for printing out the results.",
"[0092] In a practical version of the invention the sound signal can be passed on to the sound card of the computer which directly takes care of the filtering and digitalisation tasks and subsequently the analysis.",
"[0093] The basic idea of this acoustic investigation of the osteoporosis is based on the concept that the human bone, just as any other object, should sound different depending on the enclosed content.",
"That is to say the more porous the bone is the more muffled it should sound when tapped.",
"This characteristic can be very well observed by way of a spectral analysis.",
"This corresponds to an accumulation of the low frequency components of the spectrum.",
"After the FFT of the signal the shift of the spectrum in the low frequency range can be made visible.",
"[0094] As a result of the investigations on previously and precisely diagnosed patients and healthy patients some examples will now be given which show that the above named method operates in a problem-free manner with osteoporosis.",
"[0095] Thereafter the plausibiity of the method which has been presented will be shown with reference to healthy probands and osteoporosis patients pre-diagnosed by means of, for example, osteodensitometry.",
"[0096] In addition, the theoretical possibilities of the diagnostic signal analysis will be shown with respect to the large joints.",
"[0097] Furthermore, references will be made to the theoretical possibilities of the diagnosis of soft tissue diseases.",
"[0098] [0098 ]FIG. 3A shows the result of the measurement at a healthy bone of a 42 year old man.",
"[0099] The x-axis specifies the frequency in Hz whereas the y-axis delivers a potential value in V. The height of the base line, i.e. the start at the y-axis in V depends on the sound strength and does not appear to be dependent on the patient, it is thus probably unimportant for the evaluation.",
"However the amplitudes at the individual frequencies, i.e. the relative amplitudes of the frequency peaks, compared to one another, deliver important information.",
"[0100] In order to receive a clean signal the tibia is tapped several times.",
"The signal was evaluated at the tenth time.",
"As described above, the impulses were made with the doctors hammer on the ventral tibia approximately 5 cm below the knee joint gap, with the measurement being made at the tibia head.",
"[0101] [0101 ]FIG. 3B shows the bone of an osteoporotic male patient (44 years).",
"The measurement was recorded as described above in connection with FIG. 3A but here for the first tap.",
"Although the patient is of a similar age to the healthy patient on which the measurement of FIG. 3A was carried out there are visible shifts of the spectrum into the low frequency ranges.",
"The difference can be seen clearly: the 44 year old patient was previously diagnosed by means of osteodensitometry.",
"The standard deviation amounted to 1.75.",
"[0102] One can classify the osteoporosis as manifest.",
"[0103] [0103 ]FIG. 3C shows the bone of a 64 year old patient with an average degree of osteoporosis.",
"[0104] According to the finding by densitometry the bone density reduction amounts to 10-15 percent.",
"In this case the knocking sound was evaluated at the fourth time.",
"[0105] [0105 ]FIG. 3D shows the measurement of a 72 year old patient with serious osteoporosis and having undergone several fractures, including compression fractures of the spine.",
"In this case the sound was measured at the second time.",
"The visible result is very impressive.",
"[0106] [0106 ]FIGS. 3E and 3F show the difference of the amplitude between a healthy bone (patient in FIG. 3A) and an osteoporotic bone (patient in FIG. 3C) even before the computer evaluation.",
"[0107] Notable is the width of the amplitude for a person with osteoporosis.",
"For a healthy person the amplitude appears to be reduced in time (if anything) and peak-like.",
"[0108] The above named examples were investigated or recorded by means of a normal microphone.",
"It is to be assumed that when using the special sensors the results would appear even more impressive and more precise.",
"That is to say the method presented functions in principle.",
"[0109] Further investigations of joints and bones have shown that in fact many noises can be associated with a number of specific illnesses.",
"[0110] An important part of the work is the generation of reliable references, since the reliability of the decisions that are made depends strongly on the correct choice of references.",
"[0111] It is however already certain, even without references, that a distinction can be made between healthy and osteoporotic bones.",
"Simply for this reason this method should find broad acceptance.",
"By reliably excluding osteoporosis unnecessary X-ray investigations and diverse densitometric investigations can be avoided.",
"[0112] The savings in expenses of the patient and of the health insurer can be enormous.",
"[0113] The above named concept of the bone density measurement (osteodensitometry by means of measurement of the longitudinal wave sound) will also be able to be transferred to software without problem in the future.",
"This relates also to the development of special programs with investigation of the joints and soft tissues as named above.",
"The future of software manufacture will presumably enable in a short period of time osteoporosis investigation in every practice which is equipped with a computer.",
"Merely the simple confirmation or preclusion of osteoporosis without significant cost and work is to be regarded as an enormous step for the daily activity of the doctor in the practice.",
"An internet transmission can also be involved in the investigation.",
"For example a doctor's practice can call up reference patterns from other sources (doctor's practices and the like) via the internet.",
"As an alternative the computer 34 can send the result of an actual measurement (with or without prior evaluation) via the internet to an evaluation center or computer center where the evaluation is carried out.",
"The results of the evaluation can then be supplied online to the computer 34 to be displayed and/or to be printed out.",
"In this manner the measurements of a large member of practices are available to form high quality reference patterns, above all when they are linked with the result of further measurements, such as osteodensitometry measurements on the same patient.",
"[0114] It is also entirely conceivable for the reference patterns to be made available to individual doctors practices and other institutions stored on a storage medium, for example on a CD.",
"[0115] The attached reference list contains details of literature sources which deliver information concerning signal analysis in general and which can be used for assistance if required.",
"Although the previous description is concerned with measurements on humans, the method of the invention and the apparatus of the invention can also be used in connection with animals, above all with race horses, for diagnoses, for example with respect to their suitability for racing and the danger of fracture.",
"[0116] [0116 ]FIG. 4 shows a schematic representation of the right hand knee joint of a human with FIG. 4A showing the illustration from the front with the femur bone 100 , the tibia 102 with the tibia head 104 and the fibula 106 .",
"The reference numerals 108 and 110 point to the outer meniscus and the inner meniscus respectively.",
"[0117] [0117 ]FIG. 4B shows the same representation seen from the outer side of the knee and additionally shows the knee cap or patella 112 .",
"[0118] [0118 ]FIG. 4C likewise shows the knee cap 112 here in a representation corresponding to the longitudinal axis of the femur bone 100 , with the knee being shown axially in the bent position and with the femur sliding roll 107 being visible.",
"This representation is a representation of a physiologically “ideal”",
"knee joint, i.e. a joint in a good condition.",
"The double arrow 114 indicates the movements which occur during bending and stretching of the knee joints.",
"[0119] In contrast FIG. 4D shows a similar joint in which the condition of a medial osteoarthrosis is present, i.e. a wear of the inner joint gap which is shown at 116 .",
"This arthrosis 116 makes itself notable in the noise spectrum when bending at the knee joint in accordance with the arrow 114 , which is also evident in the schematic illustration of FIG. 4D.",
"[0120] An apparatus for recording the noises which arise on bending at the knee joint is shown in FIG. 5. This is an elastic stocking 120 which is drawn over the knee joint and which is equipped in this example with three microphones 122 which are coupled via lines 124 to a computer such as 34 .",
"Instead of using three microphones one can also operate with a single microphone and other sensors which pickup acoustic signals can also be used.",
"It is also not necessary to connect the microphone to the computer via signal lines 124 but rather a wireless transmission could be selected.",
"For this purpose a transmitter unit with appropriate batteries is incorporated into the stocking so that the signal transmission to the computer takes place by means of infrared signals or using another wireless transmission, with it naturally being necessary for a corresponding receiving unit to be associated with the computer 34 .",
"In this example the knee joint is either (actively) moved by the patient himself or which is moved manually by a doctor or an assistant, i.e., passively.",
"[0121] It is however, best of all when the microphones are installed into an auxiliary device or orthosis which can be secured to the knee joint independently of the anatomic circumstances of the joint.",
"The stocking 120 can form a part of this auxiliary device or the microphones can be mounted onto the auxiliary device in another way or means.",
"The sense of the auxiliary device is to ensure that the sound pickup always takes place with a like movement of the knee joint so that the recorded sound signals are reproducible;",
"whereby, on the one hand, a comparison of the recorded signals of the respective patient or program with reference values on which were recorded under the same conditions is made possible, and, on the other hand, the comparison is also possible with other recordings for the same patient or proband, i.e. a comparison between recordings made at different times.",
"[0122] One form of the auxiliary device would be a splint or brace which follows or forces the natural movement of the joint.",
"For example, a splint can be used for the knee joint such as is used in hospitals for the post-operative movement of the knee joint of a patient who has, for example, suffered ripping of the cruciate ligaments which was cured surgically.",
"With an apparatus of this kind the upper leg of the patient lies on a first splint whereas his lower leg lies on a second splint which is connected to the first splint via a polycentric joint and is driven relative to the first splint by a motor in order to force movements about the polycentric joint and to carry out corresponding movements of the knee joint of the patient.",
"This splint can be operated for the purpose of the invention and also without any motor when the second splint is (actively) moved by the patient himself or (passively) moved by an assistant about the polycentric joint.",
"An apparatus of this kind could be termed a CAPM orthosis (Continuous Active/Passive Motion orthosis).",
"[0123] Another possible design of the auxiliary device resembles a knee orthosis known per se such as for example shown in FIG. 6A.",
"This is a knee orthosis such as is available from the company Medi Bayreuth in Germany and is sold under the designation “Monarch GA.”",
"This orthosis consists of a fixing band 130 which is secured around the upper leg 132 of the proband, for example with the aid of a hook and loop fastener and also of two lower bandages 134 and 136 which are secured to the lower limb 138 and can likewise be provided, as an example, with a hoop and loop fastener.",
"Arms 140 and 142 which are in principle rigid and which are secured to one another at a joint 144 extend from the upper fastening band 130 , or from the upper fastening bands 130 if two are provided, which is also possible and from the lower two bands 134 and 136 .",
"The joint executes a polycentric movement in accordance with the movement of the human knee joint and is aligned with the knee joint of the patient or of the proband.",
"This arrangement of the two arms 140 and 142 can also be repeated at the left hand side of the lower leg in FIG. 6A, which is not shown here.",
"In order to force passive movements of the knee joint a motor 150 can be secured to this orthosis as shown in FIG. 6B.",
"This motor 150 drives a threaded spindle 152 in two alternative directions of rotation which are shown by the double arrow 145 .",
"In this connection the threaded spindle extends, as shown in FIG. 6B, through a nut 156 , which is pivotally secured about the axis 158 to an arm 160 which is rigidly connected to the arm 142 .",
"[0124] The motor 150 itself is pivotally hinged about the axis 162 to a further arm 164 which is firmly connected to the arm 140 .",
"The motor can be controlled from the computer 34 via the lines 166 in order to turn the spindle 152 alternatively in the one or other arrow direction 154 .",
"In this way a polycentric movement of the knee joint is forced in accordance with the design of the joint 144 and this movement is also precisely predeterminable via a computer 34 with respect to its amplitude, speed and frequency, so that the same movement is ensured for all probands or patients.",
"For patients with knee problems a different amplitude of the movement of the knee joint can be preset optionally via the computer 34 or a special motor control so that they do not suffer unnecessary pain or indeed damage.",
"The speed of the movements and the repetition frequency can also be selected correspondingly differently if required.",
"The motor 150 , the spindle 152 and also the arms 160 , 164 which carry the spindle and the associated parts 156 , 158 , 162 are preferably so designed that they are easily removable.",
"For example they can be secured to the orthosis by clipping them in place so that they can be removed “with one click.”",
"In this manner the auxiliary device can easily be converted into a normal orthosis.",
"[0125] [0125 ]FIG. 7A now shows in a three-dimensional representation the result of a recording of knee joint noises in a proband with a knee joint in good condition in accordance with FIGS. 4A to 4 C. [0126] This recording was made using a program for acoustic signal analysis which is commercially available as a tool for the most diverse acoustic signal analyses.",
"This is the Wave Lab program which is obtainable from Herrn Steinberg or from Miro Computer Products AG, Cham, Germany.",
"[0127] The investigation is carried out with a special microphone connected to the computer.",
"The sounds are recorded at specific joint positions.",
"For the precise investigation it is, however, as already mentioned, necessary to use a special splint device or orthosis.",
"[0128] The evaluation now takes place with a standard program for the frequency analysis, for example Wave Lab Steinberg (see above).",
"Both mathematical data is stored, such as sound level, loudness, peak, and also a schematic representation is used.",
"A totally inconspicuous joint without pathological noises of the soft tissues, of the cartilage and others is shown schematically in three dimensions in the form of a frequency analysis.",
"[0129] Three parameters are shown: frequency in Hertz, amplitude and the time from 0 to the end of the investigation (here after 8 seconds).",
"The joint is moved several times, on average five times.",
"After fast Fourier analysis the computer processes the acoustic joint situation.",
"For an inconspicuous joint, as in this example, the levels marked in color are very regular, as schematically illustrated.",
"The amplitude of the frequencies between 20 Hz to about 30 Hz is the highest (the first three-dimensional structure on the left, i.e. with the signal color brown).",
"The next structure from about 40 Hz to about 50 Hz is on average smaller by half, i.e. with the signal color red.",
"Then follows again a structure which is smaller by one third at about 50 Hz to about 80 Hz, i.e. at the signal color orange.",
"The next levels from 150 Hz onwards are extremely low and are only indicated i.e. at the signal color yellow.",
"At the frequency of about 3600 Hz there is again a small rise, which is indicated with the signal color blue.",
"[0130] The time plot on the levels is symmetrical, no differences from about 0 to 1 second and from about 0 to about 8 seconds (depending on the length of the investigation).",
"[0131] The pathological joint shows itself to be different, independently of a specific diagnosis.",
"An example is set out in FIG. 8A for a knee joint which has a medial osteoarthrosis.",
"There is a very precise correlation between functional diagnosis and the schematic representation and the mathematical data.",
"For example, with a medial osteoarthrosis significantly lower levels at 20 Hz to 40 Hz can be seen as in FIG. 8A, in contrast individual partly high and irregular peaks 171 are present at 115 Hz.",
"The determining factor is the frequency and the height of the levels between 200 Hz to about 1000 Hz (here marked yellow).",
"The seriousness of the arthrosis, i.e. of the frictional processes of the damaged cartilage/bone structures is shown in this region.",
"Of less significance are, in this case, the structures at 3500 Hz, 8000 Hz and about 18000 Hz.",
"With relief of the joint parts (effected either manually and with the already described rail) or with the known orthosis (Monarch GA) these parameters change.",
"With this program the levels (amplitudes) at the frequencies between 200 Hz to 650 Hz are significantly smaller.",
"The amplitudes of the lower frequencies are in contrast higher.",
"From this diagnostic conclusions can be drawn (as already described).",
"[0132] The computer shows a quite different picture and quite different but specific mathematical parameters for soft tissue diseases.",
"For example for tendovaginitis stenosans of the thumb (jerking thumbs) the levels at 20 Hz or 40 Hz are extremely low.",
"The yellow levels are also not present.",
"The noise is very loud and has quite different characteristics from the joint noise.",
"[0133] [0133 ]FIG. 7B shows how this three-dimensional frequency analysis can be reproduced, for example in form of a bar diagram.",
"With a computer representation one can for example, call up the histogram or the three-dimensional representation as in FIG. 7A (or both at the same time) and these representations can also be shown in color so that the different colors are associated with the respective frequency ranges, as is indicated in FIGS. 7A and 8A.",
"[0134] Thus the present invention enables, by evaluation of the noises which originate from a joint an unambiguous diagnosis of the condition of the joint and it is to be expected that the different signal evaluations will turn out so differently that one can diagnose all important medical problems in the region of the knee joint, also in connection with the soft tissues, such as the meniscuses, by different frequency spectra of the recorded signals.",
"Not only the frequency subdivision delivers useful information concerning the respectively present disease or change of condition of the knee.",
"It is for example evident from FIG. 8A that the frequencies in the range of about 150 to about 1000 Hz again have discrete peaks which are also characteristic for a knee with arthrosis in accordance with FIG. 4D.",
"[0135] Investigations in the practice of the applicant have shown that a justified hope really does exist of being able to make a diagnosis for all relevant knee joint diseases and indeed in a way and means which is not in principle painful for the patient and which can in any event under some circumstances prevent some unnecessary medical operations.",
"The same also applies for all other joints of the human where movements of bones or soft tissues occur.",
"[0136] The invention can however not only be used for diagnoses as described in connection with the FIGS. 4 to 8 but rather it can also be useful for therapeutic treatment of the respective joint.",
"In order to give an example for this reference will once again be made to the representation of FIG. 6A.",
"[0137] It has already been brought out above that this is an orthosis of the company Medi from Bayreuth.",
"With an orthosis of this kind air chambers are built into the bands 130 , 136 , 124 and in the region of the joint 144 which can be pumped up by means of an air pump.",
"It is possible in this manner or with a screw arranged in the region of the joint 144 to exert a lateral pressure onto the knee joint so that, for example, with wear effects of the joint in the region of an inner meniscus 108 , the knee joint gap at this position can be opened slightly and for this the knee joint gap in the region of the outer meniscus is if anything loaded more.",
"Through this relief of this damage point of the knee joint, by opening of the knee joint gap, a relief arises here which is reflected in the noise signal.",
"Thus the doctor, or an orthopaedic technician, can move the knee joint, optionally with the aid of the apparatus of FIG. 6B, but also without using the motor and can consider the frequency analysis until this shows that noises no longer occur in the region of the inner meniscus 108 .",
"As soon as this is achieved he knows that an adequate relief of the knee joint has been achieved and the patient can move with the apparatus in the intended way and means while the effected joint portion recovers or is brought into a better condition by special medication or treatments.",
"After the setting of the joint gap the motor 150 and the associated parts can be removed from the orthosis, as previously indicated.",
"During the therapy the patient walks around, i.e. carries out his daily work with the attached orthosis, but without the motor 150 .",
"[0138] When it is stated that the joint is moved without using the motor 150 then this is to be understood in the sense that the patient himself bends his knee, for example in that he carries out easy knee bends or walks, this would then be active movements of the knee joint.",
"Alternatively the patient can allow his knee joint to be moved manually by another person while sitting down or reclining, this would then be passive movements.",
"[0139] When the therapy is ended, i.e. an initial improvement of the condition of a knee joint has arisen, the phase of the rehabilitation then begins.",
"Here the patient is either in the care of a physiotherapist or can himself go to a fitness studio and use the exercise machines which can be used there which are intended for a strengthening of the knee joint and the muscles associated with it.",
"An apparatus of this kind is schematically shown in FIG. 9. Here the patient 170 sits on a seat part 172 of an apparatus with a fixedly arranged but rotatable roller 174 which is arranged in the back of the knee of the patient and supports his knee.",
"In this the feet of the patient engage beneath a cylindrical bar-like part 176 which is rotatable via a chassis or a frame 178 about the axis 180 of the roller 714 .",
"The patient has to attempt to lift the part 176 with his foot, so that the chassis 178 pivots about the axis of rotation 180 ;",
"in this arrangement a pivotal movement in the range between 0° and 90° would be usual, as is evident from FIG. 9B.",
"Such apparatus are designed so that the resistance to this rotary movement can be set.",
"One can now imagine that the patient again pulls on the stocking of FIG. 5 and that the acoustic signals are again recorded during this movement on the exercise machine.",
"For example, it will then turn out, for example as a result of arthrosis in the region of the knee, that an unpleasant friction occurs in the knee joint in the angular range from, for example, 60° to 80°, so that precisely in this region of the movement a resistance which originates from the exercise machine should be kept as small as possible.",
"In contrast, in the range of movement between 90° and 80° and between 60° and 0° no poor points of the knee joint are loaded, so that one can operate here with an increased resistance so that the desired condition is achieved.",
"In other words the resistance characteristic of the exercise machine is specifically set in accordance with the respective patient.",
"The rehabilitation of the knee joint by building up the muscles then progresses as desired without the damaged portion of the knee joint, which has to be rehabilitated, being loaded.",
"The exercise machines which are laid out in this way are not only to be used for rehabilitation but can also be used in leisure time for fitness training.",
"[0140] Here the example has also been given with reference to a knee joint.",
"It is, however, self-evident that any other type of exercise machine which is intended to train special muscle regions can be designed accordingly in order to rehabilitate or to train the respective associated joint of the patient.",
"[0141] Instead of installing the sensors in a knee stocking they could also eventually be incorporated into the exercise machine itself and indeed the exercise machine could also be so designed that it automatically adjusts itself while evaluating the recorded sound of signals, so that damaged joint positions are protected and can be more quickly rehabilitated.",
"Once a specific setting of the exercise machine has been found for a specific patient then the setting can be stored specifically for the patient and can be retained for future exercises on the machine, so that it is not necessary for each renewed use of the exercise machine to determine the settings anew, or for the patient to again pull on a knee stocking with microphone.",
"[0142] The invention however goes even further.",
"One can imagine that the invention is used for the setting of ski boots or other devices used in the most diverse types of sport.",
"This will be explained with reference to new ski boots.",
"[0143] It is known that good skiers, such as for example Hermann Maier, can move far into the forward knee position, i.e. can bend the knee to an extreme degree without suffering pain or deterioration of the joint to a pronounced degree.",
"In contrast there are other skiers who are older or who have a weaker musculature or have already damaged knees who could not practice such an extreme forward knee position as Hermann Maier.",
"It will be good if in this case this ski boot could be designed so that, in a specific forward knee region, it either blocks or exerts a resistance against a further forwardly disposed position, i.e. further knee bending.",
"For example this could take place by special spring arrangements in the boot or by swapping shin pads which are differently supported at the front part of the boot and thus restrict the forward knee position of the skier.",
"One can now imagine that the skier who wishes to procure a new pair of boots goes into a shop, pulls on a stocking in accordance with FIG. 5 and carries out knee bends, i.e. active movements under load (for example with weights on the shoulders).",
"Passive movements would also enter into question, i.e. the apparatus of FIGS. 6A and 6B could also be used here.",
"If now the acoustic signal analysis shows that the respective skier can easily achieve a forward knee position up to 30° but that a further going forward knee position beyond this angle leads to an undesired loading of the knee joint—determined by the changing knee sounds—then the respective sport shop knows that the boots suitable for him must be set or selected such that they block a forward knee position of 30° or make a movement beyond 30° substantially more difficult.",
"This prevents the skier skiing in a forward knee position which is damaging for him.",
"[0144] In order to realize this it is naturally necessary, which is also sensible with the embodiments described here, for the joint noises to be evaluated in an angle specific manner in accordance with the degree of bending of the joint, which also requires a device to be provided which measures the degree of bending.",
"[0145] If the signals are recorded using an orthosis in accordance with FIG. 6B then an angular measuring device can for example be incorporated in the joint 144 , or the control signals for the motor 150 , can be used for this purpose.",
"For example, the motor could be turned in one direction until the spindle 152 has been almost screwed out of the nut 156 so that the joint is located in its extended position.",
"When the stop is achieved here this is assumed to be 0° of bending.",
"If the motor 150 is for example designed as a stepping motor then a precise determination of the respective bending angle of the apparatus for each movement on the stepping motor and of the spindle can be found from the particulars of the pitch of the thread of the threaded spindle 152 and the geometry of the orthosis.",
"[0146] A special feature of the present invention lies in the fact that an animation is possible which facilitates the diagnosis of the respectively present problem and is also easily comprehended by the patient or proband.",
"With reference to the knee joint one can now imagine that the pictures which are shown in FIGS. 4A to 4 C appear schematically in the screen of the computer 34 , as shown in FIG. 10, and on the movement of the knee joint the corresponding movement of the joint parts is shown on the screen by an appropriate animation.",
"Here the angle signals which are discussed above can be useful for the purpose of the animation.",
"In any event the signal evaluation can be used in order to indicate on the screen animation the regions where problem positions are to be found as a result of the signal evaluation.",
"For example, the corresponding positions could be emphasized on the screen by a flushing representation or by a special coloring, so that the doctor can for example say to a patient “Look at that, your inner meniscus is damaged”",
"or “You are suffering from arthrosis.”",
"This emphasizing of the damaged positions can either take place by a static representation of the joint images according to FIGS. 4A to 4 C or with a simultaneous movement of the joint members or, if the problem only occurs in a specific angular range in a representation which corresponds to this angular range, for example with an angular bending of the knee of 30°, which could above all be indicated in accordance with the illustration of FIG. 4B.",
"One possibility of realizing such representation is shown schematically in FIG. 10.",
"Here we see the above discussed computer 34 and it is illustrated schematically that the computer communicates via a data line 200 with two memory areas 202 and 204 .",
"[0147] These memory areas 202 and 204 can be present in the computer itself or they can for example be realized in the external memories, for example remote memories.",
"The data line 200 could for example also be understood as an internet connection so that the computer 34 stands in the doctor's practice, whereas the memory regions which can be accessed by the computer 34 stand at a remote location.",
"[0148] In the memory 202 there are then, for example, stored a series of histograms corresponding to FIGS. 7B and 8B whereas in the region 204 corresponding representations of the knee are contained illustrating the respective problem.",
"i.e. the computer 34 carries out a spectral analysis as a result of the respective recordings by the doctor, which are supplied to the computer via the line 18 , and accesses the correspondingly stored reference histograms or patterns from the region 202 and the matching pictures from the memory 204 and shows them on the screen.",
"When the joint shown on the screen is moved in the context of the animation in accordance with the movement of the joint being investigated then this movement in the screen can take place substantially more slowly so that the problem areas can be more easily recognized by the viewer of the screen.",
"Although only four memory regions for frequency analysis and animation possibilities ( 202 A, 202 B, 202 C and 202 D and 204 A, 204 B, 204 C and 204 D) are shown in FIG. 10, in practice a large number of different frequency analyses and animation possibilities or diagnoses is stored.",
"FIG. 10 is to be understood purely by way of example and applies not only for knee joints but rather for all other joints which come into question.",
"[0149] Summarizing it is emphasized that a computer program with a specific representation of the joint that is investigated will be relatively simple to produce.",
"One can schematically represent every joint analogously to the above described scheme.",
"Problem zones such as, for example, frictional processes, trapping of soft tissues, trapping of meniscuses etc.",
"could be shown schematically.",
"In this way a particular person can observe his joint during the movement.",
"In similar manner one can show soft tissues such as the point of trapping in the cause of the tendon.",
"This would be a very important aspect in rehabilitation, performance sports etc.",
"The bio feedback roll should also not be forgotten.",
"For example, with pathological pressure of the patella on the upper limb sliding roll between, for example, 60° and 80° an exercise machine could be especially set (analogously to the Cybex 2-apparatus).",
"In this way one could avoid the pathological friction processes in this range.",
"A further example for the use of this method (data bank, corresponding apparatus, corresponding joint splint with sensors or microphones) would be the adaptation of the ski shoes with respect to the knee joint.",
"A majority of skiers suffer retropatellar pain, such as for example chondropathic patella.",
"The acoustic determination of the forward knee position of the shoe could take place depending on the pathological signals from the knee joint.",
"It would be of great importance both for the performance skier and also for the recreational skier.",
"With a physiological, non-damaged joint a very wide/soft forward knee position is naturally possible without restriction.",
"With pathology a difficult forward knee position should be used in dependence on the acoustic signal.",
"This is the only method where a picture yielding method comes about in orthopaedics from an acoustic signal.",
"The advantage of this method is an active representation—for example bending and extension, which can be repeated as desired.",
"[0150] An animation (computer animation) of the joint model controlled by acoustic waves from the real joint is realized, with this animation being capable of being used both in investigations, in therapy, in rehabilitation and/or during training.",
"[0151] The possibility of diverse attachment of an auxiliary device to the whole or to part of the extremity should also be pointed out, with the auxiliary device being able to have one joint or several joints.",
"Moreover, the possibility of adjustable and measurable movements (and force distribution) in all planes should be pointed out coupled to adjustable main movement;",
"for example the possibility of additional distractions, compressions and rotations, for example of physiological end rotations also with knee extension, additional compression with fractures or after operations and utilization of the distraction relief or action on the whole joint, not just one sided pivoting opening or distraction, analogous to the methods of Ilisarow, for example with bone extension."
] |
BACKGROUND OF THE INVENTION
This invention relates to the removal of sulfur from a hydrocarbon feedstock, particularly the removal of extremely small quantities of thiophene sulfur.
Generally, sulfur occurs in petroleum and syncrude stocks as hydrogen sulfide, organic sulfides, organic disulfides, mercaptans, also known as thiols, and aromatic ring compounds such as thiophene, benzothiophene and related compounds. The sulfur is aromatic sulfur-containing ring compounds will be herein referred to as "thiophene sulfur".
Conventionally, feeds with substantial amounts of sulfur, for example, those with more than 10 ppm sulfur, are hydrotreated with conventional catalysts under conventional conditions, thereby changing the form of most of the sulfur in the feed to hydrogen sulfide. Then the hydrogen sulfide is removed by distillation, stripping or related techniques. Such techniques can leave some traces of sulfur in the feed, including thiophenic sulfur, which is the most difficult type to convert.
Such hydrotreated naphtha feeds are frequently used as feed for catalytic dehydrocyclization, also known as reforming. Some of these catalysts are extremely sulfur sensitive, particularly those that contain zeolitic components. Others of these catalysts can tolerate sulfur in the levels found in typical reforming feeds.
One conventional method of removing residual hydrogen sulfide and mercaptan sulfur is the use of sulfur sorbents. See for example U.S. Pat. Nos. 4,204,997 and 4,163,708, both by R. L. Jacobson and K. R. Gibson. The concentration of sulfur in this form can be reduced to considerably less than 1 ppm by the use of the appropriate sorbent and conditions, but it is difficult to remove sulfur to less than 0.1 ppm or to remove any residual thiophene sulfur. See for example U.S. Pat. No. 4,179,361 by M. J. Michlmayr, and particularly Example 1 in that Patent. In particular, very low space velocities are required, to remove thiophene sulfur, requiring large reaction vessels filled with sorbent, and even with these precautions, traces of thiophene sulfur can get through.
It would be advantageous to have a process to remove most sulfur, including thiophene sulfur, from a reforming feedstream.
SUMMARY OF THE INVENTION
This invention provides a method for removing residual sulfur from a hydrotreated naphtha feedstock comprising:
(a) contacting the feedstock with hydrogen under mild reforming conditions in the presence of a less sulfur sensitive reforming catalyst, thereby carrying out some reforming reactions and also converting trace sulfur compounds to H 2 S and forming a first effluent;
(b) contacting said first effluent with a solid sulfur sorbent, to remove the H 2 S, thereby forming a second effluent which is less than 0.1 ppm sulfur;
(c) contacting said second effluent with a highly selective reforming catalyst which is more sulfur sensitive under severe reforming coditions in subsequent reactors.
DETAILED DESCRIPTION
The naphtha fraction of crude distillate, containing low molecular weight sulfur-containing impurities, such as mercaptans, thiophene, and the like, is usually subjected to a preliminary hydrodesulfurization treatment. The effluent from this treatment is subjected to distillation-like processes to remove H 2 S. The effluent from the distillation step will typically contain between 0.2 and 5 ppm sulfur, and between 0.1 and 2 ppm thiophene sulfur. This may be enough to poison selective sulfur sensitive reforming catalysts in a short period of time. So the resulting product stream, which is the feedstream to the reforming step, is then contacted with a highly efficient sulfur sorbent before being contacted with the sensitive reforming catalyst. Contacting this stream with a conventional sulfur sorbent removes most of the easily removed H 2 S sulfur and most of the mercaptans but tends to leave any unconverted thiophene sulfur. Sulfur sorbents that effectively remove thiophene sulfur require low space velocities; for example, liquid hourly space velocities of less than 1 hr. -1 have been reported in actual examples.
FIRST REFORMING CATALYST
The first reforming catalyst is a less sulfur sensitive catalyst which is a Group VIII metal plus a promotor metal if desired supported on a refractory inorganic oxide metal. Suitable refractory inorganic oxide supports include alumina, silica, titania, magnesia, boria, and the like and combinations, for example silica and alumina or naturally occurring oxide mixtures such as clays. The preferred Group VIII metal is platinum. Also a promoter metal, such as rhenium, tin, germanium, iridium, rhodium, and ruthenium, may be present. Preferably, the less sulfur sensitive reforming catalyst comprises platinum plus a promoter metal such as rhenium if desired, an alumina support, and the accompanying chloride. Such a reforming catalyst is discussed fully in U.S. Pat. No. 3,415,737, which is hereby incorporated by reference.
The hydrocarbon conversion process with the first reforming catalyst is carried out in the presence of hydrogen at a pressure adjusted so as to favor the dehydrogenation reaction thermodynamically and limit undesirable hydrocracking reaction by kinetic means. The pressures used vary from 15 psig to 500 psig, and are preferably between from about 50 psig to about 300 psig; the molar ratio of hydrogen to hydrocarbons preferably being from 1:1 to 10:1, more preferably from 2:1 to 6:1.
The sulfur conversion reaction occurs with acceptable speed and selectively in the temperature range of from 300° C. to 500° C. Therefore, the first reforming reactor is preferably operated at a temperature in the range of between about 350° C. and 480° C. which is known as mild reforming conditions.
When the operating temperature of the first reactor is more than about 300° C., the sulfur conversion reaction speed is sufficient to accomplish the desired reactions. At higher temperatures, such as 400° C. or more, some reforming reactions, particularly dehydrogenation of naphthenes, begin to accompany the sulfur conversion. These reforming reactions are endothermic and can result in a temperature drop of 10°-50° C. as the stream passes through the first reactor. When the operating temperature of the first reactor is above 500° C., an unnecessarily large amount of reforming takes place which is accompanied by hydrocracking and coking. In order to minimize these undesirable side reactions, we limit the first reactor temperature to about 500° C. or preferably 480° C. The liquid hourly space velocity of the hydrocarbons in the first reforming reactor reaction is preferably between 3 and 15.
Reforming catalysts have varying sensitivities to sulfur in the feedstream. Some reforming catalysts are less sensitive, and do not shown substantially reduced activity if the sulfur level is kept below about 5 ppm. When they are deactivated by sulfur and coke buildup they can generally be regenerated by burning off the sulfur and coke deposits. Preferably, the first reforming catalyst is this type.
SULFUR SORBENT
The effluent from the first reforming step, hereinafter the "first effluent", is then contacted with a sulfur sorbent. This sulfur sorbent must be capable of removing the H 2 S from the first effluent to less than 0.1 ppm at mild reforming temperatures, about 300° to 450° C. Several sulfur sorbents are known to work well at these temperatures. The sorbent reduces the amount of sulfur in the feedstream to amounts less than 0.1 ppm, thereby producing what will hereinafter be referred to as the "second effluent". However, the water level should be kept fairly low, preferably to less than 100 ppm, and more preferably to less than 50 ppm in the hydrogen recycle stream.
The sulfur sorbent of this invention will contain a metal that readily reacts to form a metal sulfide supported by a refractory inorganic oxide or carbon support. Preferable metals include zinc, molybdenum, cobalt, tungsten potassium, sodium, calcium, barium, and the like. The support preferred for potassium, sodium, calcium and barium is the refractory inorganic oxides, for example, alumina, silica, boria, magnesia, titania, and the like. In addition, zinc can be supported on fibrous magnesium silicate clays, such as attapulgite, sepiolite, and palygorskite. A particularly preferred support is one of attapulgite clay with about 5 to 30 weight percent binder oxide added for increased crush strength. Binder oxides can include refractory inorganic oxides, for example, alumina, silica, titania and magnesia.
A preferred sulfur sorbent of this invention will be a support containing between 20 and 40 weight percent of the metal. The metal can be placed on the support in any conventional manner, such as impregnation. But the preferred method is to mull a metal-containing compound with the support to form an extrudable paste. The paste is extruded and the extrudate dried and calcined. Typical metal compounds that can be used are the metal carbonates which decompose to form the oxide upon calcining.
The effluent from the sulfur sorber, which is the vessel containing the sulfur sorbent, hereinafter the second effluent, will contain less than 0.1 ppm sulfur and preferably less than 0.05 ppm sulfur. The sulfur levels can be maintained as low as 0.05 ppm for long periods of time. Since both the less sulfur sensitive reforming catalyst and the solid sulfur sorbent can be nearly the same size a possible and preferred embodiment of this invention is that the less sulfur sensitive reforming catalyst and the solid sulfur sorbent are layered in the same reactor. Then the thiophene sulfur can be converted to hydrogen sulfide and removed in a single process unit.
In one embodiment, more than one sulfur sorbent is used. In this embodiment, a first sulfur sorbent, such as zinc or zinc oxide on a carrier to produce a sulfurlean effluent, then a second sulfur sorbent, such as a metal compound of Group IA or Group IIA metal is used to reduce the hydrogen sulfide level of the effluent to below 50 ppb, then the effluent is contacted with the highly selective reforming catalyst.
THE MORE SELECTIVE REFORMING CATALYSTS
The second effluent is contacted with a more selective and more sulfur sensitive reforming catalyst at higher temperatures typical of reforming units. The paraffinic components of the feedstock are cyclized and aromatized while in contact with this more selective reforming catalyst. The removal of sulfur from the feed stream in the first two steps of this invention make it possible to attain a much longer life than is possible without sulfur protection.
The more selective reforming catalyst of this invention is a large-pore zeolite charged with one or more dehydrogenating constituents. The term "large-pore zeolite" is defined as a zeolite having an effective pore diameter of 6 to 15 Angstroms.
Among the large-pore crystalline zeolites which have been found to be useful in the practice of the present invention, type L zeolite, zeolite X, zeolite Y and faujasite are the most important and have apparent pore sizes on the order to 7 to 9 Angstroms.
A composition of type L zeolite, expressed in terms of mole ratios of oxides, may be represented as follows:
(0.9-1.3)M.sub.2/n O:AL.sub.2 O.sub.3 (5.2-6.9)SiO.sub.2 :yH.sub.2 O
wherein M designates a cation, n represents the valence of M, and y may be any value from 0 to about 9. Zeolite L, its X-ray diffraction pattern, its properties, and method for its preparation are described in detail in U.S. Pat. No. 3,216,789. The real formula may vary without changing the crystalline structure; for example, the mole ratio of silicon to aluminum (Si/Al) may vary from 1/.0 to 3.5.
The chemical formula for zeolite Y expressed in terms of mole ratios of oxides may be written as:
(0.7-1.1)Na.sub.2 O:Al.sub.2 O.sub.3 :xSIO.sub.2 :yH.sub.2 O
wherein x is a value greater than 3 up to about 6 and Y may be a value up to about 9. Zeolite Y has a characteristic X-ray powder diffraction pattern which may be employed with the above formula for identification. Zeolite Y is described in more detail in U.S. Pat. No. 3,130,007. U.S. Pat. No. 3,130,007 is hereby incorporated by reference to show a zeolite useful in the present invention.
Zeolite X is a synthetic crystalline zeolitic molecular sieve which may be represented by the formula:
(0.7-1.1)M.sub.2/n O:Al.sub.2 O.sub.3 :(2.0-3.0)SiO.sub.2 :yH.sub.2 O
wherein M represents a metal, particularly alkali and alkaline earth metals, n is the valence of M, and y may have any value up to about 8 depending on the identity of M and the degree of hydration of the crystalline zeolite. Zeolite X, its X-ray diffraction pattern, its properties, and method for its preparation are described in detail in U.S. Pat. No. 2,882,244.
It is preferred that the more sulfur sensitive reforming catalyst of this invention is a type L zeolite charged with one or more dehydrogenating constituents.
A preferred element of the present invention is the presence of an alkaline earth metal in the large-pore zeolite. That alkaline earth metal may be either barium, strontium or calcium, preferably barium. The alkaline earth metal can be incorporated into the zeolite by synthesis, impregnation or ion exchange. Barium is preferred to the other alkaline earths because it results in a somewhat less acidic catalyst. Strong acidity is undesirable in the catalyst because it promotes cracking, resulting in lower selectivity.
In one embodiment, at least part of the alkali metal is exchanged with barium, using techniques known for ion exchange of zeolites. This involves contacting the zeolite with a solution containing excess Ba ++ ions. The barium should constitute from 0.1% to 35% of the weight of the zeolite.
The large-pore zeolitic dehydrocyclization catalysts according to the invention are charged with one or more Group VIII metals, e.g., nickel, ruthenium, rhodium, palladium, iridium or platinum.
The preferred Group VIII metals are iridiuim and particularly platinum, which are more selective with regard to dehydrocyclization and are also more stable under the dehydrocyclization conditions than other Group VIII metals.
The preferred percentage of platinum in the dehydrocyclization catalyst is between 0.1% and 5%, preferably from 0.2% to 1%.
Group VIII metals are introduced into the large-pore zeolite by snythesis, impregnation or exchange in an aqueous solution of appropriate salt. When it is desired to introduce two Group VIII metals into the zeolite, the operation may be carried out simultaneously or sequentially.
EXAMPLE 1
This is an example of the present invention. A feedstock containing measured amounts of various impurities was passed over a reforming catalyst and then a sulfur sorbent. The less sensitive reforming catalyst was made by the method of U.S. Pat. No. 3,415,737.
The sulfur sorbent was prepared by mixing 150 grams alumina with 450 grams attapulgite clay, adding 800 grams zinc carbonate, and mixing the dry powders together. Enough water was added to the mixture to make a mixable paste which was then extruded. The resulting extrudate was dried and calcined.
The sulfur sorbent had properties as follows:
______________________________________Bulk density 0.70 gm/ccPore volume 0.60 cc/gmN.sub.2 surface area 86 m.sup.2 /gm; andCrush strength 1.5 lbs/mm.______________________________________
The final catalyst contained approximately 40 wt.% zinc as metal.
A reformer feed was first contacted with the lens sensitive reforming catalyst and then with the sulfur sorber. Thiophene was added to a sulfur free feed to bring the sulfur level to about 10 ppm. The product from the sulfur sorber was analyzed for sulfur. If the level was below 0.1 ppm it could have been used as feed for a more sulfur sensitive reforming catalyst.
The data is tabulated on Table I.
TABLE I______________________________________ Feed Sulfur Sulfur 1st Reactor 2nd Reactor (ppm)Day (ppm) Temperature °F. Temperature °F. Analysis______________________________________1-7 11.7 850 (454° C.) 650 (343° C.) 0.057-9 7.2 850 " 650 " <0.04 9-12 8.0 850 " 650 " <0.0513 10.5 850 " 650 " 0.0614-15 10.5 850 " 700 (370° C.)16 10.5 800 (425° C.) 700 " 0.0417-19 10.5 750 (400° C.) 700 " 0.0420-21 10.5 700 (370° C.) 700 "22-23 8.6 700 " 700 " <0.0424-28 8.4 700 " 700 " <0.04______________________________________
EXAMPLE 2
A small hydroprocessing reactor was set up containing: 25 cubic centimeters of a mixture of platinum on alumina, as the less sensitive reforming catalyst, and zinc oxide on alumina, as the sulfur sorbent. The effluent from this reactor was passed over 100 cc of L zeolite that had been barium exchanged, which is a highly selective, but vary sulfur sensitive reforming catalyst. The feedstock was a light naphtha feedstock. The results are shown in Table II. One ppm sulfur was added to the feed at 300 hours. The temperature was increased to provide a total C 5 + yield of 88.5 volume percent.
TABLE II______________________________________Hours of Operation Temperature °F.______________________________________200 855400 860600 860800 8701000 8751200 875______________________________________
COMPARATIVE EXAMPLE
When the same L zeolite reforming catalyst is used in the presence of sulfur, it is rapidly deactivated. The temperature was to be adjusted upwards to maintain a constant C 5 + make, but 0.5 ppm sulfur was added at 270 to 360 hours on stream, and no sulfur protection was present. The reforming catalyst deactivated so rapidly that after 450 hours it was no longer possible to maintain a constant C 5 + make. The results are shown in Table III.
TABLE III______________________________________ For 50 wt % Aromatics in Liquid, C.sub.5 + YieldRun time, Hrs. Temperature °F. LV %______________________________________200 862 84.2300 864 85.0350 876 85.6400 887 85.6450 896 85.5500 904 85.8______________________________________
The comparison shows how totally this invention protects the more sulfur sensitive catalyst adding greatly to its life.
The preceding examples are illustrative of preferred embodiments of this invention, and are not intended to narrow the scope of the appended claims. | A process for removing residual sulfur from a hydrotreated naphtha feedstock is disclosed. The feedstock is contacted with molecular hydrogen under reforming conditions in the presence of a less sulfur sensitive reforming catalyst, thereby converting trace sulfur compounds to H 2 S, and forming a first effluent. The first effluent is contacted with a solid sulfur sorbent, removing the H 2 S and forming a second effluent. The second effluent is contacted with a highly selective reforming catalyst under severe reforming conditions. | Provide a concise summary of the essential information conveyed in the given context. | [
"BACKGROUND OF THE INVENTION This invention relates to the removal of sulfur from a hydrocarbon feedstock, particularly the removal of extremely small quantities of thiophene sulfur.",
"Generally, sulfur occurs in petroleum and syncrude stocks as hydrogen sulfide, organic sulfides, organic disulfides, mercaptans, also known as thiols, and aromatic ring compounds such as thiophene, benzothiophene and related compounds.",
"The sulfur is aromatic sulfur-containing ring compounds will be herein referred to as "thiophene sulfur".",
"Conventionally, feeds with substantial amounts of sulfur, for example, those with more than 10 ppm sulfur, are hydrotreated with conventional catalysts under conventional conditions, thereby changing the form of most of the sulfur in the feed to hydrogen sulfide.",
"Then the hydrogen sulfide is removed by distillation, stripping or related techniques.",
"Such techniques can leave some traces of sulfur in the feed, including thiophenic sulfur, which is the most difficult type to convert.",
"Such hydrotreated naphtha feeds are frequently used as feed for catalytic dehydrocyclization, also known as reforming.",
"Some of these catalysts are extremely sulfur sensitive, particularly those that contain zeolitic components.",
"Others of these catalysts can tolerate sulfur in the levels found in typical reforming feeds.",
"One conventional method of removing residual hydrogen sulfide and mercaptan sulfur is the use of sulfur sorbents.",
"See for example U.S. Pat. Nos. 4,204,997 and 4,163,708, both by R. L. Jacobson and K. R. Gibson.",
"The concentration of sulfur in this form can be reduced to considerably less than 1 ppm by the use of the appropriate sorbent and conditions, but it is difficult to remove sulfur to less than 0.1 ppm or to remove any residual thiophene sulfur.",
"See for example U.S. Pat. No. 4,179,361 by M. J. Michlmayr, and particularly Example 1 in that Patent.",
"In particular, very low space velocities are required, to remove thiophene sulfur, requiring large reaction vessels filled with sorbent, and even with these precautions, traces of thiophene sulfur can get through.",
"It would be advantageous to have a process to remove most sulfur, including thiophene sulfur, from a reforming feedstream.",
"SUMMARY OF THE INVENTION This invention provides a method for removing residual sulfur from a hydrotreated naphtha feedstock comprising: (a) contacting the feedstock with hydrogen under mild reforming conditions in the presence of a less sulfur sensitive reforming catalyst, thereby carrying out some reforming reactions and also converting trace sulfur compounds to H 2 S and forming a first effluent;",
"(b) contacting said first effluent with a solid sulfur sorbent, to remove the H 2 S, thereby forming a second effluent which is less than 0.1 ppm sulfur;",
"(c) contacting said second effluent with a highly selective reforming catalyst which is more sulfur sensitive under severe reforming coditions in subsequent reactors.",
"DETAILED DESCRIPTION The naphtha fraction of crude distillate, containing low molecular weight sulfur-containing impurities, such as mercaptans, thiophene, and the like, is usually subjected to a preliminary hydrodesulfurization treatment.",
"The effluent from this treatment is subjected to distillation-like processes to remove H 2 S. The effluent from the distillation step will typically contain between 0.2 and 5 ppm sulfur, and between 0.1 and 2 ppm thiophene sulfur.",
"This may be enough to poison selective sulfur sensitive reforming catalysts in a short period of time.",
"So the resulting product stream, which is the feedstream to the reforming step, is then contacted with a highly efficient sulfur sorbent before being contacted with the sensitive reforming catalyst.",
"Contacting this stream with a conventional sulfur sorbent removes most of the easily removed H 2 S sulfur and most of the mercaptans but tends to leave any unconverted thiophene sulfur.",
"Sulfur sorbents that effectively remove thiophene sulfur require low space velocities;",
"for example, liquid hourly space velocities of less than 1 hr.",
"-1 have been reported in actual examples.",
"FIRST REFORMING CATALYST The first reforming catalyst is a less sulfur sensitive catalyst which is a Group VIII metal plus a promotor metal if desired supported on a refractory inorganic oxide metal.",
"Suitable refractory inorganic oxide supports include alumina, silica, titania, magnesia, boria, and the like and combinations, for example silica and alumina or naturally occurring oxide mixtures such as clays.",
"The preferred Group VIII metal is platinum.",
"Also a promoter metal, such as rhenium, tin, germanium, iridium, rhodium, and ruthenium, may be present.",
"Preferably, the less sulfur sensitive reforming catalyst comprises platinum plus a promoter metal such as rhenium if desired, an alumina support, and the accompanying chloride.",
"Such a reforming catalyst is discussed fully in U.S. Pat. No. 3,415,737, which is hereby incorporated by reference.",
"The hydrocarbon conversion process with the first reforming catalyst is carried out in the presence of hydrogen at a pressure adjusted so as to favor the dehydrogenation reaction thermodynamically and limit undesirable hydrocracking reaction by kinetic means.",
"The pressures used vary from 15 psig to 500 psig, and are preferably between from about 50 psig to about 300 psig;",
"the molar ratio of hydrogen to hydrocarbons preferably being from 1:1 to 10:1, more preferably from 2:1 to 6:1.",
"The sulfur conversion reaction occurs with acceptable speed and selectively in the temperature range of from 300° C. to 500° C. Therefore, the first reforming reactor is preferably operated at a temperature in the range of between about 350° C. and 480° C. which is known as mild reforming conditions.",
"When the operating temperature of the first reactor is more than about 300° C., the sulfur conversion reaction speed is sufficient to accomplish the desired reactions.",
"At higher temperatures, such as 400° C. or more, some reforming reactions, particularly dehydrogenation of naphthenes, begin to accompany the sulfur conversion.",
"These reforming reactions are endothermic and can result in a temperature drop of 10°-50° C. as the stream passes through the first reactor.",
"When the operating temperature of the first reactor is above 500° C., an unnecessarily large amount of reforming takes place which is accompanied by hydrocracking and coking.",
"In order to minimize these undesirable side reactions, we limit the first reactor temperature to about 500° C. or preferably 480° C. The liquid hourly space velocity of the hydrocarbons in the first reforming reactor reaction is preferably between 3 and 15.",
"Reforming catalysts have varying sensitivities to sulfur in the feedstream.",
"Some reforming catalysts are less sensitive, and do not shown substantially reduced activity if the sulfur level is kept below about 5 ppm.",
"When they are deactivated by sulfur and coke buildup they can generally be regenerated by burning off the sulfur and coke deposits.",
"Preferably, the first reforming catalyst is this type.",
"SULFUR SORBENT The effluent from the first reforming step, hereinafter the "first effluent", is then contacted with a sulfur sorbent.",
"This sulfur sorbent must be capable of removing the H 2 S from the first effluent to less than 0.1 ppm at mild reforming temperatures, about 300° to 450° C. Several sulfur sorbents are known to work well at these temperatures.",
"The sorbent reduces the amount of sulfur in the feedstream to amounts less than 0.1 ppm, thereby producing what will hereinafter be referred to as the "second effluent".",
"However, the water level should be kept fairly low, preferably to less than 100 ppm, and more preferably to less than 50 ppm in the hydrogen recycle stream.",
"The sulfur sorbent of this invention will contain a metal that readily reacts to form a metal sulfide supported by a refractory inorganic oxide or carbon support.",
"Preferable metals include zinc, molybdenum, cobalt, tungsten potassium, sodium, calcium, barium, and the like.",
"The support preferred for potassium, sodium, calcium and barium is the refractory inorganic oxides, for example, alumina, silica, boria, magnesia, titania, and the like.",
"In addition, zinc can be supported on fibrous magnesium silicate clays, such as attapulgite, sepiolite, and palygorskite.",
"A particularly preferred support is one of attapulgite clay with about 5 to 30 weight percent binder oxide added for increased crush strength.",
"Binder oxides can include refractory inorganic oxides, for example, alumina, silica, titania and magnesia.",
"A preferred sulfur sorbent of this invention will be a support containing between 20 and 40 weight percent of the metal.",
"The metal can be placed on the support in any conventional manner, such as impregnation.",
"But the preferred method is to mull a metal-containing compound with the support to form an extrudable paste.",
"The paste is extruded and the extrudate dried and calcined.",
"Typical metal compounds that can be used are the metal carbonates which decompose to form the oxide upon calcining.",
"The effluent from the sulfur sorber, which is the vessel containing the sulfur sorbent, hereinafter the second effluent, will contain less than 0.1 ppm sulfur and preferably less than 0.05 ppm sulfur.",
"The sulfur levels can be maintained as low as 0.05 ppm for long periods of time.",
"Since both the less sulfur sensitive reforming catalyst and the solid sulfur sorbent can be nearly the same size a possible and preferred embodiment of this invention is that the less sulfur sensitive reforming catalyst and the solid sulfur sorbent are layered in the same reactor.",
"Then the thiophene sulfur can be converted to hydrogen sulfide and removed in a single process unit.",
"In one embodiment, more than one sulfur sorbent is used.",
"In this embodiment, a first sulfur sorbent, such as zinc or zinc oxide on a carrier to produce a sulfurlean effluent, then a second sulfur sorbent, such as a metal compound of Group IA or Group IIA metal is used to reduce the hydrogen sulfide level of the effluent to below 50 ppb, then the effluent is contacted with the highly selective reforming catalyst.",
"THE MORE SELECTIVE REFORMING CATALYSTS The second effluent is contacted with a more selective and more sulfur sensitive reforming catalyst at higher temperatures typical of reforming units.",
"The paraffinic components of the feedstock are cyclized and aromatized while in contact with this more selective reforming catalyst.",
"The removal of sulfur from the feed stream in the first two steps of this invention make it possible to attain a much longer life than is possible without sulfur protection.",
"The more selective reforming catalyst of this invention is a large-pore zeolite charged with one or more dehydrogenating constituents.",
"The term "large-pore zeolite"",
"is defined as a zeolite having an effective pore diameter of 6 to 15 Angstroms.",
"Among the large-pore crystalline zeolites which have been found to be useful in the practice of the present invention, type L zeolite, zeolite X, zeolite Y and faujasite are the most important and have apparent pore sizes on the order to 7 to 9 Angstroms.",
"A composition of type L zeolite, expressed in terms of mole ratios of oxides, may be represented as follows: (0.9-1.3)M.",
"sub[.",
"].2/n O:AL.",
"sub[.",
"].2 O.sub[.",
"].3 (5.2-6.9)SiO.",
"sub[.",
"].2 :yH.",
"sub[.",
"].2 O wherein M designates a cation, n represents the valence of M, and y may be any value from 0 to about 9.",
"Zeolite L, its X-ray diffraction pattern, its properties, and method for its preparation are described in detail in U.S. Pat. No. 3,216,789.",
"The real formula may vary without changing the crystalline structure;",
"for example, the mole ratio of silicon to aluminum (Si/Al) may vary from 1/[.",
"].0 to 3.5.",
"The chemical formula for zeolite Y expressed in terms of mole ratios of oxides may be written as: (0.7-1.1)Na.",
"sub[.",
"].2 O:Al.",
"sub[.",
"].2 O.sub[.",
"].3 :xSIO.",
"sub[.",
"].2 :yH.",
"sub[.",
"].2 O wherein x is a value greater than 3 up to about 6 and Y may be a value up to about 9.",
"Zeolite Y has a characteristic X-ray powder diffraction pattern which may be employed with the above formula for identification.",
"Zeolite Y is described in more detail in U.S. Pat. No. 3,130,007.",
"U.S. Pat. No. 3,130,007 is hereby incorporated by reference to show a zeolite useful in the present invention.",
"Zeolite X is a synthetic crystalline zeolitic molecular sieve which may be represented by the formula: (0.7-1.1)M.",
"sub[.",
"].2/n O:Al.",
"sub[.",
"].2 O.sub[.",
"].3 :(2.0-3.0)SiO.",
"sub[.",
"].2 :yH.",
"sub[.",
"].2 O wherein M represents a metal, particularly alkali and alkaline earth metals, n is the valence of M, and y may have any value up to about 8 depending on the identity of M and the degree of hydration of the crystalline zeolite.",
"Zeolite X, its X-ray diffraction pattern, its properties, and method for its preparation are described in detail in U.S. Pat. No. 2,882,244.",
"It is preferred that the more sulfur sensitive reforming catalyst of this invention is a type L zeolite charged with one or more dehydrogenating constituents.",
"A preferred element of the present invention is the presence of an alkaline earth metal in the large-pore zeolite.",
"That alkaline earth metal may be either barium, strontium or calcium, preferably barium.",
"The alkaline earth metal can be incorporated into the zeolite by synthesis, impregnation or ion exchange.",
"Barium is preferred to the other alkaline earths because it results in a somewhat less acidic catalyst.",
"Strong acidity is undesirable in the catalyst because it promotes cracking, resulting in lower selectivity.",
"In one embodiment, at least part of the alkali metal is exchanged with barium, using techniques known for ion exchange of zeolites.",
"This involves contacting the zeolite with a solution containing excess Ba ++ ions.",
"The barium should constitute from 0.1% to 35% of the weight of the zeolite.",
"The large-pore zeolitic dehydrocyclization catalysts according to the invention are charged with one or more Group VIII metals, e.g., nickel, ruthenium, rhodium, palladium, iridium or platinum.",
"The preferred Group VIII metals are iridiuim and particularly platinum, which are more selective with regard to dehydrocyclization and are also more stable under the dehydrocyclization conditions than other Group VIII metals.",
"The preferred percentage of platinum in the dehydrocyclization catalyst is between 0.1% and 5%, preferably from 0.2% to 1%.",
"Group VIII metals are introduced into the large-pore zeolite by snythesis, impregnation or exchange in an aqueous solution of appropriate salt.",
"When it is desired to introduce two Group VIII metals into the zeolite, the operation may be carried out simultaneously or sequentially.",
"EXAMPLE 1 This is an example of the present invention.",
"A feedstock containing measured amounts of various impurities was passed over a reforming catalyst and then a sulfur sorbent.",
"The less sensitive reforming catalyst was made by the method of U.S. Pat. No. 3,415,737.",
"The sulfur sorbent was prepared by mixing 150 grams alumina with 450 grams attapulgite clay, adding 800 grams zinc carbonate, and mixing the dry powders together.",
"Enough water was added to the mixture to make a mixable paste which was then extruded.",
"The resulting extrudate was dried and calcined.",
"The sulfur sorbent had properties as follows: ______________________________________Bulk density 0.70 gm/ccPore volume 0.60 cc/gmN.",
"sub[.",
"].2 surface area 86 m.sup[.",
"].2 /gm;",
"andCrush strength 1.5 lbs/mm.",
"______________________________________ The final catalyst contained approximately 40 wt.",
"% zinc as metal.",
"A reformer feed was first contacted with the lens sensitive reforming catalyst and then with the sulfur sorber.",
"Thiophene was added to a sulfur free feed to bring the sulfur level to about 10 ppm.",
"The product from the sulfur sorber was analyzed for sulfur.",
"If the level was below 0.1 ppm it could have been used as feed for a more sulfur sensitive reforming catalyst.",
"The data is tabulated on Table I. TABLE I______________________________________ Feed Sulfur Sulfur 1st Reactor 2nd Reactor (ppm)Day (ppm) Temperature °F.",
"Temperature °F.",
"Analysis______________________________________1-7 11.7 850 (454° C.) 650 (343° C.) 0.057-9 7.2 850 "",
"650 "",
"<0.04 9-12 8.0 850 "",
"650 "",
"<0.0513 10.5 850 "",
"650 "",
"0.0614-15 10.5 850 "",
"700 (370° C.)16 10.5 800 (425° C.) 700 "",
"0.0417-19 10.5 750 (400° C.) 700 "",
"0.0420-21 10.5 700 (370° C.) 700 "22-23 8.6 700 "",
"700 "",
"<0.0424-28 8.4 700 "",
"700 "",
"<0.04______________________________________ EXAMPLE 2 A small hydroprocessing reactor was set up containing: 25 cubic centimeters of a mixture of platinum on alumina, as the less sensitive reforming catalyst, and zinc oxide on alumina, as the sulfur sorbent.",
"The effluent from this reactor was passed over 100 cc of L zeolite that had been barium exchanged, which is a highly selective, but vary sulfur sensitive reforming catalyst.",
"The feedstock was a light naphtha feedstock.",
"The results are shown in Table II.",
"One ppm sulfur was added to the feed at 300 hours.",
"The temperature was increased to provide a total C 5 + yield of 88.5 volume percent.",
"TABLE II______________________________________Hours of Operation Temperature °F.",
"______________________________________200 855400 860600 860800 8701000 8751200 875______________________________________ COMPARATIVE EXAMPLE When the same L zeolite reforming catalyst is used in the presence of sulfur, it is rapidly deactivated.",
"The temperature was to be adjusted upwards to maintain a constant C 5 + make, but 0.5 ppm sulfur was added at 270 to 360 hours on stream, and no sulfur protection was present.",
"The reforming catalyst deactivated so rapidly that after 450 hours it was no longer possible to maintain a constant C 5 + make.",
"The results are shown in Table III.",
"TABLE III______________________________________ For 50 wt % Aromatics in Liquid, C.sub[.",
"].5 + YieldRun time, Hrs.",
"Temperature °F.",
"LV %______________________________________200 862 84.2300 864 85.0350 876 85.6400 887 85.6450 896 85.5500 904 85.8______________________________________ The comparison shows how totally this invention protects the more sulfur sensitive catalyst adding greatly to its life.",
"The preceding examples are illustrative of preferred embodiments of this invention, and are not intended to narrow the scope of the appended claims."
] |
FIELD OF THE INVENTION
[0001] This invention relates to a three-dimensional computer graphics rendering system in particular to methods and apparatus associated with rendering of textures in a tile based rendering system.
BACKGROUND TO THE INVENTION
[0002] Within real time computer graphics it is common to perform renders to surfaces which can then be used as textures in subsequent renders i.e. the rendered surface becomes a new texture or a “Dynamically Rendered” texture. For example in order to render a scene that includes reflections of the scene it is common to first render the scene to an environment texture map. This map is then used during the shading of objects to produce a reflection of the environment on the objects. This may be used, for example to show a reflection in a mirrored building.
[0003] In addition to environment mapping it is common for modern computer graphics applications to use a technique called shadow mapping. The shadow mapping technique renders the depth of objects from the perspective of light sources within the scene into texture maps. These texture maps are used during the subsequent rendering of objects to determine if each pixel is in shadow with respect to the light sources. This is done by comparing the depth of the object pixel being rendered to a depth that is stored at the equivalent location within a “shadow map” texture, for example if the depth of the object is greater than that in the shadow map then it is behind another object with respect to the light source and therefore the illuminating effect of the light source should not be applied during the rendering of that pixel. It is very common for textures associated with shadow maps to be very large e.g. 2048×2048 or greater, with larger texture sizes generally being required for higher quality rendering.
[0004] It should be noted that there are many variations on the above techniques and that the above two are included as examples and that the scope of the invention is not limited to these techniques.
[0005] In modern graphics applications these renders to textures and the subsequent reads from them can use a significant percentage of the available memory bandwidth to render a scene at interactive frame rates. Furthermore it is not unusual for much of the data rendered into these textures to not be subsequently used. For example FIG. 1 illustrates a previously rendered texture 100 subdivided into regions T 0 to T 23 and a region 110 that maps a portion of the texture 100 into the triangle 120 . As can be seen only tiles T 3 , T 8 , T 9 , T 14 to T 16 , T 21 and T 22 of the previously rendered texture need to have been rasterised in order to satisfy the mapping of the texture to the triangle 120 .
[0006] Tile based rendering systems are well-known. These subdivide an image into a plurality of rectangular blocks or tiles. The way in which this is done and the subsequent texturing and the shading performed is shown schematically in FIG. 2 .
[0007] Firstly, a primitive/command fetch unit 201 retrieves command and primitive data from a memory and passes this to a geometry processing unit 202 . This transforms the primitive and command data into screen space using well-known methods.
[0008] This data is then supplied to a tiling unit 203 which inserts object data from the screen space geometry into object lists for each one of a set of defined rectangular regions or tiles. An object list for each tile contains primitives that exist wholly or partially in that tile. The list exists for every tile on the screen, although some object lists may have no data in them. These object lists are fetched by a tile parameter fetch unit 205 which supplies them tile by tile to a hidden surface removal unit (HSR) 206 which removes surfaces which will not contribute to the final scene (usually because they are obscured by another surface). The HSR unit processes each primitive in the tile and passes only data for visible pixels to a shading unit 208 .
[0009] The shading unit takes the data from the HSR and uses it to fetch textures using the texture unit 210 and applies shading to each pixel within a visible object using well-known techniques. The shading unit then feeds the textured and shaded data to an on chip tile buffer 212 . As the data is temporarily stored in the on chip tile buffer external memory bandwidth associated with temporary storage eliminated.
[0010] Once each tile has been textured and shaded, the resultant data is written to an external scene buffer 214 .
SUMMARY OF THE INVENTION
[0011] Preferred embodiments of the present invention provide a method and apparatus that enable a tile based rendering system to rasterise and store rendered texture surfaces only where they are to be used by subsequent renders. This is accomplished in an embodiment of the invention by performing the tiling phase as described above for all texture surfaces but deferring the rasterisation phase of those dynamically rendered texture surfaces to the point at which they are referenced. As the rendering of the scene that uses the “demand based texture renders” (e.g. 100 from FIG. 1 ) potentially only references a small area of each texture within each tile the system can render one or more texture tiles at the point of reference into a small write back cache for immediate use within the main render. Due to the localised nature of the references it is highly likely that the rendered data will continue to reside within the cache subsystem for any tiles for which it is required, thereby substantially reducing the memory bandwidth associated with both the rendering of the textures and their subsequent use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred embodiments of the invention will now be described in detail by way of example with reference to the accompanying drawings in which:
[0013] FIG. 1 illustrates schematically how a small region of a previously rendered texture may be subsequently referenced for texturing an object;
[0014] FIG. 2 shows a schematic diagram of a known tile based rendering system as discussed above;
[0015] FIG. 3 illustrates the operation of demand based texture rendering embodying the invention;
[0016] FIG. 4 illustrates the modifications to a tile based rendering system for demand based texture rendering in an embodiment of the invention; and
[0017] FIG. 5 illustrates the modifications to the texture pipeline required to implement demand based texture rendering in an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] FIG. 3 illustrates the operation of demand mode texture rasterisation in a tile based system. An application 300 first generates geometry 305 for an image which is to be rendered to a texture as in 100 in FIG. 1 . This geometry is processed at 310 using well known techniques to produce screen space geometry that is passed to a tiling unit 315 which generates tile screen space parameters 320 as described for a tile based rendering system. It should be noted that the current state of each tile within the texture i.e. if it has been rendered is indicated by a valid flags table 358 . This table is generally stored within memory and contains a status flag for each tile that indicates if it has been rendered, all flags are initially cleared to indicate that no tiles have been rendered. Each time a tile is rendered a flag corresponding to that tile is set.
[0019] The application then switches to the rendering of a main scene at 330 by producing main scene geometry 335 which is then processed into screen space by geometry processor 340 and tiled at 345 to produce an object list for each tile. The resulting main scene parameters 350 are then rasterised a tile at a time at 355 . During the rasterisation process the rasterisation hardware (not shown) detects areas of dynamic texture e.g. an environment map that are required but are not present in the texture store. These correspond to texturing of the type discussed with reference to FIG. 1 above. The rasteriser determines if each texture tile (as shown in FIG. 1 ) has been rendered by reading the tile valid flags 358 . When the rasteriser determines that a texture tile has not yet been rendered the rasteriser switches from rasterising the main scene to rasterising parameters for the texture tiles required by the texture render 320 that are associated with the required region. The subsequent rasterisation process 375 produces texture image data for T 3 380 (from FIG. 1 ) which is written to a cache 360 . A corresponding valid flag for the texture tile is then set and the rasterisation hardware then switches back to rasterising the main scene 355 at 385 . This process is repeated for all regions of the scene which are found to be required from the dynamic texture. For example from FIG. 1 regions T 3 , T 8 , T 9 , T 14 , T 15 , T 16 , T 21 and T 22 . It should be noted that the remaining regions of the dynamic texture are not rasterised saving significant memory bandwidth and processing overhead.
[0020] It should be noted that the texture tile data written to the cache may either be written back to memory (not shown) or discarded when it is evicted from the cache 360 . In the case where the data is discarded it may be re-created again in the future as described above if the tile (e.g. T 3 ) is referenced again. This approach allows very large texture surfaces to be represented by the memory associated with the tiled geometry parameters only. Where texture data is discarded instead of being writtenback to memory the corresponding valid flags 358 are cleared to indicate that the texture is no longer present.
[0021] FIG. 4 illustrates a system that implements tile based demand mode rendering of texture surfaces using dynamic textures as discussed above. It should be noted that the tiling/geometry processing units equivalent to these shown in FIG. 2 are not shown here. Tile parameter fetch unit 410 fetches the tiled parameter lists as per a normal tile based rendering system and passes the object data to the hidden surface removal unit (HSR) 420 . This removes surfaces which will not contribute to the final scene (usually because they are obscured by another surface) using well known methods. The HSR unit processes each primitive in the tile and passes only data for surfaces visible at pixels to a shading unit 430 .
[0022] The shading unit 430 takes the objects from the HSR unit 420 and applies shading and texturing to each pixel within each visible object using well-known techniques, these technique include issuing texture requests to a texture sampling unit (TSU) 460 .
[0023] The TSU is illustrated in FIG. 5 . The texture address unit 500 takes texture sample requests and calculates the X and Y address for each texture fetch using well known methods. The X and Y address is passed to the tile address calculation unit 550 which determines the address of the tile that the requested texture fetches will reside within. This calculation typically removes low order bits from the X and Y addresses to form a tile X and Y address, these values are then multiplied together and added to a base address to form the address of a “Tile valid flag” stored in the tile valid table ( FIG. 4 480 ), which is stored in memory, it should be noted that other methods of address calculation could be used. The address of the valid flag is passed to the valid flag fetch unit 560 that retrieves the specified flag from valid flag table in memory. This flag is then emitted as the “Not present” signal 570 . It should be noted that the valid flag fetch unit 560 could operate through a memory cache in order to improve its performance. The valid flag fetch unit also passes the valid flag to the address converter 520 which converts the X,Y address to a linear memory address using well known methods. If the valid flag indicates that a texture tile is not present then the address converter unit halts execution. If the valid flag indicates that a texture tile is present then the address converter unit passes the calculated texture address to the texture cache unit 530 which retrieves the texture data from either internal or external memory as necessary. The retrieved data is passed to the texture filtering unit 540 which filters the returned data using well known techniques, the resulting filtered data being passed back to the shading unit 430 in FIG. 4 .
[0024] If the flag indicates that the texture tile hasn't already been rasterised the “not present” signal 570 is sent to the context switch unit (CSU) 400 in FIG. 4 indicating that it needs to switch to rasterising a tile of the texture that “missed” i.e. the texture was not available. This occurs for dynamically rendered textures, such as environment textures.
[0025] The CSU then instructs all units within the rasteriser to switch to rasterising the requested texture i.e. the missed texture tile. It should be noted that the CSU could rasterise a single missing tile or multiple tiles within the locality of the missing texture. The CSU 400 may be implemented as a hardware module, a separate programmable processor/micro controller or using a “Host” processor and device interrupts.
[0026] As the system rasterises each tile indicated by the CSU a buffer 440 outputs each completed texture tile to memory via a cache 470 . This cache will typically use the well known caching type of “write back caching” so that the data resides locally within the cache when the tiles indicated by the CSU have been rasterised. The CSU then updates the tile valid flags 480 for the tiles that it has rasterised to indicate that they are now present. The cache will now store the dynamically mapped texture required for rasterisation of tiles which were flagged as requiring that texture.
[0027] On completion of the rasterisation process for the required tile(s) the CSU switches the rasterisation units back to processing the original render and allows the address converter 520 in FIG. 5 to proceed to issue the texture address to the cache unit as described above. As the texture tiles that were rasterised now sit locally within the cache any texture fetches for them now access the cache so reducing memory bandwidth associated with those fetches, i.e. dynamically mapped textures stored in the cache.
[0028] It should be noted that the cache could be replaced with a memory buffer that discards tiles rather than writing them back to memory when making space for new tile data. In these circumstances the discarded tiles that are references again will need to be rasterised again using the above process. | A method and apparatus are provided for shading and texturing computer graphic images in a tile based rendering system using dynamically rendered textures. Scene space geometry is derived for a dynamically rendered texture and passed to a tiling unit which derives scene space geometry for a scene which references the textures. Scene space geometry for a scene that references the dynamically rendered texture is also derived and passed to the tiling unit. The tiling unit uses object data derived from the scene space geometry to detect reference to areas of dynamically rendered textures, as yet un-rendered. These are then dynamically rendered. | Summarize the key points of the given document. | [
"FIELD OF THE INVENTION [0001] This invention relates to a three-dimensional computer graphics rendering system in particular to methods and apparatus associated with rendering of textures in a tile based rendering system.",
"BACKGROUND TO THE INVENTION [0002] Within real time computer graphics it is common to perform renders to surfaces which can then be used as textures in subsequent renders i.e. the rendered surface becomes a new texture or a “Dynamically Rendered”",
"texture.",
"For example in order to render a scene that includes reflections of the scene it is common to first render the scene to an environment texture map.",
"This map is then used during the shading of objects to produce a reflection of the environment on the objects.",
"This may be used, for example to show a reflection in a mirrored building.",
"[0003] In addition to environment mapping it is common for modern computer graphics applications to use a technique called shadow mapping.",
"The shadow mapping technique renders the depth of objects from the perspective of light sources within the scene into texture maps.",
"These texture maps are used during the subsequent rendering of objects to determine if each pixel is in shadow with respect to the light sources.",
"This is done by comparing the depth of the object pixel being rendered to a depth that is stored at the equivalent location within a “shadow map”",
"texture, for example if the depth of the object is greater than that in the shadow map then it is behind another object with respect to the light source and therefore the illuminating effect of the light source should not be applied during the rendering of that pixel.",
"It is very common for textures associated with shadow maps to be very large e.g. 2048×2048 or greater, with larger texture sizes generally being required for higher quality rendering.",
"[0004] It should be noted that there are many variations on the above techniques and that the above two are included as examples and that the scope of the invention is not limited to these techniques.",
"[0005] In modern graphics applications these renders to textures and the subsequent reads from them can use a significant percentage of the available memory bandwidth to render a scene at interactive frame rates.",
"Furthermore it is not unusual for much of the data rendered into these textures to not be subsequently used.",
"For example FIG. 1 illustrates a previously rendered texture 100 subdivided into regions T 0 to T 23 and a region 110 that maps a portion of the texture 100 into the triangle 120 .",
"As can be seen only tiles T 3 , T 8 , T 9 , T 14 to T 16 , T 21 and T 22 of the previously rendered texture need to have been rasterised in order to satisfy the mapping of the texture to the triangle 120 .",
"[0006] Tile based rendering systems are well-known.",
"These subdivide an image into a plurality of rectangular blocks or tiles.",
"The way in which this is done and the subsequent texturing and the shading performed is shown schematically in FIG. 2 .",
"[0007] Firstly, a primitive/command fetch unit 201 retrieves command and primitive data from a memory and passes this to a geometry processing unit 202 .",
"This transforms the primitive and command data into screen space using well-known methods.",
"[0008] This data is then supplied to a tiling unit 203 which inserts object data from the screen space geometry into object lists for each one of a set of defined rectangular regions or tiles.",
"An object list for each tile contains primitives that exist wholly or partially in that tile.",
"The list exists for every tile on the screen, although some object lists may have no data in them.",
"These object lists are fetched by a tile parameter fetch unit 205 which supplies them tile by tile to a hidden surface removal unit (HSR) 206 which removes surfaces which will not contribute to the final scene (usually because they are obscured by another surface).",
"The HSR unit processes each primitive in the tile and passes only data for visible pixels to a shading unit 208 .",
"[0009] The shading unit takes the data from the HSR and uses it to fetch textures using the texture unit 210 and applies shading to each pixel within a visible object using well-known techniques.",
"The shading unit then feeds the textured and shaded data to an on chip tile buffer 212 .",
"As the data is temporarily stored in the on chip tile buffer external memory bandwidth associated with temporary storage eliminated.",
"[0010] Once each tile has been textured and shaded, the resultant data is written to an external scene buffer 214 .",
"SUMMARY OF THE INVENTION [0011] Preferred embodiments of the present invention provide a method and apparatus that enable a tile based rendering system to rasterise and store rendered texture surfaces only where they are to be used by subsequent renders.",
"This is accomplished in an embodiment of the invention by performing the tiling phase as described above for all texture surfaces but deferring the rasterisation phase of those dynamically rendered texture surfaces to the point at which they are referenced.",
"As the rendering of the scene that uses the “demand based texture renders”",
"(e.g. 100 from FIG. 1 ) potentially only references a small area of each texture within each tile the system can render one or more texture tiles at the point of reference into a small write back cache for immediate use within the main render.",
"Due to the localised nature of the references it is highly likely that the rendered data will continue to reside within the cache subsystem for any tiles for which it is required, thereby substantially reducing the memory bandwidth associated with both the rendering of the textures and their subsequent use.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0012] Preferred embodiments of the invention will now be described in detail by way of example with reference to the accompanying drawings in which: [0013] FIG. 1 illustrates schematically how a small region of a previously rendered texture may be subsequently referenced for texturing an object;",
"[0014] FIG. 2 shows a schematic diagram of a known tile based rendering system as discussed above;",
"[0015] FIG. 3 illustrates the operation of demand based texture rendering embodying the invention;",
"[0016] FIG. 4 illustrates the modifications to a tile based rendering system for demand based texture rendering in an embodiment of the invention;",
"and [0017] FIG. 5 illustrates the modifications to the texture pipeline required to implement demand based texture rendering in an embodiment of the invention.",
"DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0018] FIG. 3 illustrates the operation of demand mode texture rasterisation in a tile based system.",
"An application 300 first generates geometry 305 for an image which is to be rendered to a texture as in 100 in FIG. 1 .",
"This geometry is processed at 310 using well known techniques to produce screen space geometry that is passed to a tiling unit 315 which generates tile screen space parameters 320 as described for a tile based rendering system.",
"It should be noted that the current state of each tile within the texture i.e. if it has been rendered is indicated by a valid flags table 358 .",
"This table is generally stored within memory and contains a status flag for each tile that indicates if it has been rendered, all flags are initially cleared to indicate that no tiles have been rendered.",
"Each time a tile is rendered a flag corresponding to that tile is set.",
"[0019] The application then switches to the rendering of a main scene at 330 by producing main scene geometry 335 which is then processed into screen space by geometry processor 340 and tiled at 345 to produce an object list for each tile.",
"The resulting main scene parameters 350 are then rasterised a tile at a time at 355 .",
"During the rasterisation process the rasterisation hardware (not shown) detects areas of dynamic texture e.g. an environment map that are required but are not present in the texture store.",
"These correspond to texturing of the type discussed with reference to FIG. 1 above.",
"The rasteriser determines if each texture tile (as shown in FIG. 1 ) has been rendered by reading the tile valid flags 358 .",
"When the rasteriser determines that a texture tile has not yet been rendered the rasteriser switches from rasterising the main scene to rasterising parameters for the texture tiles required by the texture render 320 that are associated with the required region.",
"The subsequent rasterisation process 375 produces texture image data for T 3 380 (from FIG. 1 ) which is written to a cache 360 .",
"A corresponding valid flag for the texture tile is then set and the rasterisation hardware then switches back to rasterising the main scene 355 at 385 .",
"This process is repeated for all regions of the scene which are found to be required from the dynamic texture.",
"For example from FIG. 1 regions T 3 , T 8 , T 9 , T 14 , T 15 , T 16 , T 21 and T 22 .",
"It should be noted that the remaining regions of the dynamic texture are not rasterised saving significant memory bandwidth and processing overhead.",
"[0020] It should be noted that the texture tile data written to the cache may either be written back to memory (not shown) or discarded when it is evicted from the cache 360 .",
"In the case where the data is discarded it may be re-created again in the future as described above if the tile (e.g. T 3 ) is referenced again.",
"This approach allows very large texture surfaces to be represented by the memory associated with the tiled geometry parameters only.",
"Where texture data is discarded instead of being writtenback to memory the corresponding valid flags 358 are cleared to indicate that the texture is no longer present.",
"[0021] FIG. 4 illustrates a system that implements tile based demand mode rendering of texture surfaces using dynamic textures as discussed above.",
"It should be noted that the tiling/geometry processing units equivalent to these shown in FIG. 2 are not shown here.",
"Tile parameter fetch unit 410 fetches the tiled parameter lists as per a normal tile based rendering system and passes the object data to the hidden surface removal unit (HSR) 420 .",
"This removes surfaces which will not contribute to the final scene (usually because they are obscured by another surface) using well known methods.",
"The HSR unit processes each primitive in the tile and passes only data for surfaces visible at pixels to a shading unit 430 .",
"[0022] The shading unit 430 takes the objects from the HSR unit 420 and applies shading and texturing to each pixel within each visible object using well-known techniques, these technique include issuing texture requests to a texture sampling unit (TSU) 460 .",
"[0023] The TSU is illustrated in FIG. 5 .",
"The texture address unit 500 takes texture sample requests and calculates the X and Y address for each texture fetch using well known methods.",
"The X and Y address is passed to the tile address calculation unit 550 which determines the address of the tile that the requested texture fetches will reside within.",
"This calculation typically removes low order bits from the X and Y addresses to form a tile X and Y address, these values are then multiplied together and added to a base address to form the address of a “Tile valid flag”",
"stored in the tile valid table ( FIG. 4 480 ), which is stored in memory, it should be noted that other methods of address calculation could be used.",
"The address of the valid flag is passed to the valid flag fetch unit 560 that retrieves the specified flag from valid flag table in memory.",
"This flag is then emitted as the “Not present”",
"signal 570 .",
"It should be noted that the valid flag fetch unit 560 could operate through a memory cache in order to improve its performance.",
"The valid flag fetch unit also passes the valid flag to the address converter 520 which converts the X,Y address to a linear memory address using well known methods.",
"If the valid flag indicates that a texture tile is not present then the address converter unit halts execution.",
"If the valid flag indicates that a texture tile is present then the address converter unit passes the calculated texture address to the texture cache unit 530 which retrieves the texture data from either internal or external memory as necessary.",
"The retrieved data is passed to the texture filtering unit 540 which filters the returned data using well known techniques, the resulting filtered data being passed back to the shading unit 430 in FIG. 4 .",
"[0024] If the flag indicates that the texture tile hasn't already been rasterised the “not present”",
"signal 570 is sent to the context switch unit (CSU) 400 in FIG. 4 indicating that it needs to switch to rasterising a tile of the texture that “missed”",
"i.e. the texture was not available.",
"This occurs for dynamically rendered textures, such as environment textures.",
"[0025] The CSU then instructs all units within the rasteriser to switch to rasterising the requested texture i.e. the missed texture tile.",
"It should be noted that the CSU could rasterise a single missing tile or multiple tiles within the locality of the missing texture.",
"The CSU 400 may be implemented as a hardware module, a separate programmable processor/micro controller or using a “Host”",
"processor and device interrupts.",
"[0026] As the system rasterises each tile indicated by the CSU a buffer 440 outputs each completed texture tile to memory via a cache 470 .",
"This cache will typically use the well known caching type of “write back caching”",
"so that the data resides locally within the cache when the tiles indicated by the CSU have been rasterised.",
"The CSU then updates the tile valid flags 480 for the tiles that it has rasterised to indicate that they are now present.",
"The cache will now store the dynamically mapped texture required for rasterisation of tiles which were flagged as requiring that texture.",
"[0027] On completion of the rasterisation process for the required tile(s) the CSU switches the rasterisation units back to processing the original render and allows the address converter 520 in FIG. 5 to proceed to issue the texture address to the cache unit as described above.",
"As the texture tiles that were rasterised now sit locally within the cache any texture fetches for them now access the cache so reducing memory bandwidth associated with those fetches, i.e. dynamically mapped textures stored in the cache.",
"[0028] It should be noted that the cache could be replaced with a memory buffer that discards tiles rather than writing them back to memory when making space for new tile data.",
"In these circumstances the discarded tiles that are references again will need to be rasterised again using the above process."
] |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of the following patent applications, the disclosures of which are specifically incorporated herein by reference: U.S. patent application Ser. No. 09/649,470, entitiled SYSTEM AND METHOD FOR VERIFYING DIGITAL POSTAL MARKS (E-998) filed on Aug. 28, 2000 now U.S. Pat No. 6,810,390; and U.S. patent application Ser. No. 09/748,889, entitiled MAIL PIECE VERIFICATION SYSTEM (F-212) filed on Dec. 27, 2000.
FIELD OF THE INVENTION
This invention relates to mail piece verification systems. More particularly, this invention is directed to a mail piece verification system conducting successive verification activities on a mail piece along different stages of a mail processing system.
BACKGROUND OF THE INVENTION
Generally, postage metering systems are well known in the art. Typically, the traditional mechanical and electronic postage meters have employed physical security and specialized inks to prevent fraud. The registers that maintain an accounting of postal funds have been located within a secure housing along with a dedicated printer. As a further measure, the dedicated printers have used fluorescent ink to provide an extra aid in the detection of an authentic postage meter indicium.
More recently, postal authorities have promulgated regulations that allow postage meter manufacturers to utilized digital printing technology (laser, ink jet, thermal transfer, etc.), either embedded as part of a mail handling system or as a general purpose office printer. As an example, the United States Postal Service (USPS) has enabled the decoupling of the postage meter and the printer and allowed the use of digital printers by establishing an Information-Based Indicia Program (IBIP). The IBIP is a distributed trusted system established by the USPS to retrofit and augment existing postage meters using new technology known as information-based indicia. The IBIP relies on digital signature techniques to produce for each mail piece an indicium whose origin cannot be repudiated. Thus, in contrast to traditional postage metering systems employing mechanical printing technology and physical security, the IBIP supports new methods of securely applying postage to mail pieces. Generally, the IBIP requires printing a high-density two-dimensional (2D) bar code on a mail piece. The 2D barcode encodes various information associated with the mail piece and is subsequently signed with a digital signature.
The USPS has published detailed specifications for the IBIP. Generally, the IBIP is directed to two types of postage metering systems. The first type is referred to as a closed system and is defined in the INFORMATION BASED INDICIA PROGRAM—PERFORMANCE CRITERIA FOR INFORMATION-BASED INDICIA AND SECURITY ARCHITECTURE FOR CLOSED IBI POSTAGE METERINGS SYSTEMS, dated Jan. 12, 1999, (“IBIP Closed System Specification”). The second type is referred to as an open system and is defined in the INFORMATION BASED INDICIA PROGRAM—PERFORMANCE CRITERIA FOR INFORMATION-BASED INDICIA AND SECURITY ARCHITECTURE FOR OPEN IBI POSTAGE EVIDENCING SYSTEMS, dated Feb. 23, 2000, (“IBIP Open System Specification”). Together, the IBIP Closed System Specification and the IBIP Open System Specification define the requirements for next generation postage metering systems.
Although the transition to digital printing provides many advantages, the postal authorities recognize that digital printing spawns potential new forms of fraud. As an example, an individual seeking to commit a fraud upon the postal authority need only utilize their computer, image scanner and printer to generate multiple copies of a single postal indicium. Thus, a valid indicium may be replicated perfectly. This technique is referred to as fraud by duplication.
As a result, measures have been developed to detect such attempts to defraud the postal authorities. Typically, these measures involve verifying the authenticity of the postal indicium on a mail piece as the mail piece is being processed by the postal authority. This verification activity seeks to ensure that the postage amount shown in the postal indicium has been properly accounted for. For instance, the postal authority may validate the digital signature discussed above to determine the authenticity of the postal indicium. However, this will not necessarily expose a second mail piece with a duplicated postal indicium representing an exact copy of a valid indicium. Thus, detection of these types of duplicates, and other issues, present problems for the postal authorities.
Another problem faced by the postal authorities is the intensive data processing required of a distributed mail processing system employing a plurality of remotely located processing centers. Typically, the processing center must scan each postal indicium to obtain its data, conduct database lookups, perform cryptographic calculations and determine whether or not the postal indicium is valid. If a mail piece cannot be validated, it is diverted to an out sort bin for further investigation and/or return to the sender. Complicating this situation is the fact that such verification processing is conducted by a single mail piece processing system. This necessitates that the verification processing is completed during the interval between mail piece scanning and the diversion location to the out sort bin. Given the rate at which the processing machines operate (up to 12 mail pieces per second), there is very little time to perform verification checks.
Still further complications exist. If the cryptographic computations are to be performed locally (on individual processing machines), then large amounts of data must be distributed to all of the processing machines (e.g. cryptographic keys for each postage meter, data to enable detection of duplicate indicia) and kept updated to reflect changes in the meter population. On the other hand, if the computations are performed remotely, then the postal indicium data for each mail piece must be transmitted in real time to a central location, validated and the results returned to the processing machine before the mail piece reaches the diversion point. Both of these arrangements require significant real time processing and rapid database access.
Yet another problem is the risk that the digital signatures and cryptography underlying the security of the postal system could be compromised. This could occur because of a successful attack or the release/use of information necessary to generate valid postal indicia by someone (a postal authority employee) having access to the security system. Once compromised in this manner, someone could print “valid” postal indicia that would pass verification by the postal authority. Thus, the postal authority would suffer losses from a fraudulent actor submitting postal indicia into the postal system that to all appearances would be beyond reproach.
Therefore, there is a need for a mail piece verification system that provides operational advantages over those described above. Furthermore, there is a need for a mail piece verification system that includes a forensic accounting capability for improving upon the detection of apparently valid postal indicia.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a mail piece verification system that addresses the drawbacks and disadvantage of the prior art systems.
In accomplishing these and other objects there is provided a mail piece verification system for processing mail pieces having associated therewith respective mail piece data. The system includes a plurality of postage metering systems for preparing mail pieces, a plurality of mail processing centers for receiving mail pieces and obtaining the respective mail piece data and a data center in operative communication with the plurality of postage metering systems and the plurality of mail processing centers, the data center including a plurality of account files corresponding to the plurality of postage metering systems. The data center stores reset data in each of the plurality of account files representative of reset activity associated with the plurality of postage metering systems, respectively, receives respective mail piece data corresponding to the mail pieces from the plurality of mail processing centers, uses the respective mail piece data, storing empirical data in each of the plurality of account files representative of mailing activity associated with the plurality of postage metering systems, respectively, and conducts a forensic accounting analysis of the empirical data and the reset data associated with a selected postage metering system.
Additionally, there are provided a method of operating the mail piece verification system, a method of operating a data center for processing mail piece data and a data structure, respectively, that are generally analogous to the summary provided above.
Therefore, it should now be apparent that the invention substantially achieves all the above objects and advantages. Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts.
FIG. 1 is a schematic representation of a mail piece verification system in accordance with the present invention.
FIG. 2 is an example of a postal indicium printed by a postage metering system that is processed by the mail piece verification system in accordance with the present invention.
FIG. 3 is an example of a prior art mail piece that may be verified by the verification system in accordance with the present invention.
FIG. 4 is a flow chart depicting the operation of the mail piece verification system in accordance with the present invention.
FIG. 5 is a flow chart depicting an account reconciliation routine conducted by the mail piece verification system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a schematic representation a mail piece verification system 100 for processing a mail piece 20 (envelope, post card, package, label, e-mail, or the like), produced by a postage metering system 25 and having a postal indicium 30 printed thereon (or attached to, embedded in or otherwise associated with electronic forms of the mail piece 20 ), in a path of travel as indicated by the solid arrows is shown. The mail piece verification system 100 includes a deposit location 110 , an incoming mail processing center 120 having an incoming out sort bin 122 , a central postal data center 130 , a transportation system 140 , an outgoing mail processing center 150 having an outgoing out sort bin 152 and a delivery location 160 . The central postal data center 130 includes an account database 132 and is in operative communication with the incoming mail processing center 120 and the outgoing mail processing center 150 over any suitable conventional communication network, such as: telephone lines, a local area network, a wide area network, the Internet or the like. The account database 132 includes a plurality of customer account files 134 , described in greater detail below. Generally, as shown in FIG. 1 , the solid lines with arrows are intended to represent the flow of the mail piece 20 while the dashed lines with arrows are intended to represent data flow, as described in greater detail below.
For the sake of clarity, the mail piece verification system 100 has been shown with respect to a particular mail piece 20 and a single postage metering system 25 . Those skilled in the art will recognize that the mail piece verification system 100 may employ a plurality of deposit locations 110 that receive mail pieces 20 from a plurality of postage metering systems 25 and direct them to a plurality of incoming mail processing centers 120 . From these centers 120 , the mail pieces 20 are transported over a plurality of transportation systems 140 to a plurality of outgoing mail processing centers 150 so that the mail pieces may be delivered to a plurality of delivery locations 160 , accordingly. Thus, the mail piece verification system 100 represents a network of systems that connect the deposit locations 110 to the delivery locations 160 . Each mail piece 20 is routed through the mail piece verification system 100 (network) according to numerous factors, such as: the class of service selected and the physical locations of the deposit 110 and the delivery location 160 .
The deposit location 110 may be any acceptance point (post office window, mail box, computer server, etc.) that the postal authority has designated for receiving mail pieces 20 from the public. The incoming mail processing center 120 may or may not be co-located with the deposit location 110 . In either case, the mail pieces 20 are directed by postal authority to the incoming mail processing center 120 which may employ one or more mail processing machines, such as the Small Parcel and Bundle Sorter, the Advanced Facer Canceller System or the Flats Sorting Machine, all available from Lockheed Martin—Postal Automation Systems. These mail processing machines typically perform preliminary tasks on the mail pieces 20 , such as: culling, positioning (facing the mail piece), POSTNET bar code printing, sorting and the like. Any mail pieces 20 that are deemed unacceptable are diverted to the out sort bin 122 . Once the preliminary mail processing tasks are completed, the mail piece 20 travels over the transportation system 140 to the outgoing mail processing center 150 . The transportation system 140 may employ any suitable combination of physical transport, such as: truck, plane, boat, car, computer network, or the like. The outgoing mail processing center 150 is very similar to the incoming mail processing center 120 and may employ one or more of the same types of mail processing machines described above. These mail processing machines typically perform secondary tasks on the mail pieces 20 , such as: culling, positioning, POSTNET bar code reading, sorting and the like. Any mail pieces 20 that are deemed unacceptable are diverted to the out sort bin 152 . Once the secondary mail processing tasks are completed, the mail piece 20 is routed via a designated post office to the delivery location 160 (home address, business address, post office box, computer account, IP address or the like).
Those skilled in the art will recognize that any combination of incoming mail processing centers 120 , transportation systems 140 and outgoing mail processing centers 150 may be employed to effect receipt of the mail piece 20 at the deposit location 110 and route the mail piece 20 to the delivery location 160 . For example, many intermediate processing centers may be employed and the transportation system 140 may be deployed in stages. Numerous factors, such as the class of service and the physical proximity of the deposit location 110 to the delivery location 160 , may influence the exact route that a particular mail piece 20 may take while it is in transit.
Furthermore, those skilled in the art will appreciate that the incoming mail processing center 120 and the outgoing mail processing center 150 may be co-located. In fact, they may actually be the same mail processing center. In some ways what differentiates the incoming mail processing center 120 from the outgoing mail processing center 150 is the status of the mail piece 20 . If the mail piece 20 has just been received, then the mail processing center is operating as the incoming mail processing center 120 . On the other hand, if the mail piece 20 is well along its delivery route, then the mail processing center is operating as the outgoing mail processing center 150 . Thus, at any given location, the same mail processing center may be operating as both an incoming mail processing center 120 (for the mail pieces 20 that have just been deposited for delivery) and as an outgoing mail processing center 150 (for the mail pieces 20 that have already been processed and are nearing their delivery points).
Still further, instead of being a singular facility, the postal data center 130 may be embodied as a plurality of regional postal data centers that are geographically dispersed and networked together using suitable communication techniques. This may allow for various advantages, such as: system redundancy (in case of failures), quicker response times and reduced communication expenses, while preserving the benefits of the communication path ways generally described above and in more detail below.
Generally, the plurality of postage metering systems 25 are in communication with the central postal data center 130 over any conventional communication lines for the purpose of conducting remote inspections and meter resets (downloading of postal funds) as is known in the art. The postage metering systems 25 may be of any conventional type, such as those commercially available (ClickStamp® Online, PostPerfect®, Paragon® II, DM200™, etc.) from Pitney Bowes Inc. of Stamford, Conn. A historical account of the disbursement of these postal funds is maintained in the account database 132 . Each of the plurality of customer account files 134 includes an account identifier (numeric, alpha-numeric, etc.) 134 a , a list of postage meter serial numbers (one or more) 134 b associated with the account identifier 134 a , meter reset activity data 134 c and empirical mailing activity data 134 d (described in greater detail below). The postage meter serial numbers 134 b correspond to the meter serial number 32 that in printed in the postal indicium 30 . Preferably, the reset activity data 134 c includes a reset date and a reset amount that is stored for each meter reset transaction associated with each particular postage metering system 25 . Thus, a historical log of an amount of postage that has been purchased by each postage metering system 25 is maintained. Those skilled in the art will recognize that the account identifier 134 a and the postage meter serial numbers 134 b may be collapsed into a single identifier that serves to identify the customer.
Referring to FIG. 2 in view of FIG. 1 , a more detailed view of the postal indicium 30 printed by the postage metering system 25 is shown. Since the postal indicium 30 does not constitute a part of the present invention, the following description is being provided with respect to a particular type of postal indicium 30 by way of background. Generally, the postal indicium 30 includes both fixed data that does not change from indicium to indicium and variable data that may change. The fixed and variable data may change depending upon postal authority requirements and the needs of the postage system manufacturer, but generally can be summarized as follows. The fixed data includes a graphic design 31 (an eagle with stars and US POSTAGE), a meter serial number 32 uniquely identifying the postage meter (not shown) that produced the postal indicium 30 , a licensing post office ID (Zip Code) 33 and an optional facer identification mark (FIM) 34 used during post office processing. The variable data includes a date 35 indicating when the postage was dispensed, a postal value 36 indicating an amount of postage, an indication of a service class (first class, bulk rate, priority, overnight, certified, etc.) that has been selected for the mail piece 20 , a bar code 37 containing both elements of both fixed and variable data and, in the most preferred embodiment, authentication information 38 . The bar code 37 may be of any conventional format and is provided for the purpose of improving machine readability and increasing automated processing of the mail piece 20 . Generally, the authentication information 38 is an encrypted message, such as a digital signature, digital token or other data, derived from the information contained with the postal indicium 30 . The authentication information 38 may be in any format, such as: alphanumeric string, bar code or the like. Most preferably, the authentication information 38 is incorporated into the bar code 37 . Using the authentication information 38 and other data contained within the postal indicium 30 , the postal authority can verify the authenticity of the postal indicium 30 using conventional techniques. Thus, the postal indicium 30 may also be classified as containing authentication information 38 and non-authentication information 31 - 37 and 39 .
As mentioned above, the postal indicium 30 need only be associated with the particular mail piece 20 . Therefore, when the mail piece 20 takes electronic form, the postal indicium 30 may be reconfigured accordingly.
Referring to FIG. 3 , in view of FIGS. 1 and 2 , an example of a prior art mail piece 20 that may be processed by the verification system 100 is shown. The mail piece 20 includes the postal indicium 30 (as described above) produced by a postage metering system 25 , a sender address 40 (optional) and a recipient address 50 . The recipient address 50 provides information to the postal authority corresponding to the delivery location 160 . The typical recipient address 50 includes a recipient name 52 (personal, business or generic (occupant)), recipient delivery information 54 (street address, post office box number, etc.), a city name 56 , a state name 57 and a ZIP code 58 .
With the structure of the present invention described as above, the operational characteristics will now be described with respect to receipt and delivery of the mail piece 20 . For the sake of clarity, it is assumed that the mail piece 20 is processed by only one incoming mail processing center 120 and only one outgoing mail processing center 150 . Referring primarily to FIG. 4 while referencing the structure of FIGS. 1 , 2 and 3 , a flow chart 400 of the general operation of the mail piece verification system 100 in accordance with the present invention is shown. A further detailed discussion of a forensic account reconciliation routine is provided below.
After receiving the mail piece 20 at the deposit location 110 , at 402 , the mail piece 20 is scanned at the incoming mail processing center 120 to obtain mail piece data. The mail piece data may include the postal indicium 30 , the recipient address 50 , the sender address 40 or any combination or subset of the above. Next, at 404 , a determination may optionally be made whether or not the mail piece 20 meets preliminary conditions. In the most preferred embodiment, the preliminary conditions do not involve cryptographic calculations or access to complicated databases. The preliminary conditions may include: recognition of a valid meter serial number 32 , a posting date 35 within an acceptable range of the current date, suitable readability of the mail piece 20 in terms of accuracy and completeness and recognition of a valid recipient address 50 . If at 404 the answer is no, then at 406 the mail piece 20 is out sorted to out sort bin 122 for further investigation, human reading, return to the sender or some other suitable action. On the other hand, if the answer at 404 is yes, then at 408 a global identification number (preferably an alphanumeric string) (not shown) is assigned to the mail piece 20 that uniquely identifies the mail piece 20 to the postal authority. The global identification number may preferably be chosen to reflect other information, such as: the particular incoming mail processing center 110 that received the mail piece 20 . Optionally, the global identification number may be printed on the mail piece 20 in bar code or some other conventional format. Generally, the global identification numbers are allocated to the incoming mail processing center 120 by the central postal data center 130 . In this way, the incoming mail processing center 120 may assign the numbers one at a time as the mail pieces 20 are received. Next, at 410 , the mail piece data and the global identification number are uploaded from the incoming mail processing center 120 to the central postal data center 130 . Next, at 412 , the mail piece 20 is advanced downstream in the path of travel along the delivery route by the transportation system 140 . Next, at 414 , the central postal data center 130 conducts an analysis to see if the mail piece 20 meets secondary conditions. In the most preferred embodiment, the secondary conditions involve cryptographic calculations to determine the validity of the postal indicium 30 . Those skilled in the art will recognize that the mail piece data may be transmitted to a central postal data center 130 for verification either immediately or as a batch process at some later time. Since the incoming mail processing center 120 does not perform cryptographic verification checks, there is no need to distribute sensitive information (e.g., cryptographic keys, “license plates,” duplicate data and the like) to the incoming mail processing center 120 . In addition, the computational requirements for the incoming mail processing center 120 are significantly reduced (no need to rapidly perform database lookups or cryptographic operations).
Next, at 416 , the central postal data center 130 downloads instructions, as necessary, to the outgoing mail processing center 150 for use in processing the mail piece 20 . In the most preferred embodiment, the processing instructions are associated with the global identification number of the mail piece 20 . For example, the instruction may indicate that the mail piece 20 should be diverted to the out sort bin 152 for follow up by a postal authority investigator. As another example, the instructions may indicate that the mail piece 20 should be processed in a normal fashion. In the alternative, instructions may only be supplied for “special” (other than normal) processing. In this situation, the absence of a special instruction (divert instruction) may indicate that the outgoing mail processing center 150 should process the mail piece 20 in a normal fashion. Next, at 418 , the outgoing mail processing center 150 scans the mail piece 20 to obtain the global identification number. As discussed above, it may have even been printed on the mail piece 20 by the incoming mail processing center 120 . Next, at 420 , the outgoing mail processing center 150 retrieves any processing instructions associated with the global identification number through simple database access. Next, at 422 , the outgoing mail processing center 150 processes the mail piece 20 in accordance with the processing instructions, as described above.
With the basic operation of the mail piece verification system described as above, a forensic account reconciliation routine that may be additionally performed by the data center 130 will now be described. Referring primarily to FIG. 5 while referencing the structure of FIGS. 1 , 2 and 3 , a flow chart 500 of the account reconciliation routine of the mail piece verification system 100 in accordance with the present invention is shown. At 502 , the central postal data center 130 conducts a summation of all the mail piece data associated with each individual mail piece 20 that has been processed by the plurality of incoming mail processing centers 120 . Preferably, this summation analysis occurs at predetermined occasions (time based and/or event based) and gathers the mail piece data by the account identifier 134 a and/or by postage meter serial number 134 b . Thus, the summation analysis yields data indicative of the empirical activity associated with each account identifier 134 a and/or postage meter serial number 134 b for a given time period. Accordingly, respective empirical activity data 134 d is stored in each of the plurality of customer account files 134 . The empirical activity data 134 d may include piece counts for each given mail class, postage amounts or any other mailing activity related data sufficient to derive an exact or reliable estimate of an amount of postage consumed. Thus, a historical account of observed mailing activity is maintained by the empirical activity data 134 d . Next, at 504 , the central postal data center 130 reconciles the reset activity data 134 c with the empirical activity data 134 d for consistency. This may involve any degree of forensic account analysis to determine the fidelity of the empirical activity data 134 d in view of the reset activity data 134 c . An example will now be provided. The reset activity data 134 c may be used to ascertain an amount of postage that has been purchased by a respective postage metering system 25 over a given time period. Likewise, the empirical activity data 134 d may be used to ascertain an amount of postage that has been consumed in relation to the given time period. Thus, by comparing the purchased postage amount with the consumed postage amount, the propriety of the customers mailing activities may be established. Those skilled in the art will recognize that because there is generally a time lag between when postage is purchased and when it is consumed, care must be taken when defining what postage purchases should be compared against what mailing activity.
Next, at 506 , a determination is made whether or not the reset activity data 134 c is consistent with the empirical activity data 134 d . For the sake of clarity, it should be understood that this determination could be made for each one of or any subset of the plurality of customer account files 134 . Thus, the plurality of customer account files 134 selected for analysis may be those where suspicions have arisen or based on a period sampling for audit purposes. If at 506 the answer is yes, then at 508 the routine 500 continues normally and no responsive (corrective and/or investigative) action is taken with respect to the customer account file 134 /meter serial number 134 b for which the forensic analysis was conducted. On the other hand, if the answer at 506 is no, then at 510 responsive action is taken. Many possibilities for responsive action exist. As an example, an inspection of the metering system 25 may be conducted. This inspection may involve dispatching an authorized representative to perform a site inspection at the customer's location and/or a remote diagnostic inspection during a subsequent communication session between the metering system 25 and the data center 130 . These inspections would seek to determine if the metering system 25 has been tampered with either physically or electronically. As another example, delivery of mail pieces 20 from the suspect customer account file 134 /meter serial number 134 b may be withheld. As yet another example, new graphic data 31 may be down loaded to the metering system 25 during a subsequent communication session with the data center 130 . The new graphic data 31 may include a tell (hidden clue) that facilitates discerning whether or not the fraudulent indicium 30 has been created by the customer or a third party. As yet still another example, a new meter serial number 134 b may be issued to replace the existing meter serial number 134 b from the suspect customer account file 134 /meter serial number 134 b . Preferably, this occurs after the postage metering system 25 has passed inspection. Then, delivery of mail pieces 20 containing the existing meter serial number 134 b may be withheld while delivery of mail pieces 20 containing the new meter serial number 134 b may continue normally. In this manner, any fraudulent use of the existing meter serial number 134 b by third parties will be met with a suitable counter measure from the postal authority while the rightful use of the new meter serial number 134 b by the customer continues uninterrupted. As yet still another example, the data center 130 may limit a recharge amount of postage that may be downloaded to the postage metering system 25 during a reset operation. In this way, a closed system type of postage metering system 25 would likely have to contact the data center 130 more frequently and thus allow more frequent remote inspections of the postage metering system 25 . Advantages for open system type postage metering systems 25 may also apply. Those skilled in the art will recognize that the examples described above are mutually exclusive and may be implemented in any combination.
The data center 130 may execute this responsive action by providing suitable instructions to the postage metering system 25 and the mail processing centers 120 and 150 .
Those skilled in the art will now recognize that the present invention substantially addresses many of the drawbacks and deficiencies associated with conventional mail processing in addition to those discussed above. Since all cryptographic verification operations (indicium verification, duplicate detection) are performed at the central postal data center 130 , the overall security and integrity of the system 100 are improved but access to the cryptographic information is limited. Since the cryptographic verification operations are generally performed while the mail piece 20 is in transit from the incoming mail processing center 120 to the outgoing mail processing center 150 , this significantly increases the time allotted to perform verification. This extra time enables more detailed checks to be performed. Furthermore, by migrating cryptographic verification operations to the central postal data center 130 , the verification procedures may be more easily modified on an as needed basis (the current system would require major distributed system updates to be performed in order to change verification procedures).
When the mail piece 20 is scanned at the incoming mail processing center 120 , the delivery route through the system 100 to the delivery location 160 is often determined using the ZIP code 33 in view of existing transportation hubs and the proximity of the delivery location 160 to available outgoing mail processing centers 150 . Therefore, even further efficiencies may be available. For example, the need to broadcast the down load of the processing instruction to the entire population of outgoing mail processing centers 150 may be eliminated. Instead, the processing instructions may be directly sent to a particular one of the outgoing mail processing centers 150 corresponding to the determined delivery route of the mail piece. In this manner, the amount of data that is download and the total communications between the central postal data center 130 and the population of outgoing mail processing centers 150 is reduced.
If 100% inspection of the mail stream is conducted by the plurality of incoming mail processing centers 120 , then the verification system 100 becomes a closed loop system due to the account reconciliation routine 500 . Furthermore, because of the summation activity performed by the data center 130 against the mail piece data that has been collected across the plurality of incoming mail processing centers 120 , it does not matter if fraudulent mail pieces 20 are being deposited with different incoming mail centers 120 in an attempt to disperse (and thus conceal) the fraudulent activity. Thus, dispersed fraudulent activity that may otherwise fall within an acceptable “noise” parameter established for a micro level of operation (individual incoming mail centers 120 ) may be detected at a macro level of operation (the data center 130 ).
Furthermore, by having a closed loop system, detection of a successful attack on the system 100 or the unauthorized release/use of postal authority and/or meter manufacturer information necessary to generate postal indicia 30 that would pass cryptographic scrutiny would be detected. Thus, the forensic analysis and counter measures associated with the response actions described above would assist in detecting and controlling this type of fraud.
If limited inspection (less than 100%) of the mail stream is being conducted by the plurality of incoming mail processing centers 120 , then the verification system 100 may operate in a more selective manner. For example, the empirical activity data 134 d that is actually observed may be extrapolated in view of the sampling rates employed by the incoming mail processing centers 120 to develop estimated actual activity data. This estimated actual activity data may then be compared with the reset activity 134 c . If the estimated activity data is exceeds the reset activity 134 c by more than a previously defined threshold amount (i.e. 20%), then the sampling rate for mail pieces 20 associated with the respective meter serial number 134 b may be increased. That is, an instruction may be provided by the data center 130 to the incoming mail processing centers 120 to sample data during the preliminary mail processing tasks from mail pieces 20 containing the respective meter serial number 134 b at a greater frequency (even 100%) than that employed for the mail stream at large. Thus, the data center 130 may develop more precise empirical activity data 134 d.
As a further benefit, the system 100 of the present invention also increases the chance that a pair of duplicate mail pieces 20 can be captured for investigation and/or prosecution. In the current system, a duplicate mail piece 20 can only be detected after the “original” has been processed. Therefore, the current system is not set up to out sort both an original mail piece 20 and a fraudulent copy. Without both mail pieces 20 , prosecution of the offender is likely to be much harder. Since the present invention performs duplicate checking while the mail pieces 20 are in transit and provides the opportunity for downstream diversion, both the original and the duplicate may be captured. In other words, if a duplicate enters the mail stream prior to delivery of the original mail piece 20 , then both mail pieces 20 can be out sorted for investigation.
As yet still another benefit, the service class 39 information may be used to determine a priority for scheduling: (i) the uploading of the mail piece data; (ii) the performance of the secondary checks; and/or (iii) the downloading of the processing instructions. As examples, in this manner, the different data handling needs of a mail piece 20 that has been sent by overnight delivery may be expedited, those of a 1 st class mail piece 20 may be somewhat more moderately attended to while those of a bulk rate mail piece 20 may be addressed in an even more deliberate manner. Thus, the postal authority may more efficiently process the mail piece data based on the service class 39 in view of the amount of delivery time available, the anticipated likelihood of fraud (large volume mailings, such as bulk rate, often are targeted by fraudulent actors than lower volume mailings, such as priority mail) and other factors. As a result, the incoming mail processing center 120 may communicate more frequently with the central postal data center 130 for the purpose of uploading mail piece data associated with short delivery cycles while those of mail pieces 20 having longer delivery cycles may occur during “off peak” periods. Thus, the service class 39 may be used to set a priority for the upload of mail piece data and in analogous fashion the subsequent download of processing instructions.
Those skilled in the art will recognize that various modifications can be made without departing from the spirit of the present invention. For example, a series of central postal data centers 130 in communication with each other could be set up to share and distribute verification tasks. As another example, letter carriers or mail boxes could perform scanning of the postal indicium 30 at time of deposit. This would accelerate the input of the mail piece data into the system 100 . As yet another example, a list of valid mail pieces 20 could be transmitted to the outgoing mail processing centers to ensure that fraudulent mail pieces were not introduced into the mail stream during transport due to corrupt postal authority employees or otherwise. Thus, the central postal data center 130 could download a list of valid global identification numbers. In the absence of the scanned global identification number appearing on such a list, the mail piece 20 could be diverted. As yet still another example, those skilled in the art will recognize that many of the steps and activities described above may be performed in differing orders or concurrently. As still yet another example, if the mail piece 20 is an electronic file, then the postal indicium 30 may be replaced with any other suitable indication of payment and instead of scanning the mail piece 20 , the mail piece data may already be associated with the mail piece 20 such as by attachment as a header file. As still yet another example, the verification system 100 has been described with respect to an unrestricted access system where anyone may utilize the mail piece delivery network. However, those skilled in the art will recognize that the verification system 100 would work equally as well in a restricted access system (such as: subscription based delivery services and the like) where delivery services would only be provided for selected individuals and/or organizations.
As still yet another example, those skilled in the art will recognize that various modifications to the preferred embodiments described above may be made so that the inventive concepts are applied to permit mailing activity. In permit mailing activity, postage metering systems 25 are generally not used. Instead, the postal authority only excepts permit mail under controlled conditions. Typically, for permit mail, the postal authority issues a permit number to the customer and the customer brings the permit mail pieces to the postal authority along with a manifest describing the size or other characteristics of the mail run. In response, the postal authority charges or debits the customer's account accordingly. Thus, this customer account activity is directly analogous to the reset activity data 134 c . As a result, the term reset activity data 134 c should be construed as including any form of postal funds account record keeping that may be employed.
As yet still another example, although the data center 130 has been described generally as under the control of a single entity at a single location, this need not necessarily be the case. The postage meter manufacture may be authorized by the postal authority to conduct be in contact with the postage metering systems 25 and conduct reset operations. However, typically the postal authority is more directly involved with the processing of mail pieces 20 by the mail processing centers 130 and 150 . Thus, in this scenario, an exchange of data between to the data centers 130 operated at different locations or by different entities may be required in order to practice the present invention as described with respect to the preferred embodiments.
Furthermore, although the above description has been provided with respect to pre-payment (debit from existing funds) type postage metering systems 25 (as employed in the United States), the concepts of the present invention apply equally well to post-payment (credit) type postage metering systems 25 (as employed in France). Thus, although the exact reset operations conducted for pre-payment and post-payment postage metering systems 25 may be different, the important similarities are authorization of continued use of the postage metering system 25 and/or inspection of the accounting registers contained with the postage metering system 25 . Thus, reset activity data 134 c should be construed as being directed to those types of activities associated with either type of postage metering system 25 .
Therefore, the inventive concept in its broader aspects is not limited to the specific details of the preferred embodiments but is defined by the appended claims and their equivalents. | A mail piece verification system for processing mail pieces having associated therewith respective mail piece data. The system includes a plurality of postage metering systems for preparing mail pieces, a plurality of mail processing centers for receiving mail pieces and obtaining the respective mail piece data and a data center means in operative communication with the plurality of postage metering systems and the plurality of mail processing centers, the data center means including a plurality of account files corresponding to the plurality of postage metering systems. The data center means stores reset data in each of the plurality of account files representative of reset activity associated with the plurality of postage metering systems, respectively, receives respective mail piece data corresponding to the mail pieces from the plurality of mail processing centers, uses the respective mail piece data, storing empirical data in each of the plurality of account files representative of mailing activity associated with the plurality of postage metering systems, respectively, and conducts a forensic accounting analysis of the empirical data and the reset data associated with a selected postage metering system. | Concisely explain the essential features and purpose of the concept presented in the passage. | [
"CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part application of the following patent applications, the disclosures of which are specifically incorporated herein by reference: U.S. patent application Ser.",
"No. 09/649,470, entitiled SYSTEM AND METHOD FOR VERIFYING DIGITAL POSTAL MARKS (E-998) filed on Aug. 28, 2000 now U.S. Pat No. 6,810,390;",
"and U.S. patent application Ser.",
"No. 09/748,889, entitiled MAIL PIECE VERIFICATION SYSTEM (F-212) filed on Dec. 27, 2000.",
"FIELD OF THE INVENTION This invention relates to mail piece verification systems.",
"More particularly, this invention is directed to a mail piece verification system conducting successive verification activities on a mail piece along different stages of a mail processing system.",
"BACKGROUND OF THE INVENTION Generally, postage metering systems are well known in the art.",
"Typically, the traditional mechanical and electronic postage meters have employed physical security and specialized inks to prevent fraud.",
"The registers that maintain an accounting of postal funds have been located within a secure housing along with a dedicated printer.",
"As a further measure, the dedicated printers have used fluorescent ink to provide an extra aid in the detection of an authentic postage meter indicium.",
"More recently, postal authorities have promulgated regulations that allow postage meter manufacturers to utilized digital printing technology (laser, ink jet, thermal transfer, etc.), either embedded as part of a mail handling system or as a general purpose office printer.",
"As an example, the United States Postal Service (USPS) has enabled the decoupling of the postage meter and the printer and allowed the use of digital printers by establishing an Information-Based Indicia Program (IBIP).",
"The IBIP is a distributed trusted system established by the USPS to retrofit and augment existing postage meters using new technology known as information-based indicia.",
"The IBIP relies on digital signature techniques to produce for each mail piece an indicium whose origin cannot be repudiated.",
"Thus, in contrast to traditional postage metering systems employing mechanical printing technology and physical security, the IBIP supports new methods of securely applying postage to mail pieces.",
"Generally, the IBIP requires printing a high-density two-dimensional (2D) bar code on a mail piece.",
"The 2D barcode encodes various information associated with the mail piece and is subsequently signed with a digital signature.",
"The USPS has published detailed specifications for the IBIP.",
"Generally, the IBIP is directed to two types of postage metering systems.",
"The first type is referred to as a closed system and is defined in the INFORMATION BASED INDICIA PROGRAM—PERFORMANCE CRITERIA FOR INFORMATION-BASED INDICIA AND SECURITY ARCHITECTURE FOR CLOSED IBI POSTAGE METERINGS SYSTEMS, dated Jan. 12, 1999, (“IBIP Closed System Specification”).",
"The second type is referred to as an open system and is defined in the INFORMATION BASED INDICIA PROGRAM—PERFORMANCE CRITERIA FOR INFORMATION-BASED INDICIA AND SECURITY ARCHITECTURE FOR OPEN IBI POSTAGE EVIDENCING SYSTEMS, dated Feb. 23, 2000, (“IBIP Open System Specification”).",
"Together, the IBIP Closed System Specification and the IBIP Open System Specification define the requirements for next generation postage metering systems.",
"Although the transition to digital printing provides many advantages, the postal authorities recognize that digital printing spawns potential new forms of fraud.",
"As an example, an individual seeking to commit a fraud upon the postal authority need only utilize their computer, image scanner and printer to generate multiple copies of a single postal indicium.",
"Thus, a valid indicium may be replicated perfectly.",
"This technique is referred to as fraud by duplication.",
"As a result, measures have been developed to detect such attempts to defraud the postal authorities.",
"Typically, these measures involve verifying the authenticity of the postal indicium on a mail piece as the mail piece is being processed by the postal authority.",
"This verification activity seeks to ensure that the postage amount shown in the postal indicium has been properly accounted for.",
"For instance, the postal authority may validate the digital signature discussed above to determine the authenticity of the postal indicium.",
"However, this will not necessarily expose a second mail piece with a duplicated postal indicium representing an exact copy of a valid indicium.",
"Thus, detection of these types of duplicates, and other issues, present problems for the postal authorities.",
"Another problem faced by the postal authorities is the intensive data processing required of a distributed mail processing system employing a plurality of remotely located processing centers.",
"Typically, the processing center must scan each postal indicium to obtain its data, conduct database lookups, perform cryptographic calculations and determine whether or not the postal indicium is valid.",
"If a mail piece cannot be validated, it is diverted to an out sort bin for further investigation and/or return to the sender.",
"Complicating this situation is the fact that such verification processing is conducted by a single mail piece processing system.",
"This necessitates that the verification processing is completed during the interval between mail piece scanning and the diversion location to the out sort bin.",
"Given the rate at which the processing machines operate (up to 12 mail pieces per second), there is very little time to perform verification checks.",
"Still further complications exist.",
"If the cryptographic computations are to be performed locally (on individual processing machines), then large amounts of data must be distributed to all of the processing machines (e.g. cryptographic keys for each postage meter, data to enable detection of duplicate indicia) and kept updated to reflect changes in the meter population.",
"On the other hand, if the computations are performed remotely, then the postal indicium data for each mail piece must be transmitted in real time to a central location, validated and the results returned to the processing machine before the mail piece reaches the diversion point.",
"Both of these arrangements require significant real time processing and rapid database access.",
"Yet another problem is the risk that the digital signatures and cryptography underlying the security of the postal system could be compromised.",
"This could occur because of a successful attack or the release/use of information necessary to generate valid postal indicia by someone (a postal authority employee) having access to the security system.",
"Once compromised in this manner, someone could print “valid”",
"postal indicia that would pass verification by the postal authority.",
"Thus, the postal authority would suffer losses from a fraudulent actor submitting postal indicia into the postal system that to all appearances would be beyond reproach.",
"Therefore, there is a need for a mail piece verification system that provides operational advantages over those described above.",
"Furthermore, there is a need for a mail piece verification system that includes a forensic accounting capability for improving upon the detection of apparently valid postal indicia.",
"SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a mail piece verification system that addresses the drawbacks and disadvantage of the prior art systems.",
"In accomplishing these and other objects there is provided a mail piece verification system for processing mail pieces having associated therewith respective mail piece data.",
"The system includes a plurality of postage metering systems for preparing mail pieces, a plurality of mail processing centers for receiving mail pieces and obtaining the respective mail piece data and a data center in operative communication with the plurality of postage metering systems and the plurality of mail processing centers, the data center including a plurality of account files corresponding to the plurality of postage metering systems.",
"The data center stores reset data in each of the plurality of account files representative of reset activity associated with the plurality of postage metering systems, respectively, receives respective mail piece data corresponding to the mail pieces from the plurality of mail processing centers, uses the respective mail piece data, storing empirical data in each of the plurality of account files representative of mailing activity associated with the plurality of postage metering systems, respectively, and conducts a forensic accounting analysis of the empirical data and the reset data associated with a selected postage metering system.",
"Additionally, there are provided a method of operating the mail piece verification system, a method of operating a data center for processing mail piece data and a data structure, respectively, that are generally analogous to the summary provided above.",
"Therefore, it should now be apparent that the invention substantially achieves all the above objects and advantages.",
"Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.",
"Moreover, the objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.",
"BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.",
"As shown throughout the drawings, like reference numerals designate like or corresponding parts.",
"FIG. 1 is a schematic representation of a mail piece verification system in accordance with the present invention.",
"FIG. 2 is an example of a postal indicium printed by a postage metering system that is processed by the mail piece verification system in accordance with the present invention.",
"FIG. 3 is an example of a prior art mail piece that may be verified by the verification system in accordance with the present invention.",
"FIG. 4 is a flow chart depicting the operation of the mail piece verification system in accordance with the present invention.",
"FIG. 5 is a flow chart depicting an account reconciliation routine conducted by the mail piece verification system in accordance with the present invention.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1 , a schematic representation a mail piece verification system 100 for processing a mail piece 20 (envelope, post card, package, label, e-mail, or the like), produced by a postage metering system 25 and having a postal indicium 30 printed thereon (or attached to, embedded in or otherwise associated with electronic forms of the mail piece 20 ), in a path of travel as indicated by the solid arrows is shown.",
"The mail piece verification system 100 includes a deposit location 110 , an incoming mail processing center 120 having an incoming out sort bin 122 , a central postal data center 130 , a transportation system 140 , an outgoing mail processing center 150 having an outgoing out sort bin 152 and a delivery location 160 .",
"The central postal data center 130 includes an account database 132 and is in operative communication with the incoming mail processing center 120 and the outgoing mail processing center 150 over any suitable conventional communication network, such as: telephone lines, a local area network, a wide area network, the Internet or the like.",
"The account database 132 includes a plurality of customer account files 134 , described in greater detail below.",
"Generally, as shown in FIG. 1 , the solid lines with arrows are intended to represent the flow of the mail piece 20 while the dashed lines with arrows are intended to represent data flow, as described in greater detail below.",
"For the sake of clarity, the mail piece verification system 100 has been shown with respect to a particular mail piece 20 and a single postage metering system 25 .",
"Those skilled in the art will recognize that the mail piece verification system 100 may employ a plurality of deposit locations 110 that receive mail pieces 20 from a plurality of postage metering systems 25 and direct them to a plurality of incoming mail processing centers 120 .",
"From these centers 120 , the mail pieces 20 are transported over a plurality of transportation systems 140 to a plurality of outgoing mail processing centers 150 so that the mail pieces may be delivered to a plurality of delivery locations 160 , accordingly.",
"Thus, the mail piece verification system 100 represents a network of systems that connect the deposit locations 110 to the delivery locations 160 .",
"Each mail piece 20 is routed through the mail piece verification system 100 (network) according to numerous factors, such as: the class of service selected and the physical locations of the deposit 110 and the delivery location 160 .",
"The deposit location 110 may be any acceptance point (post office window, mail box, computer server, etc.) that the postal authority has designated for receiving mail pieces 20 from the public.",
"The incoming mail processing center 120 may or may not be co-located with the deposit location 110 .",
"In either case, the mail pieces 20 are directed by postal authority to the incoming mail processing center 120 which may employ one or more mail processing machines, such as the Small Parcel and Bundle Sorter, the Advanced Facer Canceller System or the Flats Sorting Machine, all available from Lockheed Martin—Postal Automation Systems.",
"These mail processing machines typically perform preliminary tasks on the mail pieces 20 , such as: culling, positioning (facing the mail piece), POSTNET bar code printing, sorting and the like.",
"Any mail pieces 20 that are deemed unacceptable are diverted to the out sort bin 122 .",
"Once the preliminary mail processing tasks are completed, the mail piece 20 travels over the transportation system 140 to the outgoing mail processing center 150 .",
"The transportation system 140 may employ any suitable combination of physical transport, such as: truck, plane, boat, car, computer network, or the like.",
"The outgoing mail processing center 150 is very similar to the incoming mail processing center 120 and may employ one or more of the same types of mail processing machines described above.",
"These mail processing machines typically perform secondary tasks on the mail pieces 20 , such as: culling, positioning, POSTNET bar code reading, sorting and the like.",
"Any mail pieces 20 that are deemed unacceptable are diverted to the out sort bin 152 .",
"Once the secondary mail processing tasks are completed, the mail piece 20 is routed via a designated post office to the delivery location 160 (home address, business address, post office box, computer account, IP address or the like).",
"Those skilled in the art will recognize that any combination of incoming mail processing centers 120 , transportation systems 140 and outgoing mail processing centers 150 may be employed to effect receipt of the mail piece 20 at the deposit location 110 and route the mail piece 20 to the delivery location 160 .",
"For example, many intermediate processing centers may be employed and the transportation system 140 may be deployed in stages.",
"Numerous factors, such as the class of service and the physical proximity of the deposit location 110 to the delivery location 160 , may influence the exact route that a particular mail piece 20 may take while it is in transit.",
"Furthermore, those skilled in the art will appreciate that the incoming mail processing center 120 and the outgoing mail processing center 150 may be co-located.",
"In fact, they may actually be the same mail processing center.",
"In some ways what differentiates the incoming mail processing center 120 from the outgoing mail processing center 150 is the status of the mail piece 20 .",
"If the mail piece 20 has just been received, then the mail processing center is operating as the incoming mail processing center 120 .",
"On the other hand, if the mail piece 20 is well along its delivery route, then the mail processing center is operating as the outgoing mail processing center 150 .",
"Thus, at any given location, the same mail processing center may be operating as both an incoming mail processing center 120 (for the mail pieces 20 that have just been deposited for delivery) and as an outgoing mail processing center 150 (for the mail pieces 20 that have already been processed and are nearing their delivery points).",
"Still further, instead of being a singular facility, the postal data center 130 may be embodied as a plurality of regional postal data centers that are geographically dispersed and networked together using suitable communication techniques.",
"This may allow for various advantages, such as: system redundancy (in case of failures), quicker response times and reduced communication expenses, while preserving the benefits of the communication path ways generally described above and in more detail below.",
"Generally, the plurality of postage metering systems 25 are in communication with the central postal data center 130 over any conventional communication lines for the purpose of conducting remote inspections and meter resets (downloading of postal funds) as is known in the art.",
"The postage metering systems 25 may be of any conventional type, such as those commercially available (ClickStamp® Online, PostPerfect®, Paragon® II, DM200™, etc.) from Pitney Bowes Inc. of Stamford, Conn.",
"A historical account of the disbursement of these postal funds is maintained in the account database 132 .",
"Each of the plurality of customer account files 134 includes an account identifier (numeric, alpha-numeric, etc.) 134 a , a list of postage meter serial numbers (one or more) 134 b associated with the account identifier 134 a , meter reset activity data 134 c and empirical mailing activity data 134 d (described in greater detail below).",
"The postage meter serial numbers 134 b correspond to the meter serial number 32 that in printed in the postal indicium 30 .",
"Preferably, the reset activity data 134 c includes a reset date and a reset amount that is stored for each meter reset transaction associated with each particular postage metering system 25 .",
"Thus, a historical log of an amount of postage that has been purchased by each postage metering system 25 is maintained.",
"Those skilled in the art will recognize that the account identifier 134 a and the postage meter serial numbers 134 b may be collapsed into a single identifier that serves to identify the customer.",
"Referring to FIG. 2 in view of FIG. 1 , a more detailed view of the postal indicium 30 printed by the postage metering system 25 is shown.",
"Since the postal indicium 30 does not constitute a part of the present invention, the following description is being provided with respect to a particular type of postal indicium 30 by way of background.",
"Generally, the postal indicium 30 includes both fixed data that does not change from indicium to indicium and variable data that may change.",
"The fixed and variable data may change depending upon postal authority requirements and the needs of the postage system manufacturer, but generally can be summarized as follows.",
"The fixed data includes a graphic design 31 (an eagle with stars and US POSTAGE), a meter serial number 32 uniquely identifying the postage meter (not shown) that produced the postal indicium 30 , a licensing post office ID (Zip Code) 33 and an optional facer identification mark (FIM) 34 used during post office processing.",
"The variable data includes a date 35 indicating when the postage was dispensed, a postal value 36 indicating an amount of postage, an indication of a service class (first class, bulk rate, priority, overnight, certified, etc.) that has been selected for the mail piece 20 , a bar code 37 containing both elements of both fixed and variable data and, in the most preferred embodiment, authentication information 38 .",
"The bar code 37 may be of any conventional format and is provided for the purpose of improving machine readability and increasing automated processing of the mail piece 20 .",
"Generally, the authentication information 38 is an encrypted message, such as a digital signature, digital token or other data, derived from the information contained with the postal indicium 30 .",
"The authentication information 38 may be in any format, such as: alphanumeric string, bar code or the like.",
"Most preferably, the authentication information 38 is incorporated into the bar code 37 .",
"Using the authentication information 38 and other data contained within the postal indicium 30 , the postal authority can verify the authenticity of the postal indicium 30 using conventional techniques.",
"Thus, the postal indicium 30 may also be classified as containing authentication information 38 and non-authentication information 31 - 37 and 39 .",
"As mentioned above, the postal indicium 30 need only be associated with the particular mail piece 20 .",
"Therefore, when the mail piece 20 takes electronic form, the postal indicium 30 may be reconfigured accordingly.",
"Referring to FIG. 3 , in view of FIGS. 1 and 2 , an example of a prior art mail piece 20 that may be processed by the verification system 100 is shown.",
"The mail piece 20 includes the postal indicium 30 (as described above) produced by a postage metering system 25 , a sender address 40 (optional) and a recipient address 50 .",
"The recipient address 50 provides information to the postal authority corresponding to the delivery location 160 .",
"The typical recipient address 50 includes a recipient name 52 (personal, business or generic (occupant)), recipient delivery information 54 (street address, post office box number, etc.), a city name 56 , a state name 57 and a ZIP code 58 .",
"With the structure of the present invention described as above, the operational characteristics will now be described with respect to receipt and delivery of the mail piece 20 .",
"For the sake of clarity, it is assumed that the mail piece 20 is processed by only one incoming mail processing center 120 and only one outgoing mail processing center 150 .",
"Referring primarily to FIG. 4 while referencing the structure of FIGS. 1 , 2 and 3 , a flow chart 400 of the general operation of the mail piece verification system 100 in accordance with the present invention is shown.",
"A further detailed discussion of a forensic account reconciliation routine is provided below.",
"After receiving the mail piece 20 at the deposit location 110 , at 402 , the mail piece 20 is scanned at the incoming mail processing center 120 to obtain mail piece data.",
"The mail piece data may include the postal indicium 30 , the recipient address 50 , the sender address 40 or any combination or subset of the above.",
"Next, at 404 , a determination may optionally be made whether or not the mail piece 20 meets preliminary conditions.",
"In the most preferred embodiment, the preliminary conditions do not involve cryptographic calculations or access to complicated databases.",
"The preliminary conditions may include: recognition of a valid meter serial number 32 , a posting date 35 within an acceptable range of the current date, suitable readability of the mail piece 20 in terms of accuracy and completeness and recognition of a valid recipient address 50 .",
"If at 404 the answer is no, then at 406 the mail piece 20 is out sorted to out sort bin 122 for further investigation, human reading, return to the sender or some other suitable action.",
"On the other hand, if the answer at 404 is yes, then at 408 a global identification number (preferably an alphanumeric string) (not shown) is assigned to the mail piece 20 that uniquely identifies the mail piece 20 to the postal authority.",
"The global identification number may preferably be chosen to reflect other information, such as: the particular incoming mail processing center 110 that received the mail piece 20 .",
"Optionally, the global identification number may be printed on the mail piece 20 in bar code or some other conventional format.",
"Generally, the global identification numbers are allocated to the incoming mail processing center 120 by the central postal data center 130 .",
"In this way, the incoming mail processing center 120 may assign the numbers one at a time as the mail pieces 20 are received.",
"Next, at 410 , the mail piece data and the global identification number are uploaded from the incoming mail processing center 120 to the central postal data center 130 .",
"Next, at 412 , the mail piece 20 is advanced downstream in the path of travel along the delivery route by the transportation system 140 .",
"Next, at 414 , the central postal data center 130 conducts an analysis to see if the mail piece 20 meets secondary conditions.",
"In the most preferred embodiment, the secondary conditions involve cryptographic calculations to determine the validity of the postal indicium 30 .",
"Those skilled in the art will recognize that the mail piece data may be transmitted to a central postal data center 130 for verification either immediately or as a batch process at some later time.",
"Since the incoming mail processing center 120 does not perform cryptographic verification checks, there is no need to distribute sensitive information (e.g., cryptographic keys, “license plates,” duplicate data and the like) to the incoming mail processing center 120 .",
"In addition, the computational requirements for the incoming mail processing center 120 are significantly reduced (no need to rapidly perform database lookups or cryptographic operations).",
"Next, at 416 , the central postal data center 130 downloads instructions, as necessary, to the outgoing mail processing center 150 for use in processing the mail piece 20 .",
"In the most preferred embodiment, the processing instructions are associated with the global identification number of the mail piece 20 .",
"For example, the instruction may indicate that the mail piece 20 should be diverted to the out sort bin 152 for follow up by a postal authority investigator.",
"As another example, the instructions may indicate that the mail piece 20 should be processed in a normal fashion.",
"In the alternative, instructions may only be supplied for “special”",
"(other than normal) processing.",
"In this situation, the absence of a special instruction (divert instruction) may indicate that the outgoing mail processing center 150 should process the mail piece 20 in a normal fashion.",
"Next, at 418 , the outgoing mail processing center 150 scans the mail piece 20 to obtain the global identification number.",
"As discussed above, it may have even been printed on the mail piece 20 by the incoming mail processing center 120 .",
"Next, at 420 , the outgoing mail processing center 150 retrieves any processing instructions associated with the global identification number through simple database access.",
"Next, at 422 , the outgoing mail processing center 150 processes the mail piece 20 in accordance with the processing instructions, as described above.",
"With the basic operation of the mail piece verification system described as above, a forensic account reconciliation routine that may be additionally performed by the data center 130 will now be described.",
"Referring primarily to FIG. 5 while referencing the structure of FIGS. 1 , 2 and 3 , a flow chart 500 of the account reconciliation routine of the mail piece verification system 100 in accordance with the present invention is shown.",
"At 502 , the central postal data center 130 conducts a summation of all the mail piece data associated with each individual mail piece 20 that has been processed by the plurality of incoming mail processing centers 120 .",
"Preferably, this summation analysis occurs at predetermined occasions (time based and/or event based) and gathers the mail piece data by the account identifier 134 a and/or by postage meter serial number 134 b .",
"Thus, the summation analysis yields data indicative of the empirical activity associated with each account identifier 134 a and/or postage meter serial number 134 b for a given time period.",
"Accordingly, respective empirical activity data 134 d is stored in each of the plurality of customer account files 134 .",
"The empirical activity data 134 d may include piece counts for each given mail class, postage amounts or any other mailing activity related data sufficient to derive an exact or reliable estimate of an amount of postage consumed.",
"Thus, a historical account of observed mailing activity is maintained by the empirical activity data 134 d .",
"Next, at 504 , the central postal data center 130 reconciles the reset activity data 134 c with the empirical activity data 134 d for consistency.",
"This may involve any degree of forensic account analysis to determine the fidelity of the empirical activity data 134 d in view of the reset activity data 134 c .",
"An example will now be provided.",
"The reset activity data 134 c may be used to ascertain an amount of postage that has been purchased by a respective postage metering system 25 over a given time period.",
"Likewise, the empirical activity data 134 d may be used to ascertain an amount of postage that has been consumed in relation to the given time period.",
"Thus, by comparing the purchased postage amount with the consumed postage amount, the propriety of the customers mailing activities may be established.",
"Those skilled in the art will recognize that because there is generally a time lag between when postage is purchased and when it is consumed, care must be taken when defining what postage purchases should be compared against what mailing activity.",
"Next, at 506 , a determination is made whether or not the reset activity data 134 c is consistent with the empirical activity data 134 d .",
"For the sake of clarity, it should be understood that this determination could be made for each one of or any subset of the plurality of customer account files 134 .",
"Thus, the plurality of customer account files 134 selected for analysis may be those where suspicions have arisen or based on a period sampling for audit purposes.",
"If at 506 the answer is yes, then at 508 the routine 500 continues normally and no responsive (corrective and/or investigative) action is taken with respect to the customer account file 134 /meter serial number 134 b for which the forensic analysis was conducted.",
"On the other hand, if the answer at 506 is no, then at 510 responsive action is taken.",
"Many possibilities for responsive action exist.",
"As an example, an inspection of the metering system 25 may be conducted.",
"This inspection may involve dispatching an authorized representative to perform a site inspection at the customer's location and/or a remote diagnostic inspection during a subsequent communication session between the metering system 25 and the data center 130 .",
"These inspections would seek to determine if the metering system 25 has been tampered with either physically or electronically.",
"As another example, delivery of mail pieces 20 from the suspect customer account file 134 /meter serial number 134 b may be withheld.",
"As yet another example, new graphic data 31 may be down loaded to the metering system 25 during a subsequent communication session with the data center 130 .",
"The new graphic data 31 may include a tell (hidden clue) that facilitates discerning whether or not the fraudulent indicium 30 has been created by the customer or a third party.",
"As yet still another example, a new meter serial number 134 b may be issued to replace the existing meter serial number 134 b from the suspect customer account file 134 /meter serial number 134 b .",
"Preferably, this occurs after the postage metering system 25 has passed inspection.",
"Then, delivery of mail pieces 20 containing the existing meter serial number 134 b may be withheld while delivery of mail pieces 20 containing the new meter serial number 134 b may continue normally.",
"In this manner, any fraudulent use of the existing meter serial number 134 b by third parties will be met with a suitable counter measure from the postal authority while the rightful use of the new meter serial number 134 b by the customer continues uninterrupted.",
"As yet still another example, the data center 130 may limit a recharge amount of postage that may be downloaded to the postage metering system 25 during a reset operation.",
"In this way, a closed system type of postage metering system 25 would likely have to contact the data center 130 more frequently and thus allow more frequent remote inspections of the postage metering system 25 .",
"Advantages for open system type postage metering systems 25 may also apply.",
"Those skilled in the art will recognize that the examples described above are mutually exclusive and may be implemented in any combination.",
"The data center 130 may execute this responsive action by providing suitable instructions to the postage metering system 25 and the mail processing centers 120 and 150 .",
"Those skilled in the art will now recognize that the present invention substantially addresses many of the drawbacks and deficiencies associated with conventional mail processing in addition to those discussed above.",
"Since all cryptographic verification operations (indicium verification, duplicate detection) are performed at the central postal data center 130 , the overall security and integrity of the system 100 are improved but access to the cryptographic information is limited.",
"Since the cryptographic verification operations are generally performed while the mail piece 20 is in transit from the incoming mail processing center 120 to the outgoing mail processing center 150 , this significantly increases the time allotted to perform verification.",
"This extra time enables more detailed checks to be performed.",
"Furthermore, by migrating cryptographic verification operations to the central postal data center 130 , the verification procedures may be more easily modified on an as needed basis (the current system would require major distributed system updates to be performed in order to change verification procedures).",
"When the mail piece 20 is scanned at the incoming mail processing center 120 , the delivery route through the system 100 to the delivery location 160 is often determined using the ZIP code 33 in view of existing transportation hubs and the proximity of the delivery location 160 to available outgoing mail processing centers 150 .",
"Therefore, even further efficiencies may be available.",
"For example, the need to broadcast the down load of the processing instruction to the entire population of outgoing mail processing centers 150 may be eliminated.",
"Instead, the processing instructions may be directly sent to a particular one of the outgoing mail processing centers 150 corresponding to the determined delivery route of the mail piece.",
"In this manner, the amount of data that is download and the total communications between the central postal data center 130 and the population of outgoing mail processing centers 150 is reduced.",
"If 100% inspection of the mail stream is conducted by the plurality of incoming mail processing centers 120 , then the verification system 100 becomes a closed loop system due to the account reconciliation routine 500 .",
"Furthermore, because of the summation activity performed by the data center 130 against the mail piece data that has been collected across the plurality of incoming mail processing centers 120 , it does not matter if fraudulent mail pieces 20 are being deposited with different incoming mail centers 120 in an attempt to disperse (and thus conceal) the fraudulent activity.",
"Thus, dispersed fraudulent activity that may otherwise fall within an acceptable “noise”",
"parameter established for a micro level of operation (individual incoming mail centers 120 ) may be detected at a macro level of operation (the data center 130 ).",
"Furthermore, by having a closed loop system, detection of a successful attack on the system 100 or the unauthorized release/use of postal authority and/or meter manufacturer information necessary to generate postal indicia 30 that would pass cryptographic scrutiny would be detected.",
"Thus, the forensic analysis and counter measures associated with the response actions described above would assist in detecting and controlling this type of fraud.",
"If limited inspection (less than 100%) of the mail stream is being conducted by the plurality of incoming mail processing centers 120 , then the verification system 100 may operate in a more selective manner.",
"For example, the empirical activity data 134 d that is actually observed may be extrapolated in view of the sampling rates employed by the incoming mail processing centers 120 to develop estimated actual activity data.",
"This estimated actual activity data may then be compared with the reset activity 134 c .",
"If the estimated activity data is exceeds the reset activity 134 c by more than a previously defined threshold amount (i.e. 20%), then the sampling rate for mail pieces 20 associated with the respective meter serial number 134 b may be increased.",
"That is, an instruction may be provided by the data center 130 to the incoming mail processing centers 120 to sample data during the preliminary mail processing tasks from mail pieces 20 containing the respective meter serial number 134 b at a greater frequency (even 100%) than that employed for the mail stream at large.",
"Thus, the data center 130 may develop more precise empirical activity data 134 d. As a further benefit, the system 100 of the present invention also increases the chance that a pair of duplicate mail pieces 20 can be captured for investigation and/or prosecution.",
"In the current system, a duplicate mail piece 20 can only be detected after the “original”",
"has been processed.",
"Therefore, the current system is not set up to out sort both an original mail piece 20 and a fraudulent copy.",
"Without both mail pieces 20 , prosecution of the offender is likely to be much harder.",
"Since the present invention performs duplicate checking while the mail pieces 20 are in transit and provides the opportunity for downstream diversion, both the original and the duplicate may be captured.",
"In other words, if a duplicate enters the mail stream prior to delivery of the original mail piece 20 , then both mail pieces 20 can be out sorted for investigation.",
"As yet still another benefit, the service class 39 information may be used to determine a priority for scheduling: (i) the uploading of the mail piece data;",
"(ii) the performance of the secondary checks;",
"and/or (iii) the downloading of the processing instructions.",
"As examples, in this manner, the different data handling needs of a mail piece 20 that has been sent by overnight delivery may be expedited, those of a 1 st class mail piece 20 may be somewhat more moderately attended to while those of a bulk rate mail piece 20 may be addressed in an even more deliberate manner.",
"Thus, the postal authority may more efficiently process the mail piece data based on the service class 39 in view of the amount of delivery time available, the anticipated likelihood of fraud (large volume mailings, such as bulk rate, often are targeted by fraudulent actors than lower volume mailings, such as priority mail) and other factors.",
"As a result, the incoming mail processing center 120 may communicate more frequently with the central postal data center 130 for the purpose of uploading mail piece data associated with short delivery cycles while those of mail pieces 20 having longer delivery cycles may occur during “off peak”",
"periods.",
"Thus, the service class 39 may be used to set a priority for the upload of mail piece data and in analogous fashion the subsequent download of processing instructions.",
"Those skilled in the art will recognize that various modifications can be made without departing from the spirit of the present invention.",
"For example, a series of central postal data centers 130 in communication with each other could be set up to share and distribute verification tasks.",
"As another example, letter carriers or mail boxes could perform scanning of the postal indicium 30 at time of deposit.",
"This would accelerate the input of the mail piece data into the system 100 .",
"As yet another example, a list of valid mail pieces 20 could be transmitted to the outgoing mail processing centers to ensure that fraudulent mail pieces were not introduced into the mail stream during transport due to corrupt postal authority employees or otherwise.",
"Thus, the central postal data center 130 could download a list of valid global identification numbers.",
"In the absence of the scanned global identification number appearing on such a list, the mail piece 20 could be diverted.",
"As yet still another example, those skilled in the art will recognize that many of the steps and activities described above may be performed in differing orders or concurrently.",
"As still yet another example, if the mail piece 20 is an electronic file, then the postal indicium 30 may be replaced with any other suitable indication of payment and instead of scanning the mail piece 20 , the mail piece data may already be associated with the mail piece 20 such as by attachment as a header file.",
"As still yet another example, the verification system 100 has been described with respect to an unrestricted access system where anyone may utilize the mail piece delivery network.",
"However, those skilled in the art will recognize that the verification system 100 would work equally as well in a restricted access system (such as: subscription based delivery services and the like) where delivery services would only be provided for selected individuals and/or organizations.",
"As still yet another example, those skilled in the art will recognize that various modifications to the preferred embodiments described above may be made so that the inventive concepts are applied to permit mailing activity.",
"In permit mailing activity, postage metering systems 25 are generally not used.",
"Instead, the postal authority only excepts permit mail under controlled conditions.",
"Typically, for permit mail, the postal authority issues a permit number to the customer and the customer brings the permit mail pieces to the postal authority along with a manifest describing the size or other characteristics of the mail run.",
"In response, the postal authority charges or debits the customer's account accordingly.",
"Thus, this customer account activity is directly analogous to the reset activity data 134 c .",
"As a result, the term reset activity data 134 c should be construed as including any form of postal funds account record keeping that may be employed.",
"As yet still another example, although the data center 130 has been described generally as under the control of a single entity at a single location, this need not necessarily be the case.",
"The postage meter manufacture may be authorized by the postal authority to conduct be in contact with the postage metering systems 25 and conduct reset operations.",
"However, typically the postal authority is more directly involved with the processing of mail pieces 20 by the mail processing centers 130 and 150 .",
"Thus, in this scenario, an exchange of data between to the data centers 130 operated at different locations or by different entities may be required in order to practice the present invention as described with respect to the preferred embodiments.",
"Furthermore, although the above description has been provided with respect to pre-payment (debit from existing funds) type postage metering systems 25 (as employed in the United States), the concepts of the present invention apply equally well to post-payment (credit) type postage metering systems 25 (as employed in France).",
"Thus, although the exact reset operations conducted for pre-payment and post-payment postage metering systems 25 may be different, the important similarities are authorization of continued use of the postage metering system 25 and/or inspection of the accounting registers contained with the postage metering system 25 .",
"Thus, reset activity data 134 c should be construed as being directed to those types of activities associated with either type of postage metering system 25 .",
"Therefore, the inventive concept in its broader aspects is not limited to the specific details of the preferred embodiments but is defined by the appended claims and their equivalents."
] |
RELATED APPLICATIONS
[0001] This application claims the benefit of Indian Patent Application Nos. 665/MUM/2009 filed on Mar. 23, 2009; 2211/MUM/2009 filed on Sep. 23, 2009; 2212/MUM/2009 filed on Sep. 23, 2009; 2891/MUM/2009 filed on Dec. 15, 2009; 2892/MUM/2009 filed on Dec. 15, 2009 and U.S. Provisional Application Nos 61/171,355 filed on Apr. 21, 2009; 61/251,944 filed on Oct. 15, 2009; 61/253,263 filed on Oct. 20, 2009; 61/294,463 filed on Jan. 12, 2010 and 61/300,241 filed on Feb. 1, 2010 all of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present patent application relates to fused pyrimidinedinedione derivatives with transient receptor potential ankyrin1 (TRPA1) activity.
BACKGROUND OF THE INVENTION
[0003] The transient receptor potential (TRP) channels or receptors are pain receptors. They have been classified into seven subfamilies: TRPC (canonical), TRPV (vanilloid), TRPM (melastatin), TRPP (polycystin), TRPML (mucolipin), TRPA (ankyrin, ANKTM1) and TRPN (NOMPC) families. The TRPC family can be divided into 4 subfamilies (i) TRPC1 (ii) TRPC2 (iii) TRPC3, TRPC6, TRPC7 and (iv) TRPC4, TRPC5 based on sequence functional similarities. Currently the TRPV family has 6 members. TRPV5 and TRPV6 are more closely related to each other than to TRPV1, TRPV2, TRPV3 or TRPV4. TRPA1 is most closely related to TRPV3 and is more closely related to TRPV1 and TRPV2 than to TRPV5 and TRPV6. The TRPM family has 8 members. Constituents include the following: the founding member TRPM1 (melastatin or LTRPC1), TRPM3 (KIAA1616 or LTRPC3), TRPM7 (TRP-PLIK, ChaK(1), LTRPC7), TRPM6 (ChaK2), TRPM2 (TRPC7 or LTRPC2), TRPM8 (TRP-p8 or CMR1), TRPM5 (MTR1 or LTRPC5) and TRPM4 (FLJ20041 or LTRPC4). The TRPML family consists of the mucolipins, which include TRPML1 (mucolipin 1), TRPML2 (mucolipin 2) and TRPML3 (mucolipin 3). The TRPP family consists of two groups of channels: those predicted to have six transmembrane domains and those that have eleven. TRPP2 (PKD2), TRPP3 (PKD2L1), TRPP5 (PKD2L2) are all predicted to have six transmembrane domains. TRPP1 (PKD1, PC1), PKD-REJ and PKD-1L1 are all thought to have eleven transmembrane domains. The sole mammalian member of the TRPA family is ANKTM1.
[0004] It is believed TRPA1 is expressed in nociceptive neurons. Nociceptive neurons of the nervous system sense the peripheral damage and transmit pain signals. TRPA1 is membrane bound and most likely acts as a heterodimeric voltage gated channel. It is believed to have a particular secondary structure, its N-terminus is lined with a large number of ankyrin repeats which are believed to form a spring-like edifice. TRPA1 is activated by a variety of noxious stimuli, including cold temperatures (activated at 17° C.), pungent natural compounds (e.g., mustard, cinnamon and garlic) and environmental irritants (MacPherson L J et al, Nature, 2007, 445; 541-545). Noxious compounds activate TRPA1 ion channels through covalent modification of cysteines to form covalently linked adducts. Variety of endogenous molecules produced during tissue inflammation/injury have been identified as pathological activators of TRPA1 receptor. These include hydrogen peroxide which is produced due to oxidative stress generated during inflammation, alkenyl aldehyde 4-HNE—an intracellular lipid peroxidation product and cyclopentenone prostaglandin 15dPGJ2 which is produced from PGD2 during inflammation/allergic response. TRPA1 is also activated in receptor dependant fashion by Bradykinin (BK) which is released during tissue injury at peripheral terminals
[0005] The difference between TRPA1 and other TRP receptors is that TRPA1 ligand binding persists for hours due to which the physiological response (e.g., pain) is greatly prolonged. Hence to dissociate the electrophile, an effective antagonist is required.
[0006] WO 2009/158719, WO 2009/002933, WO 2008/0949099, WO 2007/073505, WO 2004/055054 and WO 2005/089206 describe the TRP channels as the targets for the treatment of pain and related conditions.
[0007] In efforts to discover better analgesics for the treatment of both acute and chronic pain and to develop treatments for various neuropathic and nociceptive pain states, there exists a need for a more effective and safe therapeutic treatment of diseases, conditions and/or disorders modulated by TRPA1.
SUMMARY OF THE INVENTION
Definitions
[0008] The present invention relates to compounds of the formula (I):
[0000]
[0009] or a pharmaceutically acceptable salt thereof,
[0010] wherein,
[0011] Z 1 is NR a or CR a ;
[0012] Z 2 is NR b or CR b ;
[0013] Z 3 is N or C;
[0014] with the proviso that when Z 2 is CR b then both Z 1 and Z 3 are not nitrogen at the same time;
[0015] at each occurrence, R a and R b which may be same or different, are independently selected from hydrogen, hydroxyl, cyano, halogen, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, —(CR x R y ) n OR x , —COR x , —COOR x , —CONR x R y , —S(O) m NR x R y , —NR x R y , —NR x (CR x R y ) n OR x , —(CH 2 ) n NR x R y , —(CH 2 ) n CHR x R y , —(CH 2 )NR x R y , —NR x (CR x R y ) n CONR x R y , —(CH 2 ) n NHCOR x , —(CH 2 ) n NH(CH 2 ) n SO 2 R x and (CH 2 ) n NHSO 2 R x ;
[0016] alternatively either of R a or R b is absent;
[0017] R 1 and R 2 , which may be same or different, are independently selected from hydrogen, hydroxyl, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, arylalkyl, (CR x R y ) n OR x , COR x , COOR x , CONR x R y , (CH 2 ) n NR x R y , (CH 2 ) n CHR x R y , (CH 2 )NR x R y and (CH 2 ) n NHCOR x ;
[0018] R 3 is selected from hydrogen, substituted or unsubstituted alkyl, alkenyl, haloalkyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl;
[0019] L is a linker selected from —(CR x R y ) n —, —O—(CR x R y ) n —, —C(O)—, —NR x —, —S(O) n NR x —, —NR x (CR x R y ) n — and —S(O) m NR x (CR x R y ) n ;
[0020] U is selected from substituted or unsubstituted aryl, substituted or unsubstituted five membered heterocycles selected from the group consisting of thiazole, isothiazole, oxazole, isoxazole, thiadiazole, oxadiazole, pyrazole, imidazole, furan, thiophene, pyrroles, 1,2,3-triazoles and 1,2,4-triazole; and substituted or unsubstituted six membered heterocycles selected from the group consisting of pyrimidine, pyridine and pyridazine;
[0021] V is selected from hydrogen, cyano, nitro, —NR x R y , halogen, hydroxyl, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, haloalkyl, haloalkoxy, cycloalkylalkoxy, aryl, arylalkyl, biaryl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl, —C(O)OR x , —OR x , —C(O)NR x R y , —C(O)R x and —SO 2 NR x R y ; or U and V together may form an optionally substituted 3 to 7 membered saturated or unsaturated cyclic ring, that may optionally include one or more heteroatoms selected from O, S and N;
[0022] at each occurrence, R x and R y are independently selected from the group consisting of hydrogen, hydroxyl, halogen, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl; and
[0023] at each occurrence ‘m’ and ‘n’ are independently selected from 0 to 2, both inclusive.
[0024] According to one embodiment, there is provided a compound of the formula (Ia):
[0000]
[0025] or a pharmaceutically acceptable salt thereof,
[0026] wherein,
[0027] R 1 and R 2 which may be same or different, are independently selected from hydrogen, hydroxyl, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, arylalkyl, (CR x R y ) n OR x , COR x , COOR x , CONR x R y , (CH 2 ) n NR x R y , (CH 2 ) n CHR x R y , (CH 2 )NR x R y and (CH 2 ) n NHCOR x ;
[0028] U is selected from substituted or unsubstituted aryl, substituted or unsubstituted five membered heterocycles selected from the group consisting of thiazole, isothiazole, oxazole, isoxazole, thiadiazole, oxadiazole, pyrazole, imidazole, furan, thiophene, pyrroles, 1,2,3-triazoles and 1,2,4-triazole; and substituted or unsubstituted six membered heterocycles selected from the group consisting of pyrimidine, pyridine and pyridazine;
[0029] V is selected from hydrogen, cyano, nitro, —NR x R y , halogen, hydroxyl, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, haloalkyl, haloalkoxy, cycloalkylalkoxy, aryl, arylalkyl, biaryl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl, —C(O)OR x , —OR x , —C(O)NR x R y , —C(O)R x and —SO 2 NR x R y ; or U and V together may form an optionally substituted 3 to 7 membered saturated or unsaturated cyclic ring, which may optionally include one or more heteroatoms selected from O, S and N;
[0030] at each occurrence, R a and R b which may be same or different, are independently selected from hydrogen, hydroxyl, cyano, halogen, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, —(CR x R y ) n OR x , —COR x , —COOR x , —CONR x R y , —S(O) m NR x R y , —NR x R y , —NR x (CR x R y ) n OR x , —(CH 2 ) n NR x R y , —(CH 2 ) n CHR x R y , —(CH 2 )NR x R y , —NR x (CR x R y ) n CONR x R y , —(CH 2 ) n NHCOR x , —(CH 2 ) n NH(CH 2 ) n SO 2 R x and (CH 2 ) n NHSO 2 R x ;
[0031] at each occurrence, R x and R y are independently selected from hydrogen, hydroxyl, halogen, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl;
[0032] at each occurrence ‘m’ and ‘n’ are independently selected from 0 to 2, both inclusive.
[0033] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.
[0034] According to another embodiment, specifically provided are compounds of the formula (Ia) in which R a is hydrogen, halogen (for example bromine), alkyl (for example methyl) or alkylaminoalkyl (for example dimethylaminomethyl or diethylaminomethyl).
[0035] According to one embodiment, specifically provided are compounds of the formula (Ia) in which R b is hydrogen or alkyl for example methyl.
[0036] According to yet another embodiment, specifically provided are compounds of the formula (Ia) in which R 1 and R 2 are independently hydrogen or alkyl for example methyl.
[0037] According to yet another embodiment, specifically provided are compounds of the formula (Ia) in which U is substituted or unsubstituted heterocycle, preferably thiazole or isoxazole.
[0038] According to yet another embodiment, specifically provided are compounds of the formula (Ia) in which V is substituted or unsubstituted aryl, preferably phenyl. In this embodiment the substitutents on phenyl may be one or more are independently selected from halogen (for example F, Cl or Br), haloalkyl (for example CF 3 ), alkoxy (for example methoxy, ethoxy, OCH 2 CH(CH 3 ) 2 , OCH 2 C(CH 3 ) 3 or OCH 2 CH 2 CH(CH 3 ) 2 ), haloalkoxy (for example OCHF 2 , OCF 3 , OCH 2 CF 3 , OCH 2 CH 2 CF 3 or OCH 2 CH 2 CF 2 CF 3 ), cycloalkylalkoxy (for example cyclopropylmethoxy, cyclobutylmethoxy or cyclopentylmethoxy) and, substituted or unsubstituted arylalkoxy (for example trifluoromethylbenzyloxy).
[0039] According to one embodiment, there is provided a compound of the formula (Ib):
[0000]
[0040] or a pharmaceutically acceptable salt thereof, wherein,
[0041] U, V, R 1 , R 2 , R a and R b are as defined herein above.
[0042] According to one embodiment, there is provided a compound of the formula (Ic):
[0000]
[0043] or a pharmaceutically acceptable salt thereof, wherein,
[0044] U, V, R 1 , R 2 , R a and R b are as defined herein above.
[0045] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.
[0046] According to another embodiment, specifically provided are compounds of the formula (Ic) in which R a is hydrogen or alkyl (for example methyl).
[0047] According to one embodiment, specifically provided are compounds of the formula (Ic) in which R b is hydrogen.
[0048] According to yet another embodiment, specifically provided are compounds of the formula (Ic) in which R 1 and R 2 are independently hydrogen or alkyl (for example methyl).
[0049] According to yet another embodiment, specifically provided are compounds of the formula (Ic) in which U is substituted or unsubstituted heterocycle, preferably thiazole.
[0050] According to yet another embodiment, specifically provided are compounds of the formula (Ic) in which V is substituted or unsubstituted aryl, preferably phenyl. In this embodiment the substitutents on phenyl may be one or more and are independently selected from halogen (for example F, Cl or Br), haloalkyl (for example CF 3 ), alkoxy (for example OCH 2 C(CH 3 ) 3 or haloalkoxy (for example OCH 2 CF 3 ).
[0051] According to one embodiment, there is provided a compound of the formula (Id):
[0000]
or a pharmaceutically acceptable salt thereof, wherein,
[0053] R 1 , R 2 , R b , U and V are as defined herein above;
[0054] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.
[0055] According to one embodiment, specifically provided are compounds of the formula (Id) in which R 1 and R 2 are alkyl, preferably methyl.
[0056] According to another embodiment, specifically provided are compounds of the formula (Id) in which R b is hydrogen or (C 1 -C 4 ) alkyl, preferably methyl.
[0057] According to yet another embodiment, specifically provided are compounds of the formula (Id) in which ‘U’ is substituted or unsubstituted five membered heterocycle, preferably thiazole or isoxazole.
[0058] According to yet another embodiment, specifically provided are compounds of the formula (Id) in which ‘V’ is substituted or unsubstituted aryl, preferably phenyl. In this embodiment the substituents on phenyl may be one or more and are independently selected from halogen (for example F, Cl or Br), cyano, alkyl (for example t-butyl or iso-butyl), haloalkyl (for example CF 3 ) and haloalkoxy (for example OCHF 2 , OCF 3 or OCH 2 CF 3 ).
[0059] According to yet another embodiment, specifically provided are compounds of the formula (Id) in which U and V together form an optionally substituted fused ring system which may optionally include one or more heteroatoms selected from O, S and N. In this embodiment the fused ring system is benzothiazole and the optional substituent is haloalkoxy (for example OCF 3 ).
[0060] According to one embodiment, there is provided a compound of the formula (Ie):
[0000]
[0061] or a pharmaceutically acceptable salt thereof, wherein,
[0062] R 1 , R 2 , R a , U and V are as defined herein above;
[0063] According to one embodiment, there is provided a compound of the formula (If):
[0000]
[0064] or a pharmaceutically acceptable salt thereof, wherein,
[0065] R 1 , R 2 , R a , U and V are as defined herein above;
[0066] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.
[0067] According to one embodiment, specifically provided are compounds of the formula (If) in which R 1 and R 2 are methyl.
[0068] According to another embodiment, specifically provided are compounds of the formula (If) in which R a is hydrogen or (C 1 -C 4 ) alkyl.
[0069] According to yet another embodiment, specifically provided are compounds of the formula (If) in which ‘U’ is substituted or unsubstituted five membered heterocycle, preferably thiazole or oxazole.
[0070] According to yet another embodiment, specifically provided are compounds of the formula (If) in which ‘V’ is substituted or unsubstituted aryl, preferably phenyl. In this embodiment one or more substituents on phenyl may be same or different and are independently selected from halogen (for example F, Cl or Br), cyano, alkyl, haloalkyl (for example CF 3 ), alkoxy [for example OCH 2 CH(CH 3 ) 2 , OCH 2 CH 2 CH(CH 3 ) 2 or OCH 2 C(CH 3 ) 3 ], cycloalkylalkoxy (for example cyclobutylmethoxy) and haloalkoxy (for example OCHF 2 , OCF 3 , OCH 2 CF 3 or OCH 2 CH 2 CF 3 ).
[0071] Particularly contemplated are compounds of the formulas (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) which possess IC 50 of less than 250 nM, preferably, less than 100 nM, more preferably, less than 50 nM with respect to TRPA1 activity as measured by method as described in the present patent application.
[0072] It should be understood that the compounds of the formulas (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) structurally encompasses all stereoisomers, enantiomers and diastereomers and pharmaceutically acceptable salts that may be contemplated from the chemical structure of the genera described herein.
[0073] In accordance with another aspect, the present patent application provides a pharmaceutical composition that includes at least one compound described herein and at least one pharmaceutically acceptable excipient (such as a pharmaceutically acceptable carrier or diluent). Preferably, the pharmaceutical composition comprises a therapeutically effective amount of at least one compound described herein. The compounds described in the present patent application may be associated with a pharmaceutically acceptable excipient (such as a carrier or a diluent) or be diluted by a carrier, or enclosed within a carrier which can be in the form of a capsule, sachet, paper or other container.
[0074] The compounds and pharmaceutical compositions described herein are useful for modulating TRPA1 receptors, wherein modulation is believed to be related to a variety of disease states.
[0075] In accordance with another aspect, the present patent application further provides a method of inhibiting TRPA1 receptors in a subject in need thereof by administering to the subject one or more compounds described herein in the amount effective to cause inhibition of such receptor.
DETAILED DESCRIPTION OF THE INVENTION
[0076] The terms “halogen” or “halo” includes fluorine, chlorine, bromine or iodine.
[0077] The term “alkyl” refers to a straight or branched hydrocarbon chain radical consisting solely of carbon and hydrogen atoms, containing no unsaturation, having from one to eight carbon atoms, and which is attached to the rest of the molecule by a single bond, e.g., methyl, ethyl, n-propyl, 1-methylethyl (isopropyl), n-butyl, n-pentyl and 1,1-dimethylethyl (tert-butyl). The term “C 1-6 alkyl” refers to an alkyl chain having 1 to 6 carbon atoms. Unless set forth or recited to the contrary, all alkyl groups described herein may be straight chain or branched, substituted or unsubstituted
[0078] The term “alkenyl” refers to an aliphatic hydrocarbon group containing a carbon-carbon double bond and which may be a straight or branched chain having 2 to about 10 carbon atoms, e.g., ethenyl, 1-propenyl, 2-propenyl (allyl), iso-propenyl, 2-methyl-1-propenyl, 1-butenyl and 2-butenyl. Unless set forth or recited to the contrary, all alkenyl groups described herein may be straight chain or branched, substituted or unsubstituted.
[0079] The term “alkynyl” refers to a straight or branched chain hydrocarbyl radical having at least one carbon-carbon triple bond and having 2 to about 12 carbon atoms (with radicals having 2 to about 10 carbon atoms being preferred) e.g., ethynyl, propynyl and butynyl. Unless set forth or recited to the contrary, all alkynyl groups described herein may be straight chain or branched, substituted or unsubstituted.
[0080] The term “alkoxy” refers to a straight or branched, saturated aliphatic hydrocarbon radical bonded to an oxygen atom that is attached to a core structure. Examples of alkoxy groups include but are not limited to methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tert-butoxy, pentoxy, 3-methyl butoxy and the like. Unless set forth or recited to the contrary, all alkoxy groups described herein may be straight chain or branched, substituted or unsubstituted.
[0081] The term “haloalkyl” and “haloalkoxy” means alkyl or alkoxy, as the case may be, substituted with one or more halogen atoms, where alkyl and alkoxy groups are as defined above. The term “halo” is used herein interchangeably with the term “halogen” means F, Cl, Br or I. Examples of “haloalkyl” include but are not limited to trifluoromethyl, difluoromethyl, 2,2,2-trifluoroethyl, pentafluoroethyl, pentachloroethyl 4,4,4-trifluorobutyl, 4,4-difluorocyclohexyl, chloromethyl, dichloromethyl, trichloromethyl, 1-bromoethyl and the like. Examples of “haloalkoxy” include but are not limited to fluoromethoxy, difluoromethoxy, trifluoromethoxy, 2,2,2-trifluoroethoxy, pentafluoroethoxy, pentachloroethoxy, chloromethoxy, dichloromethoxy, trichloromethoxy, 1-bromoethoxy and the like. Unless set forth or recited to the contrary, all “haloalkyl” and “haloalkoxy” groups described herein may be straight chain or branched, substituted or unsubstituted.
[0082] The term “cycloalkyl” denotes a non-aromatic mono or multicyclic ring system of 3 to about 12 carbon atoms, such as cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl. Examples of multicyclic cycloalkyl groups include, but are not limited to, perhydronapththyl, adamantyl and norbornyl groups, bridged cyclic groups or spirobicyclic groups, e.g., spiro(4,4) non-2-yl. Unless set forth or recited to the contrary, all cycloalkyl groups described herein may be substituted or unsubstituted.
[0083] The term “cycloalkylalkyl” refers to a cyclic ring-containing radical having 3 to about 8 carbon atoms directly attached to an alkyl group. The cycloalkylalkyl group may be attached to the main structure at any carbon atom in the alkyl group that results in the creation of a stable structure. Non-limiting examples of such groups include cyclopropylmethyl, cyclobutylethyl and cyclopentylethyl. Unless set forth or recited to the contrary, all cycloalkylalkyl groups described herein may be substituted or unsubstituted.
[0084] The term “cycloalkylalkoxy” is used to denote alkoxy substituted with cycloalkyl, wherein ‘alkoxy’ and ‘cycloalkyl’ are as defined above (either in the broadest aspect or a preferred aspect). Examples of cycloalkylalkoxy groups include cyclopropylmethoxy, 1- or 2-cyclopropylethoxy, 1-, 2- or 3-cyclopropylpropoxy, 1-, 2-, 3- or 4-cyclopropyl-butoxy, cyclobutylmethoxy, 1- or 2-cyclobutylethoxy, 1-, 2- or 3-cyclobutylpropoxy, 1-, 2-, 3- or 4-cyclobutylbutoxy, cyclopentylmethoxy, 1- or 2-cyclopentylethoxy, 1-, 2- or 3-cyclopentylpropoxy, 1-, 2-, 3- or 4-cyclopentylbutoxy, cyclohexylmethoxy, 1- or 2-cyclohexylethoxy and 1-, 2- or 3-cyclohexylpropoxy. Preferably, ‘cycloalkylalkoxy’ is (C 3-6 )cycloalkyl-(C 1-6 )alkoxy. Unless set forth or recited to the contrary, all cycloalkylalkoxy groups described herein may be substituted or unsubstituted.
[0085] The term “cycloalkenyl” refers to a cyclic ring-containing radical having 3 to about 8 carbon atoms with at least one carbon-carbon double bond, such as cyclopropenyl, cyclobutenyl and cyclopentenyl. Unless set forth or recited to the contrary, all cycloalkenyl groups described herein may be substituted or unsubstituted.
[0086] The term “aryl” means a carbocyclic aromatic system containing one, two or three rings wherein such rings may be fused. If the rings are fused, one of the rings must be fully unsaturated and the fused ring(s) may be fully saturated, partially unsaturated or fully unsaturated. The term “fused” means that a second ring is present (ie, attached or formed) by having two adjacent atoms in common (i.e., shared) with the first ring. The term “fused” is equivalent to the term “condensed”. The term “aryl” embraces aromatic radicals such as phenyl, naphthyl, tetrahydronaphthyl, indane and biphenyl. Unless set forth or recited to the contrary, all aryl groups described herein may be substituted or unsubstituted.
[0087] The term “arylalkyl” refers to an aryl group as defined above directly bonded to an alkyl group as defined above, e.g., —CH 2 C 6 H 5 or —C 2 H 4 C 6 H 5 . Unless set forth or recited to the contrary, all arylalkyl groups described herein may be substituted or unsubstituted.
[0088] The term “heterocyclic ring” refers to a stable 3- to 15-membered ring radical which consists of carbon atoms and from one to five heteroatoms selected from nitrogen, phosphorus, oxygen and sulfur. For purposes of this invention, the heterocyclic ring radical may be a monocyclic, bicyclic or tricyclic ring system, which may include fused, bridged or spiro ring systems and the nitrogen, phosphorus, carbon, oxygen or sulfur atoms in the heterocyclic ring radical may be optionally oxidized to various oxidation states. In addition, the nitrogen atom may be optionally quaternized; and the ring radical may be partially or fully saturated (i.e., heterocyclic or heteroaryl). Examples of such heterocyclic ring radicals include, but are not limited to, azetidinyl, acridinyl, benzodioxolyl, benzodioxanyl, benzofuranyl, carbazolyl, cinnolinyl, dioxolanyl, indolizinyl, naphthyridinyl, perhydroazepinyl, phenazinyl, phenothiazinyl, phenoxazinyl, phthalazinyl, pyridyl, pteridinyl, purinyl, quinazolinyl, quinoxalinyl, quinolinyl, isoquinolinyl, tetrazolyl, imidazolyl, tetrahydroisoqinolyl, piperidinyl, piperazinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolidinyl, 2-oxoazepinyl, azepinyl, pyrrolyl, 4-piperidonyl, pyrrolidinyl, pyrazinyl, pyrimidinyl, pyridazinyl, oxazolyl, oxazolinyl, oxazolidinyl, triazolyl, indanyl, isoxazolyl, isoxazolidinyl, morpholinyl, thiazolyl, thiazolinyl, thiazolidinyl, isothiazolyl, quinuclidinyl, isothiazolidinyl, indolyl, isoindolyl, indolinyl, isoindolinyl, octahydroindolyl, octahydroisoindolyl, quinolyl, isoquinolyl, decahydroisoquinolyl, benzimidazolyl, thiadiazolyl, benzopyranyl, benzothiazolyl, benzooxazolyl, furyl, tetrahydrofuryl, tetrahydropyranyl, thienyl, benzothienyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiamorpholinyl sulfone, dioxaphospholanyl, oxadiazolyl, chromanyl and isochromanyl. The heterocyclic ring radical may be attached to the main structure at any heteroatom or carbon atom that results in the creation of a stable structure. Unless set forth or recited to the contrary, all heterocyclic ring described herein may be substituted or unsubstituted.
[0089] The term “heterocyclyl” refers to a heterocyclic ring radical as defined above. The heterocyclyl ring radical may be attached to the main structure at any heteroatom or carbon atom that results in the creation of a stable structure. Unless set forth or recited to the contrary, all heterocyclyl groups described herein may be substituted or unsubstituted.
[0090] The term “heterocyclylalkyl” refers to a heterocyclic ring radical directly bonded to an alkyl group. The heterocyclylalkyl radical may be attached to the main structure at any carbon atom in the alkyl group that results in the creation of a stable structure. Unless set forth or recited to the contrary, all heterocyclylalkyl groups described herein may be substituted or unsubstituted.
[0091] The term “heteroaryl” refers to an aromatic heterocyclic ring radical. The heteroaryl ring radical may be attached to the main structure at any heteroatom or carbon atom that results in the creation of a stable structure. Unless set forth or recited to the contrary, all heteroaryl groups described herein may be substituted or unsubstituted.
[0092] The term “heteroarylalkyl” refers to a heteroaryl ring radical directly bonded to an alkyl group. The heteroarylalkyl radical may be attached to the main structure at any carbon atom in the alkyl group that results in the creation of a stable structure. Unless set forth or recited to the contrary, all heteroarylalkyl groups described herein may be substituted or unsubstituted.
[0093] Unless otherwise specified, the term “substituted” as used herein refers to substitution with any one or more or any combination of the following substituents: hydroxy, halogen, carboxyl, cyano, nitro, oxo (═O), thio (═S), substituted or unsubstituted alkyl, substituted or unsubstituted haloalkyl, substituted or unsubstituted alkoxy, substituted or unsubstituted haloalkoxy, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenylalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted amino, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heterocyclylalkyl ring, substituted or unsubstituted heteroarylalkyl, substituted or unsubstituted heterocyclic ring, substituted or unsubstituted guanidine, —COOR x′ , —C(O)R x′ , —C(S)R x′ , —C(O)NR x′ R y′ , —C(O)ONR x′ R y′ , —NR x′ CONR y′ R z′ , —N(R x′ )SOR y′ , —N(R x′ )SO 2 R y′ , —(═N—N(R x′ )R y′ ), —NR x′ C(O)OR y′ , —NR x′ R y′ , —NR x′ C(O)R y′ , —NR x′ C(S)R y′ , —NR x′ C(S)NR y′ R z′ , —SONR x′ R y′ , —SO 2 NR x′ R y′ , —OR x′ , —OR x′ C(O)NR y′ R z′ , —OR x′ C(O)OR y′ , —OC(O)R x′ , —OC(O)NR x′ R y′ , —R x′ NR y′ C(O)R z′ , —R x′ OR y′ , —R x′ C(O)OR y′ , —R x′ C(O)NR y′ R z′ , —R x′ C(O)R y′ , —R x′ OC(O)R y′ , —SR x′ , —SOR x′ , —SO 2 R x′ and —ONO 2 , wherein R x′ , R y′ and R z′ are independently selected from hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted alkoxy, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted amino, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted heterocyclylalkyl ring, substituted or unsubstituted heteroarylalkyl or substituted or unsubstituted heterocyclic ring.
[0094] The term “treating” or “treatment” of a state, disorder or condition includes; (a) preventing or delaying the appearance of clinical symptoms of the state, disorder or condition developing in a subject that may be afflicted with or predisposed to the state, disorder or condition but does not yet experience or display clinical or subclinical symptoms of the state, disorder or condition; (b) inhibiting the state, disorder or condition, i.e., arresting or reducing the development of the disease or at least one clinical or subclinical symptom thereof; or (c) relieving the disease, i.e., causing regression of the state, disorder or condition or at least one of its clinical or subclinical symptoms.
[0095] The term “subject” includes mammals (especially humans) and other animals, such as domestic animals (e.g., household pets including cats and dogs) and non-domestic animals (such as wildlife).
[0096] A “therapeutically effective amount” means the amount of a compound that, when administered to a subject for treating a state, disorder or condition, is sufficient to effect such treatment. The “therapeutically effective amount” will vary depending on the compound, the disease and its severity and the age, weight, physical condition and responsiveness of the subject to be treated.
[0097] The compounds described in the present patent application may form salts. Non-limiting examples of pharmaceutically acceptable salts forming part of this patent application include salts derived from inorganic bases salts of organic bases, salts of chiral bases, salts of natural amino acids and salts of non-natural amino acids.
[0098] Certain compounds of the present invention, including compounds of formula (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) are capable of existing in stereoisomeric forms (e.g. diastereomers and enantiomers). The present invention includes these stereoisomeric forms (including diastereomers and enantiomers) and mixtures of them. The various stereoisomeric forms of the compounds of the present invention may be separated from one another by methods known in the art or a given isomer may be obtained by stereospecific or asymmetric synthesis. Tautomeric forms and mixtures of compounds described herein are also contemplated.
Pharmaceutical Compositions
[0099] The pharmaceutical composition of the present patent application includes at least one compound described herein and at least one pharmaceutically acceptable excipient (such as a pharmaceutically acceptable carrier or diluent). Preferably, the pharmaceutical composition includes the compound(s) described herein in an amount sufficient to inhibit TRPA1 in a subject (e.g., a human). The inhibitory activity of compounds falling within the formulas (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) may be measured by an assay provided below.
[0100] The compound of the present invention may be associated with a pharmaceutically acceptable excipient (such as a carrier or a diluent) or be diluted by a carrier, or enclosed within a carrier which can be in the form of a capsule, sachet, paper or other container.
[0101] The pharmaceutical compositions may be prepared by techniques known in the art. For example, the active compound can be mixed with a carrier, or diluted by a carrier, or enclosed within a carrier, which may be in the form of an ampoule, capsule, sachet, paper, or other container. When the carrier serves as a diluent, it may be a solid, semi-solid, or liquid material that acts as a vehicle, excipient, or medium for the active compound. The active compound can be adsorbed on a granular solid container, for example, in a sachet.
[0102] The pharmaceutical compositions may be in conventional forms, for example, capsules, tablets, aerosols, solutions, suspensions or products for topical application.
Methods of Treatment
[0103] The compounds and pharmaceutical compositions of the present invention can be administered to treat any disorder, condition, or disease treatable by inhibition of TRPA1. For instance, the compounds and pharmaceutical compositions of the present invention are suitable for treatment or prophylaxis of the following diseases, conditions and disorders mediated or associated with the activity of TRPA1 receptors: pain, chronic pain, complex regional pain syndrome, neuropathic pain, postoperative pain, rheumatoid arthritic pain, osteoarthritic pain, back pain, visceral pain, cancer pain, algesia, neuralgia, migraine, neuropathies, diabetic neuropathy, sciatica, HIV-related neuropathy, post-herpetic neuralgia, fibromyalgia, nerve injury, ischaemia, neurodegeneration, stroke, post stroke pain, multiple sclerosis, respiratory diseases, asthma, cough, COPD, inflammatory disorders, oesophagitis, gastroeosophagal reflux disorder (GERD), irritable bowel syndrome, inflammatory bowel disease, pelvic hypersensitivity, urinary incontinence, cystitis, burns, psoriasis, eczema, emesis, stomach duodenal ulcer and pruritus. The connection between therapeutic effect and inhibition of TRPA1 is illustrated, for example, in Story G M et al, Cell, 2003, 112, 819-829; McMahon S B and Wood J N, Cell, 2006, 124, 1123-1125; Voorhoeve P M et al., Cell, 2006, 124, 1169-1181; Wissenbach U, Niemeyer B A and Flockerzi V, Biology of the Cell, 2004, 96, 47-54; Dayne Y O, Albert Y H & Michael X, Expert Opinion on Therapeutic Targets, 2007, 11(3), 391-401 and the references cited therein.
[0104] Pain can be acute or chronic. While acute pain is usually self-limiting, chronic pain persists for 3 months or longer and can lead to significant changes in a patient's personality; lifestyle, functional ability and overall quality of life (K. M. Foley, Pain , in Cecil Textbook of Medicine; J. C. Bennett & F. Plum (eds.), 20th ed., 1996, 100-107). The sensation of pain can be triggered by any number of physical or chemical stimuli and the sensory neurons which mediate the response to this harmful stimulus are termed as “nociceptors”. Nociceptors are primary sensory afferent (C and Aδ fibers) neurons that are activated by a wide variety of noxious stimuli including chemical, mechanical, thermal and proton (pH<6) modalities. Nociceptors are the nerves which sense and respond to parts of the body which suffer from damage. They signal tissue irritation, impending injury, or actual injury. When activated, they transmit pain signals (via the peripheral nerves as well as the spinal cord) to the brain.
[0105] Chronic pain can be classified as either nociceptive or neuropathic. Nociceptive pain includes tissue injury-induced pain and inflammatory pain such as that associated with arthritis. Neuropathic pain is caused by damage to the sensory nerves of the peripheral or central nervous system and is maintained by aberrant somatosensory processing. The pain is typically well localized, constant and often with an aching or throbbing quality. Visceral pain is the subtype of nociceptive pain that involves the internal organs. It tends to be episodic and poorly localized. Nociceptive pain is usually time limited, meaning when the tissue damage heals, the pain typically resolves (arthritis is a notable exception in that it is not time limited).
General Methods of Preparation
[0106] The compounds described herein, including compounds of general formula (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) and specific examples, can be prepared by techniques known to one in the art, for example, through the reaction scheme depicted in Schemes 1-12. Furthermore, in the following schemes, where specific acids, bases, reagents, coupling agents, solvents etc. are mentioned, it is understood that other suitable acids, bases, reagents, coupling agents etc. may be used and are included within the scope of the present invention. Modifications to reaction conditions, for example, temperature, duration of the reaction or combinations thereof are envisioned as part of the present invention. The compounds obtained by using the general reaction scheme may be of insufficient purity. These compounds can be purified by any of the methods for purification of organic compounds known in the art, for example, crystallization or silica gel or alumina column chromatography using different solvents in suitable ratios. All possible stereo isomers are envisioned within the scope of this invention.
[0107] An approach for the synthesis of 2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide of the general formula (Ia-1) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 1. The starting substituted uracil derivative of formula (1), wherein R 1 and R 2 are alkyl (e.g., methyl, ethyl) are available commercially or can be prepared by reaction of 1,3-dialkylurea and acetic anhydride or by condensation of monosubstituted urea and ethyl acetoacetate according to methods known in the art (Egg, H. et al. Synthesis, 1982, 1071-1073; Senda S. et al. Chem. Pharm. Bull., 1972, 6, 404-408). Nitro derivative of general formula (2) can be prepared by nitration of uracil derivative of formula (1) using mixture of sulphuric acid and fuming nitric acid followed by condensation with DMF-dimethyl acetal in a suitable solvent (e.g., DMF, THF). Reductive cyclization of compound of formula (2) using 10% Pd—C under hydrogen atmosphere in suitable solvent (e.g., EtOH, MeOH) affords compound of general formula (3). Alkylation of compound of formula (3) using appropriate electrophile of a general formula (4) [prepared from haloacetyl halide and appropriate substituted amine as described in Ohkubo M. et al., Chem. Pharm. Bull., 1995, 43(9), 1497-1504] in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compound of general formula (Ia-1).
[0000]
[0108] An approach for the synthesis of compounds of the general formula (Ia-2) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 2. Compounds of general formula (3) is converted to a compound of formula (6) by using suitable amine of formula (5) [wherein R and R′ are alkyl (e.g., methyl, ethyl)] and formaldehyde as described by Tsupak, E. B. et al. in Chemistry of Heterocyclic Compounds, 1994, 30(9), 1077-1082. Alternatively, the intermediate (6) can be prepared by formylation of compound of formula (3) using mixture of phosphorous oxychloride and dimethyl formamide to give compound of formula (7) followed by reductive amination of the formyl group using a suitable amine of formula (5). Alkylation of compound of formula (6) using appropriate electrophile of a general formula (4) in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compounds of general formula (Ia-2).
[0000]
[0109] An approach for the synthesis of compounds of the general formula (Ia-3) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 2. Deoxygenation of formyl pyrrole of formula (7) with suitable reducing system (e.g., triethylsilane/trifluoroacetic acid) affords methylpyrrole of formula (8). Alkylation of compound of formula (8) using appropriate electrophile of a general formula (4) in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compounds of the general formula (Ia-3).
[0110] An approach for the synthesis of compounds of the general formula (Ia-4) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 3. Halogenation of compound of formula (3) with suitable halogenating agent (e.g., N-bromosuccinimide, N-iodosuccinimide, bromine) gives corresponding halogenated compound of formula (9). Alkylation of compound of formula (9) using appropriate electrophile of a general formula (4) in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compounds of general formula (Ia-4).
[0000]
[0111] An approach for the synthesis of compounds of the general formula (Ia-5) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 4. 1,3,6-trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione of the formula (12) can be prepared by the reaction of 5-amino-1,3-dimethyluracil of the formula (10) with propargyl bromide in a suitable solvent such as MeOH followed by cyclization of the intermediate (11) at elevated temperature as described in Townsend, L. B. et al., J. Heterocyclic Chem., 1975, 12, 711-716 and Kawahara, N. et al., Chem. Pharm. Bull., 1985, 33(11), 4740-4748. Alkylation of compound of formula (12) with an appropriate electrophile of a general formula (4) affords compounds of general formula (Ia-5).
[0000]
[0112] A general approach for the synthesis of 2,4-dioxo-2,3,4,6-tetrahydro-1H-pyrrolo[3,4-d]pyrimidin-5-yl)acetamide of the general formula (Ib-1) where R 1 , R 2 , R b , U and V are as defined herein above is depicted in Scheme 5. The formyl derivative of formula (13) can be prepared by formylation of uracil derivative of formula (1) [Senda, S. et al., Yakugaku Zasshi, 1971, 91, 1372] followed by bromination of formyl derivative thus formed. Cyclization of formyl derivative of formula (13) [as described in Senda, S. et al., Synthesis, 1978, 463-465] with amine of the formula (19) in suitable solvent (e.g., EtOAc) followed by halogenation using suitable halogenating reagent (e.g., N-bromosuccinimide, N-iodosuccinimide, Br 2 in acetic acid) gives halopyrrole of general formula (14). Halopyrrole of formula (14) on reaction with allyl boronic acid pinacol ester of the formula (15) in the presence of a palladium catalyst, such as bis(triphenylphosphine)palladium dichloride or tetrakis(triphenylphosphine) palladium(0) gives allyl pyrrole of the formula (16) [procedure is similar to the Suzuki-Miyaura Coupling described by Kotha, et al., Synlett, 2005, 12, 1877-1890]. Transformation of allyl pyrrole of formula (16) into corresponding aldehyde can be accomplished by methods known in the art [e.g., Postema, M. H. D. et al., in J. Org. Chem., 2003, 68, 4748-4754]. Further oxidation of aldehyde thus formed can be carried out by oxidation methods well known in the literature to give corresponding carboxylic acid of general formula (17). Coupling of carboxylic acid (17) with appropriate amines of formula (18) using a standard amide coupling method gives compounds of general formula (Ib-1).
[0000]
[0113] A general approach for the synthesis of 2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide of the general formula (Ic-1) where R a is an alkyl group, R 1 , R 2 , U and V are as defined above is depicted in Scheme 6. Reaction of 6-chlorouracil derivative of the formula (20) with amino ester of formula (21) followed by cyclization gives pyrrolidinone of formula (22) [Similar procedure described by Edstrom, E. D. et al., J. Org. Chem., 1995, 60, 5069-5076]. Pyrrolidinone of formula (22) can be converted to halopyrrole of formula (23) (wherein X is halogen) using triflic anhydride or hydrazine followed by iodine. Halopyrrole of formula (23) on reaction with allyl boronic acid pinacol ester of the formula (15) in the presence of a palladium catalyst, such as bis(triphenylphosphine)palladium dichloride or tetrakis(triphenylphosphine) palladium(0) gives allyl pyrrole of the formula (24). Transformation of allyl pyrrole of formula (24) to the corresponding aldehyde followed by further oxidation of aldehyde thus formed can be carried out by oxidation methods well known in the literature to give corresponding carboxylic acid of general formula (25). Coupling of carboxylic acid of formula (25) with appropriate amines of formula (18) by using a standard amide coupling method gives compounds of general formula (Ic-1).
[0000]
[0114] An alternative approach for the synthesis of compounds of the general formula (Ic-1) is described in Scheme 7. Reaction of commercially available 6-aminouracil derivative of the formula (26) with chloroacetaldehyde dimethyl acetal gives pyrrole derivative (as described by Noell, C. W. et al., J. Het. Chem., 1964, 34-41) which upon alkylation with appropriate alkylating agent (R a X) gives compound of formula (27). Compound of formula (27) can be converted into α-keto ester of general formula (28) using oxalyl chloride followed by reaction of acid chloride thus formed with anhydrous protic solvent (e.g., methanol, ethanol, tert-butanol). Deoxygenation of α-keto ester of general formula (28) with triethylsilane in the presence of trifluoroacetic acid affords ester of general formula (29) [similar procedure described by Han, Q. et al., J. Med. Chem., 2000, 43, 4398-4415]. Acidic hydrolysis of ester of formula (29) gives corresponding carboxylic acid of formula (25). Coupling of carboxylic acid of formula (25) with appropriate amines of formula (18) by using a standard amide coupling method give compounds of general formula (Ic-1).
[0000]
[0115] An approach for the synthesis of compounds of the general formula (Id-1) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 8. The synthesis starts from known 6-hydrazino-1,3-dimethyluracil (30) which is readily prepared by the displacement of halogen of 6-chloro-1,3-dialkyuracil of the formula (20) with hydrazine hydrate according to the known procedure. The cyclisation of compound of the formula (30) with acetic anhydride gave pyrazole of the formula (31). The deacetylation followed by selective N-alkylation of pyrazole (31) with dimethyl sulfate afforded compounds of the formula (33) (Pfleiderer, W. et al., Justus Liebigs Ann Chem. 1958, 615, 42-47). The reaction of compound of formula (33) with dimethyl carbonate in presence of a strong base (e.g. NaH) under reflux conditions gives ester of the formula (34). Hydrolysis of ester (34) with aqueous acid afforded the desired pyrazolo[3,4-d]pyrimidinedione acetic acid of the formula (35). The coupling of compound of formula (35) with respective amines of formula (18) by using a standard amide coupling method gives compounds of general formula (Id-1).
[0000]
[0116] An approach for the synthesis of compounds of the general formula (Ie) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 9. Synthesis starts from readily available 1,3-dialkylbarbituric acid of the formula (36). The known 6-chloro-5-formyl-1,3-dimethyluracil of formula (37) wherein R 1 and R 2 are methyl is prepared according to a reported procedure (Singh, J. S. et al., Synthesis, 1988, 342-344). The reaction of 6-chloro-5-formyl-1,3-dimethyluracil (37) with hydroxylamine in methanol followed by dehydration with phosphorous oxychloride give 6-chloro-5-cyano-1,3-dimethyluracil of formula (38). The cyclisation of compounds of the formula (38) with alkylhydrazine of the formula (39) in the presence of suitable base afforded amino pyrazole of the formula (40). The amino pyrazole (40) on diazotization followed by halide substitution with copper halide (such as copper bromide or copper iodide) gives a halide derivative of the formula (41) (wherein X is halogen). Suzuki-Miyaura coupling reaction of aryl halide of formula (41) with allyl boronic acid pinacol ester of the formula (15) as described by Kotha et al., Synlett, 2005, 12, 1877-1890) gives allyl pyrazole of the formula (42). This can be converted to pyrazolo[3,4-d]pyrimidinylacetic acid of the formula (43) by oxidative cleavage methods well known in the literature. The coupling of carboxylic acid of the formula (43) with respective amines of formula (18) by using a standard amide coupling method can give compounds of general formula (Ie).
[0000]
[0117] An approach for the synthesis of compounds of the general formula (If-1) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 10. The approach described is similar to that described by Papesch, P. et al., J. Org. Chem., 1965, 30, 199-203. Compound of the formula (44) was prepared by nitration of pyrimidine-2,4(1H,3H)-dione of the formula (1) followed by reduction (Egg, H. et al., Synthesis, 1982, 12, 1071-1073). The compound of the formula (44) was transformed into the compound of the formula (45) by diazotization followed by in situ cyclisation with base (eg. NaOH). The compound of the formula (45) on alkylation with suitable 2-halo-acetamide of general formula (4) in the presence of a suitable base (e.g. Cs 2 CO 3 , NaH etc.) and a suitable solvent (e.g. DMF, THF, DMSO etc.) gives compound of general formula (If-1).
[0000]
[0118] The 2-haloacetamides of formula (53) (wherein R z is selected from alkyl, cyano, halogen, haloalkyl, alkoxy, haloalkoxy, cycloalkylalkoxy and arylalkoxy, and ‘p’ is selected from 0 to 5) required for the synthesis of compound of the present invention can be prepared according to methods known to one skilled in the art (Carroll, L. et al., J. Am. Chem. Soc., 1950, 72, 3722-3725; Ohkubo, M. et al., Chem. Pharm. Bull., 1995, 43(9), 1497-1504). Thus, acylation of an aryl, heteroaryl or aryl alkyl amine with bromoacetyl bromide in the presence of a suitable base such as triethylamine or pyridine gives N-substituted bromoacetamide of the general formula (53) (Scheme 11).
[0119] A few of aniline derivatives, arylalkylamines and 2-amino-4-arylthiazoles (52) were commercially available. Many of the disubstituted and trisubstituted arylaminothiazoles were prepared from appropriate aryl alkyl ketones. Commercially unavailable aryl alkyl ketones were prepared from the corresponding benzoic acids as shown in Scheme 11. Substituted benzoic acid of the formula (46) was converted to the corresponding acetophenone in three steps as shown in Scheme 11. Thus, acid (46) was converted to the corresponding acid chloride (47) using oxalyl chloride in the presence of catalytic amounts of DMF in dry dichloromethane. Alternatively, this transformation can be carried out using excess thionyl chloride. The acid chloride (47) was converted to corresponding Weinreb amide (48) by treating with N,O-dimethyl hydroxylamine hydrochloride in the presence of a suitable base such as triethylamine. Addition of methyl magnesium iodide to Weinreb amide (48) gives acetophenone derivative of the formula (49). In addition, commercially unavailable aryl alkyl ketones were prepared from mono or di-substituted phenol (50) as depicted in Scheme 11. Thus, acetylation of phenol (50) with acetic anhydride followed by Fries rearrangement of the ester formed in the presence of Lewis acid (e.g. AlCl 3 ) affords corresponding hydroxyacetophenone of general formula (51). Alkylation of hydroxyacetophenone of general formula (51) with suitable alkyl halide in suitable base (e.g., NaH, Cs 2 CO 3 ) and suitable solvent (e.g., DMSO, THF, DMF) gives acetophenone derivative of general formula (49).
[0120] The aryl alkyl ketone of the formula (49) is converted to 2-aminothiazole of the formula (52) in one step by its reaction with thiourea in the presence of iodine in ethanol. This conversion is similar to the one described by Carroll, K. et al., J. Am. Chem. Soc. 1950, 3722; and Naik, S., J.; Halkar, U. P., ARKIVOC, 2005, xiii, 141-149. Alternatively, 2-aminothiazoles of the formula (52) can be prepared by the reaction of compounds of formula (49) with bromine in acetic acid to give the alpha halo intermediate, which on reaction with thiourea in THF at reflux condition give compounds of the formula (52). The compound of the formula (52) is converted to 2-bromo-N-thiazolyl acetamide of the formula (53) by acylation with bromoacetyl bromide in the presence of a suitable base (e.g., pyridine or triethylamine) and in a suitable solvent (e.g., THF, DMF).
[0000]
[0121] 5-Aryl-1H-imidazol-2-amines of the formula (55) were prepared as shown in Scheme 12. The reaction of acetophenones of the formula (49) (wherein R z and ‘p’ are as defined above in scheme 11) with bromine in acetic acid to give the alpha bromo intermediate, which on reaction with acetyl guanidine in acetonitrile at reflux condition give compounds of the formula (54). The deacetylation of (54) in the presence of catalytic amount of concentrated sulphuric acid using suitable solvent afforded desired 5-Aryl-1H-imidazol-2-amine of the formula (55). (This is similar to procedure reported by Thomas, L. et al., J. Org. Chem., 1994, 59, 7299-7305).
[0000]
[0122] The intermediates and examples described in the present invention are prepared using the procedure described below. However, it is understood that these intermediates and examples can be prepared by alternate approaches which are within the scope of the present invention.
EXPERIMENTAL
[0123] Unless otherwise stated, work-up includes distribution of the reaction mixture between the organic and aqueous phase indicated within parentheses, separation of layers and drying the organic layer over sodium sulphate, filtration and evaporation of the solvent. Purification, unless otherwise mentioned, includes purification by silica gel chromatographic techniques, generally using ethyl acetate/petroleum ether mixture of a suitable polarity as the mobile phase. Use of a different eluent system is indicated within parentheses. The following abbreviations are used in the text: DMSO-d 6 : Hexadeuterodimethyl sulfoxide; DMF: N,N-dimethylformamide, M.P.: Melting point; J: Coupling constant in units of Hz; RT or rt: room temperature (22-26° C.). Aq.: aqueous AcOEt: ethyl acetate; equiv. or eq.: equivalents.
Intermediate 1
1,3-Dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione
[0124]
[0125] Step 1 1,3,6-Trimethyl-5-nitrouracil: A mixture of concentrated H 2 SO 4 (7.0 mL) and fuming HNO 3 (7.0 mL) was cooled to 0-5° C. and 1,3,6-trimethylpyrimidine-2,4(1H,3H)-dione (3.5 g, 22.702 mmol) was gradually added to the reaction mixture. After stirring for 2 h. at the same temperature the reaction mixture was partitioned between ethyl acetate (200 mL) and water (100 mL). The organic layer was washed with brine (2×50 mL), dried (Na 2 SO 4 ) and evaporated under reduced pressure. Crude product obtained was purified by column chromatography to give 1.30 g of the product as yellow solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.38 (s, 3H), 3.20 (s, 3H), 3.40 (s, 3H); APCI-MS (m/z) 198.30 (M−H).
[0126] Step 2 1,3-Dimethyl-6-[2-(dimethylamino)vinyl]-5-nitrouracil: To a solution of Step 1 intermediate, 1,3,6-Trimethyl-5-nitrouracil (0.60 g, 3.012 mmol) in dry N,N-dimethylformamide (5.0 mL) was added N,N-dimethylformamide dimethyl acetal (0.53 g, 4.447 mmol) and the reaction mixture was stirred at room temperature for 2 h. After this time, diethyl ether was added to the reaction mixture and the precipitate was collected by filtration and washed with diethyl ether to give 0.45 g of the product as brownish solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.98 (s, 6H), 3.16 (s, 3H), 3.40 (s, 3H), 4.78 (d, J=12.6 Hz, 1H), 7.05 (d, J=12.6 Hz, 1H); APCI-MS (m/z) 255.11 (M+H) + .
[0127] Step 3 1,3-Dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: To a solution of Step 2 intermediate (0.40 g, 1.573 mmol) in MeOH (80 mL) was added 10% Pd—C (0.2 g) and the mixture was stirred under a hydrogen atmosphere at room temperature for 2 h. The mixture was filtered through a celite bed and was thoroughly washed with MeOH (50 mL). The filtrate was collected and evaporated and the residue thus obtained was purified by column chromatography to afford 0.120 g of the desired compound as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.23 (s, 3H), 3.38 (s, 3H), 6.17 (s, 1H), 7.25 (s, 1H), 12.09 (s, 1H); APCI-MS (m/z) 180.28 (M+H) + .
Intermediate 2
1,3,6-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione
[0128]
[0129] Step 1 5-Amino-1,3-dimethylpyrimidine-2,4(1H,3H)-dione: To a stirred solution of 1,3-dimethyl-5-nitropyrimidine-2,4(1H,3H)-dione (2.0 g, 10.802 mmol) in methanol (200 mL), 10% Pd—C (0.500 g) was added under hydrogen atmosphere and the reaction mixture was stirred at room temperature for 2 h. Reaction mixture was filtered through a celite bed and washed with methanol. The filtrate was collected and concentrated under reduced pressure to give 1.5 g of the product.
[0130] Step 2 1,3-Dimethyl-5-(prop-2-yn-1-ylamino)pyrimidine-2,4(1H,3H)-dione: To a stirred solution of Step 1 intermediate (1.4 g, 9.023 mmol) in 1:1 mixture of dichloromethane and methanol (28 mL) was added propargyl bromide (1.4 mL) and the mixture was stirred at room temperature for 2 h. Reaction mixture was filtered through celite bed and washed with methanol. The filtrate was concentrated under reduced pressure to give 500 mg of the product.
[0131] Step 3 1,3,6-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: A solution of Step 2 intermediate (500 mg, 2.587 mmol) in dry N,N-dimethylformamide (20 mL) was refluxed for 40 h under nitrogen atmosphere. The excess of solvent was evaporated and the residue obtained was purified by silica gel column chromatography by using 5% methanol in chloroform to obtain 200 mg of the product as a yellow solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.26 (s, 3H), 3.21 (s, 3H), 3.33 (s, 3H), 5.91 (s, 1H), 11.84 (br s, 1H); ESI-MS (m/z) 194.28 (M+H) + .
Intermediate 3
1,3,7-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione
[0132]
[0133] Step 1 1,3-Dimethyl-2,4-dioxo-2,3,4,5-tetrahydro-1H-pyrrolo[3,2-d]pyrimidine-7-carbaldehyde: At a temperature of 5-10° C., phosphorous oxychloride (1.84 ml, 20.087 mmol) was mixed with N,N-dimethylformamide (2 mL). Then a solution of Intermediate 1 (600 mg, 3.348 mmol) in N,N-dimethylformamide (3 mL) was added while stirring. The reaction mixture was held for 2 h at 95° C., cooled and poured onto ice (10 g). The precipitate formed was filtered off and recrystallised from water to give 300 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.25 (s, 3H), 3.75 (s, 3H), 8.06 (s, 1H), 9.79 (s, 1H), 13.15 (br s, 1H); APCI-MS (m/z) 208.20 (M+H) + .
[0134] Step 2 1,3,7-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: To a stirred and cooled (−10° C.) solution of trifluoroacetic acid (5 mL) was added triethylsilane (294 mg, 2.528 mmol) followed by portionwise addition of Step 1 intermediate (150 mg, 0.723 mmol). The reaction mixture was warmed to room temperature and stirred for another 1 h. Reaction mixture was diluted with ethyl acetate (25 mL) and water (25 mL). Two layers were separated. The aqueous layer was extracted with ethyl acetate (2×25 mL). The combined organic layers were washed with water (25 mL), dried (Na 2 SO 4 ) and filtered. The filtrate was evaporated to give 110 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.27 (s, 3H), 3.22 (s, 3H), 3.56 (s, 3H), 7.03 (s, 1H), 11.75 (br s, 1H); APCI-MS (m/z) 194.28 (M+H) + .
Intermediate 4
7-Bromo-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione
[0135]
[0136] To a solution of Intermediate 1 (500 mg, 2.800 mmol) in acetic acid (5 mL) was added a solution of bromine (430 mg, 2.700 mmol) in acetic acid (5 mL) dropwise with stirring, after which water (1.2 mL) was added. The reaction mixture was stirred for another 20 min and diluted with two volumes of cold water. After 3 h, the precipitate was filtered off and washed with diethyl ether to afford 400 mg of the product as a white solid; 1 H NMR (6 ppm, 300 MHz, DMSO-d 6 ) 3.23 (s, 3H), 3.65 (s, 3H), 7.42 (s, 1H), 12.59 (br s, 1H); APCI-MS (m/z) 258.19 (M+H) + .
Intermediate 5
7-[(Dimethylamino)methyl]-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione
[0137]
[0138] To a mixture of 50% dimethyl amine (0.4 mL), acetic acid (0.4 mL) and 38% formaldehyde (0.4 mL) were added, after which Intermediate 1 (0.4 g, 2.232 mmol) was added. The reaction mixture was refluxed for 10 min and then held for 20 min at 90° C. Reaction mixture was cooled to room temperature and diluted with water (25 mL). Two layers were separated. The aqueous layer was extracted with ethyl acetate (2×25 mL). The combined organic layers were washed with water (25 mL), dried (Na 2 SO 4 ) and filtered. The filtrate was evaporated to give a crude product which was recrystallised from acetonitrile to give 97 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.08 (s, 6H), 3.23 (s, 3H), 3.30 (s, 2H), 3.69 (s, 3H), 7.13 (s, 1H), 11.93 (br s, 1H); APCI-MS (m/z) 237.00 (M+H) + .
Intermediate 6
7-[(Diethylamino)methyl]-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione
[0139]
[0140] To a stirred solution of diethyl amine (52 mg, 0.723 mmol) in dichloromethane (5 mL) Intermediate 3, Step 1 (150 mg, 0.723 mmol) was added portionwise followed by the addition of sodium triacetoxyborohydried (230 mg, 1.085 mmol) at room temperature. After stirring for 24 h, the excess of solvent was evaporated and the crude product obtained was purified by column chromatography by using 1% methanol in chloroform to afford 130 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 0.93 (t, J=7.2 Hz, 6H), 2.40-2.56 (m, 4H), 3.23 (s, 3H), 3.48 (s, 2H), 3.73 (s, 3H), 7.18 (s, 1H), 11.92 (br s, 1H); APCI-MS (m/z) 265.00 (M+H) + .
Intermediate 7
(1,3,7-Trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetic acid
[0141]
[0142] Step 1 1,3-Dimethyl-1H-pyrrolo[2,3-d]pyrimidine-2,4(3H,7H)-dione: (374-ABK-023) To a stirred solution of chloroacetaldehyde dimethyl acetal (26.0 g, 208.717 mmol) in water (60 mL) concentrated hydrochloric acid (4 mL) was added at room temperature and the reaction mixture was stirred at near boiling until a homogeneous solution was obtained. Solution of sodium acetate (8.0 g, 97.525 mmol) was then added. The resulting mixture was then added to a stirred solution consisting of 6-amino-1,3-dimethyl uracil (20.0 g, 128.907 mmol) and sodium acetate (16.0 g, 195.051) in water (100 mL) at 90° C. All solid material was dissolved, then after 10 min. a precipitate was started to form. The reaction mixture was stirred for another 30 min. at the same temperature. The reaction mixture was cooled to room temperature and solid obtained was filtered, washed with water (2×250 mL) and then acetone (2×150 mL). The solid obtained was dried in oven at 65° C. to obtain 7.81 g of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.42 (s, 3H), 6.35 (s, 1H), 6.77 (s, 1H), 11.71 (br s, 1H); APCI-MS (m/z) 180.25 (M+H) + .
[0143] Step 2 7-[(Dimethylamino)methyl]-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: To a stirred solution of sodium hydroxide (3.4 g, 84.830 mmol) in water (80 mL) was added Step 1 intermediate (7.6 g, 42.415 mmol) at room temperature and the reaction mixture was stirred for 30 min. Dimethyl sulfate (10.7 g, 84.830 mmol) was added dropwise to the reaction mixture and stirred for another 4 h. Solid was precipitated out and collected by filtration, washed with water. The crude solid obtained was purified by column chromatography by using 3% methanol in chloroform to obtain 5.4 g of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.70 (s, 3H), 3.90 (s, 3H), 6.32 (s, 1H), 6.69 (s, 1H); APCI-MS (m/z) 194.21 (M+H) + .
[0144] Step 3 Methyl oxo(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetate: To a well stirred solution of oxalyl chloride (1.6 g, 12.939 mmol) in dichloromethane (10 mL) was added Step 2 intermediate (1.0 g, 5.176 mmol) in small portions at −10° C. and the resulting mixture was stirred overnight at room temperature. The excess of solvent was removed under vacuum and the residue was again taken in dichloromethane (10 mL). The reaction mixture was cooled to −10° C. and dry methanol (10 mL) was added dropwise over a period of 10-15 min. The resulting reaction mixture was stirred overnight at room temperature. Excess of solvent was evaporated under vacuum. The residue obtained was basified with saturated solution of NaHCO 3 (25 mL) and extracted with ethyl acetate (2×50 mL). The combined organic layers were washed with water (25 mL), brine (25 mL) and dried (Na 2 SO 4 ). The crude product obtained after evaporation of the solvent was purified by silica gel column chromatography by using 5% methanol in chloroform to give 1.1 g of the product as a pale yellow solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.62 (s, 3H), 3.72 (s, 6H), 3.83 (s, 2H), 6.29 (s, 1H); APCI-MS (m/z) 266.23 (M+H) + .
[0145] Step 4 Methyl (1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetate: To a stirred solution of triethylsilane (364 mg, 3.133 mmol) in trifluoroacetic acid (4.0 mL) was added Step 3 intermediate (250 mg, 0.892 mmol) slowly at −10° C. The resulting mixture was warmed slowly to room temperature. After overnight stirring at room temperature, excess of solvent was removed under reduced pressure and the residue obtained was neutralized with saturated solution of NaHCO 3 (15 mL). Two layers were separated after the addition of ethyl acetate (25 mL). The aqueous layer was extracted with ethyl acetate (2×25 mL). The combined organic layers were washed with water (25 mL) and brine (25 mL). The crude product obtained was purified by silica gel column chromatography by using 20% ethyl acetate in petroleum ether to give 147 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.65-3.72 (m, 8H), 6.29 (s, 1H), 12.62 (br s, 1H); APCI-MS (m/z) 252.38 (M+H) + .
[0146] Step 5 (1,3,7-Trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetic acid: A mixture of Step 4 intermediate (130 mg, 0.491 mmol) and concentrated hydrochloric acid (4 mL) was heated at 60° C. for 2 h. The excess of hydrochloric acid was evaporated under reduced pressure and the residue obtained was purified by silica gel column chromatography using 5% methanol in chloroform to obtain 94 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.21 (s, 3H), 3.65-3.72 (m, 8H), 6.29 (s, 1H), 12.62 (br s, 1H); APCI-MS (m/z) 252.38 (M+H) + .
Intermediate 8
2,5,7-Trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetic acid
[0147]
[0148] Step 1 6-Chloro-1,3-dimethylpyrimidine-2,4(1H,3H)-dione: To a stirred solution of 1,3-dimethylbarbituric acid (20.0 g, 128.09 mmol) in water (10 ml), phosphorous oxychloride (80 ml) was added slowly in externally cooling condition and then the reaction was slowly warmed to room temperature. After refluxing for 3 h the reaction mixture was allowed to cool to 0° C. and quenched with ice cold water (350 ml). The reaction mixture was extracted with chloroform (2×200 ml) and the combined organic extracts were washed with water (2×100 ml), dried over Na 2 SO 4 and concentrated. The residue obtained was purified by silica gel column chromatography using 5% ethyl acetate in chloroform to obtain 21g of the product as a pale brown solid; 1 H NMR (300 MHz , CDCl 3 ) δ 3.33 (s, 3H), 3.57 (s, 3H), 5.94 (s, 1H).
[0149] Step 2 6-Hydrazino-1,3-dimethylpyrimidine-2,4(1H,3H)-dione: A mixture of Step 1 intermediate (17 g, 97.34 mmol) and hydrazine hydrate (119 ml) in isopropyl alcohol (280 ml) were refluxed for 1 h. The excess of solvent was removed under reduced pressure, solid obtained was filtered, washed with methanol (25 ml) and dried to obtain 8.1 g of the product as white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.09 (s, 3H), 3.21 (s, 3H), 4.37 (br s, 2H), 5.10 (s, 1H), 8.02 (br s, 1H).
[0150] Step 3 1-Acetyl-3,5,7-trimethyl-1H-pyrazolo[3,4-d]pyrimidine-4,6(5H,7H)-dione: A mixture of Step 2 intermediate (8.0 g, 47.01 mmol) and acetic anhydride (40 ml) in dry pyridine (78 ml) were refluxed for 3 h. The reaction mixture was cooled to 0° C. and acidified with 1N HCl (200 ml). The solid obtained was collected by filtration, washed with 1 N HCl (25 ml), water (25 ml) and dried to give 6.9 g of the product as a white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 2.71 (s, 3H), 2.96 (s, 3H), 3.37 (s, 3H), 3.50 (s, 3H).
[0151] Step 4 3,5,7-Trimethyl-1H-pyrazolo[3,4-d]pyrimidine-4,6(5H,7H)-dione: Step 3 above intermediate (6.9 g, 29.211 mmol) was refluxed in 1 N sodium hydroxide (69 ml) for 10 min. The reaction mixture was cooled to room temperature and poured into ice water and stirred for 2 h. The precipitated solid was collected by filtration and dried to give 5.1 g of the desired product as off-white solid; 1 H NMR (300 MHz, CF 3 CO 2 D): δ 3.05 (s, 3H), 3.78 (s, 3H), 3.93 (s, 3H).
[0152] Step 5 2,3,5,7-Tetramethyl-2H-pyrazolo[3,4-d]pyrimidine-4,6(5H,7H)-dione: A solution of Step 4 intermediate (5.2 g, 26.77 mmol) in 1 N sodium hydroxide (52 ml) was added dimethylsulphate (5.2 ml) and stirred at room temperature for 1 h. The reaction mixture was diluted with water and the solid precipitated out was filtered, washed with water and dried to give 3.85 g of the product as off white solid; 1 H NMR (300 MHz, CDCl 3 ): δ 2.59 (s, 3H), 3.36 (s, 3H), 3.48 (s, 3H), 3.79 (s, 3H).
[0153] Step 6 Methyl (2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetate: To a stirred solution of Step 5 intermediate (3.8 g, 18.24 mmol) in dimethylcarbonate (91 ml) was added sodium hydride (60% dispersion in mineral oil, 4.5 g, 187.5 mmol) at room temperature. The reaction mixture was heated to reflux for overnight. The reaction mixture was cooled to room temperature, quenched into 1N HCl (200 ml), extracted with ethyl acetate (2×250 ml) and the combined organic layers were washed with water (2×250 ml), dried over Na 2 SO 4 and concentrated. The residue obtained was triturated in hexane, solid obtained was filtered to give 5.5 g of the product as a white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.37 (s, 3H), 3.50 (s, 3H), 3.82 (s, 5H), 3.90 (s, 3H).
[0154] Step 7 (2,5,7-Trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetic acid: A mixture of Step 6 intermediate (1.0 g, 3.755 mmol) and 6 N H 2 SO 4 (9.3 ml) in dioxane (9.3 ml) stirred at reflux temperature for 2 h to give a homogeneous pale yellow solution. This solution was cooled, diluted with water and extracted with ethyl acetate (2×50 ml). The combined organic layers were washed with water, dried over Na 2 SO 4 and concentrated. The residue obtained was triturated in diethyl ether, solid obtained was collected by filtration to give 330 mg of the product as a white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.34 (s, overlapping with DMSO, 3H), 3.79 (s, 3H), 4.11 (s, 2H), 12.95 (br s, 1H) and 1 H NMR (300 MHz, CDCl 3 ): δ 3.39 (s, 3H), 3.50 (s, 3H), 3.88 (s, 3H), 4.10 (s, 2H).
Intermediate 9
4,6-Dimethyl-1H-pyrazolo[4,3-d]pyrimidine-5,7(4H,6H)-dione
[0155]
[0156] Step 1 5-Amino-1,3,6-trimethylpyrimidine-2,4(1H,3H)-dione: To a stirred suspension of 5-nitro-1,3,6-trimethylpyrimidine-2,4(1H,3H)-dione (4.2 g, 20.084 mmol) in 1:1 mixture of methanol and toluene (200 ml) was added 10% Pd—C (1.2 g). The reaction mixture was stirred under hydrogen atmosphere at room temperature overnight. The mixture was then filtered over a celite bed and was thoroughly washed with methanol (200 ml). The filtrate was collected and evaporated to give viscous residue which was then purified by column chromatography to afford 4.1 g of the product as an off-white solid.
[0157] Step 2 4,6-Dimethyl-1H-pyrazolo[4,3-d]pyrimidine-5,7(4H,6H)-dione: To a stirred solution of Step 1 intermediate (4.0 g, 23.634 mmol) in a mixture of ice (24g) and concentrated HCl (5 ml) was added a solution of sodium nitrite (1.42 g, 20.580 mmol) in water (5 ml). The resulting suspension was stirred below 10° C. for 30 min. The solid formed at this stage was removed by filtration and the filtrate was added slowly with continuous stirring to 20% aq. NaOH (20 ml) by maintaining the temperature below 10° C. After addition the basic solution was filtered and neutralized with hydrochloric acid (5 N HCl). The precipitate separated was filtered and dried to get 300 mg of the product as dark orange solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.45 (s, 3H), 3.52 (s, 3H), 7.53 (s, 1H).
Intermediate 10
3,4,6-Trimethyl-1H-pyrazolo[4,3-d]pyrimidine-5,7(4H,6H)-dione
[0158]
[0159] The title compound was prepared in 2 steps from 6-ethyl-1,3-dimethyl-5-nitropyrimidine-2,4(1H,3H)-dione (3.5 g, 16.279 mmol) as described in intermediate 9 to give 110 mg of the product as a white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 2.62 (s, 3H), 3.45 (s, 3H), 3.67 (s, 3H), 11.59 (br s, 1H); ESI-MS (m/z) 193.31 (M−H).
Intermediate 11
4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-amine
[0160]
[0161] Step 1 N-{-4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-yl}acetamide: To a stirred solution of 2-bromo-1-[3-fluoro-4-(trifluoromethyl)phenyl]ethanone (4.5 g, 15.73 mmol) in acetonitrile (45 ml) was added acetyl guanidine (2.38 g, 23.60 mmol). The reaction mixture was stirred and refluxed for overnight. The solvent was evaporation under reduced pressure and diluted with water and extracted with ethyl acetate (75 ml×3) and organic layers were washed with brine, dried (Na 2 SO 4 ) and filtered. The filtrate was concentrated under reduced pressure and the residue obtained after the evaporation of the solvent was purified by silica gel column chromatography using 2% methanol in chloroform to obtain 1.15 g of the product as a yellow solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 2.07 (s, 3H), 7.58 (s, 1H), 7.69-7.78 (m, 3H), 11.31 (br s, 1H), 11.91 (br s, 1H).
[0162] Step 2 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-amine: To a stirred solution of Step 1 intermediate (1.1 g, 3.829 mmol) in a mixture of methanol (20 ml) and water (20 ml) was added conc. H 2 SO 4 (2 ml) and the resulting mixture was refluxed for 24 h. The reaction mixture was cooled to room temperature, saturated solution of potassium carnonate was added and extracted with ethyl acetate (2×50 ml). The organic layers were combined and dried over Na 2 SO 4 and filtered. The filtrate was concentrated under reduced pressure. The residue obtained after the evaporation of the solvent was purified by silica gel column chromatography using 5% methanol in chloroform to obtain 290 mg of the product as a yellow solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 5.55 (br s, 2H), 7.32 (s, 1H), 7.59-7.67 (m, 3H), 11.30 (br s, 1H).
[0000] General Procedure for the Preparation of 2-halo N-thiazolyl Acetamide Derivatives
[0163] To a stirred and cooled (0° C.) solution of appropriate thiazoleamine (1.0 equiv.) and pyridine (1.2 equiv.) in dichloromethane (5 volume) was added bromoacetyl bromide (1.2 eq.) over 5 min and the resulting mixture was allowed to warm to room temperature and then further stirred at room temperature for 2 h. The reaction mixture was diluted with dichloromethane (50 mL) and water (50 mL). The layers were separated. The aqueous layer was extracted with dichloromethane (2×50 mL) and the combined organic layers were washed with water (2×50 mL) followed by brine (50 mL), dried (Na 2 SO 4 ) and filtered. The filtrate was concentrated under reduced pressure. The residue obtained after the evaporation of the solvent was purified by silica gel column chromatography using 5-10% ethyl acetate in petroleum ether to obtain the desired product as an off-white solid.
[0164] Structure information and characterization data for selected 2-bromo-N-thiazolyl acetamide intermediates are given in Table 1.
[0000] TABLE 1 Structure and 1 H NMR data of selected 2-bromo-N-thiazolyl acetamides S Mol. Formula/ 1 H NMR (δ ppm, DMSO-d 6 , No Structure Mass (m/z) 300 MHz) 1. C 11 H 7 BrF 2 N 2 OS 333.98 (M + H) + 4.19 (s, 2H), 7.21 (t, J = 8.1 Hz, 1H), 7.37 (t, J = 9.3 Hz, 1H), 7.57 (s, 1H), 8.00-8.08 (m, 1H), 12.75 (br s, 1H) 2. C 12 H 7 BrF 4 N 2 OS 382.35 (M + H) + 4.18 (s, 2H), 7.84 (d, J = 7.8 Hz, 1H), 7.91 (d, J = 8.7 Hz, 2H), 8.03 (s, 1H), 12.76 (br s, 1H). 3. C 12 H 7 BrF 4 N 2 OS 382.99 (M + H) + 4.20 (s, 2H), 7.84 (d, J = 7.8 Hz, 1H), 7.95 (d, J = 8.7 Hz, 2H), 8.06 (s, 1H), 12.82 (br s, 1H). 4. C 12 H 7 BrClF 3 N 2 OS 401.00 (M + H) + 4.18 (s, 2H), 7.88 (d, J = 7.2 Hz, 1H), 7.95 (d, J = 9.3 Hz, 1H), 8.18 (d, J = 7.8 Hz, 1H), 8.31 (s, 1H), 12.77 (br s, 1H). 5. C 11 H 6 BrCl 3 N 2 OS 399.05 (M + H) + 4.18 (s, 2H), 7.74-7.80 (m, 3H), 12.78 (br s, 1H). 6. C 15 H 15 BrF 2 N 2 O 2 S 405.13 (M + H) + 0.98 (d, J = 6.3 Hz, 6H), 1.93-2.00 (m, 1H), 3.91 (d, J = 6.3 Hz, 2H), 4.18 (s, 2H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.72 (br s, 1H) 7. C 16 H 17 BrF 2 N 2 O 2 S 420.63 DMSO-d 6 : 0.92 (d, J = 6.9 Hz, 6H), 1.55-1.63 (m, 2H), 1.75-1.85 (m, 1H), 4.12-4.20 (m, 4H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.74 (br s, 1H) 8. C 16 H 17 BrF 2 N 2 O 2 S 419.11 (M + H) + 1.00 (s, 9H), 3.80 (s, 2H), 4.18 (s, 2H), 7.62 (s, 1H), 7.66 (m, 1H), 7.82 (s, 1H), 12.73 (br s, 1H). 9. C 12 H 6 BrF 5 N 2 OS 400.02 (M + H) + 4.20 (s, 2H), 7.47-7.55 (m, 1H), 7.71 (s, 1H), 8.28-8.34 (m, 1H), 12.79 (br s, 1H). 10. C 12 H 7 BrF 4 N 2 O 2 S 399.71 (M + H) + 4.18 (s, 2H), 7.25 (t, J = 71.7 Hz, 1H), 7.75 (d, J = 9.0 Hz, 2H), 7.93 (s, 1H), 12.73 (br s, 1H). 11. C 13 H 8 BrF 5 N 2 O 2 S 430.18 (M + H) + 2.50-2.80 (m, 2H), 4.18 (s, 2H), 4.34 (t, J = 5.7 Hz, 2H), 7.63-7.70 (m, 2H), 7.85 (s, 1H), 12.74 (br s, 1H). 12. C 14 H 10 BrF 5 N 2 O 2 S 445.01 (M + H) + 2.50-2.80 (m, 2H), 4.18 (s, 2H), 4.34 (t, J = 5.7 Hz, 2H), 7.63-7.70 (m, 2H), 7.85 (s, 1H), 12.74 (br s, 1H) 13. C 16 H 17 BrCl 2 N 2 O 2 S 451.66 (M + H) + 1.07 (s, 9H), 3.67 (s, 2H), 4.18 (s, 2H), 7.90 (s, 1H), 7.99 (s, 2H), 12.72 (br s, 1H) 14. C 14 H 10 BrCl 2 F 3 N 2 O 2 S 477.54 (M + H) + 2.79-2.89 (m, 2H), 4.16-4.22 (m, 4H), 7.90 (s, 1H), 7.99 (s, 2H), 12.70 (br s, 1H). 15. C 15 H 10 BrCl 2 F 5 N 2 O 2 S 527.07 (M + H) + 2.81 (t, J = 6.0 Hz, 2H), 4.19 (s, 2H), 4.28 (t, J = 6.0 Hz, 2H), 7.93 (s, 1H), 8.02 (s, 2H), 12.75 (br s, 1H). 16. C 13 H 8 BrClF 4 N 2 O 2 S 446.93 (M + H) + 4.19 (s, 2H), 4.80-4.90 (m, 2H), 7.71 (d, J = 9.3 Hz, 2H), 7.88 (s, 1H), 12.74 (br s, 1H) 17. C 15 H 13 BrF 2 N 2 O 2 S 403.24 (M + H) + 0.23-0.30 (m, 2H), 0.50-0.56 (m, 2H), 1.17-1.22 (m, 1H), 3.97 (d, J = 6.9 Hz, 2H), 4.19 (s, 2H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.72 (br s, 1H) 18. C 16 H 15 BrF 2 N 2 O 2 S 417.05 (M + H) + 1.82-1.90 (m, 4H), 1.90-2.05 (m, 2H), 2.65-2.71 (m, 1H), 4.10 (d, J = 6.3 Hz, 2H), 4.19 (s, 2H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.72 (br s, 1H) 19. C 16 H 15 BrCl 2 N 2 O 2 S 449.05 (M + H) + 1.85-1.95 (m, 4H), 2.04-2.10 (m, 2H), 2.72-2.79 (m, 1H), 4.00 (d, J = 6.3 Hz, 2H), 4.18 (s, 2H), 7.90 (s, 1H), 7.99 (s, 2H), 12.73 (br s, 1H). 20. C 19 H 12 BrF 5 N 2 O 2 S 504.92 (M − H) 4.11 (s, 2H), 5.39 (s, 2H), 7.14 (s, 1H), 7.39-7.47 (m, 3H), 7.62 (t, J = 7.8 Hz, 1H), 7.68 (d, J = 7.8 Hz, 1H), 7.88 (d, J = 7.8 Hz, 1H), 9.62 (br s, 1H) 21. C 19 H 12 BrF 5 N 2 O 2 S 507.16 (M + H) + 4.18 (s, 2H), 5.31 (s, 2H), 7.60-7.69 (m, 4H), 7.72-7.80 (m, 2H), 7.84 (s, 1H), 12.72 (br s, 1H). 22. C 13 H 9 Br 2 F 3 N 2 O 2 S 473.03 (M + H) + 4.18 (s, 2H), 4.86-4.96 (m, 2H), 7.31 (d, J = 8.7 Hz, 1H), 7.75 (s, 1H), 7.91 (d, J = 9.0 Hz, 1H), 8.16 (s, 1H), 12.71 (br s, 1H). 23. C 16 H 17 BrClFN 2 O 2 S 435.17 (M + H) + 3.78 (s, 2H), 4.18 (s, 2H), 7.76 (s, 1H), 7.80 (s, 1H), 7.85 (s, 1H), 12.73 (br s, 1H). 24. C 16 H 18 BrFN 2 O 2 S 401.29 DMSO-d 6 : 1.02 (s, 9H), 3.74 (s, 2H), 4.18 (s, 2H), 7.22 (t, J = 8.7 Hz, 1H), 7.65-7.74 (m, 3H), 12.68 (br s, 1H) 25. C 16 H 18 BrClN 2 O 2 S 417.75 DMSO-d 6 : 1.04 (s, 9H), 3.75 (s, 2H), 4.18 (s, 2H), 7.19 (d, J = 8.4 Hz, 1H), 7.67 (s, 1H), 7.81 (d, J = 8.7 Hz, 1H), 7.95 (s, 1H), 12.69 (br s, 1H) 26. C 11 H 8 BrClN 2 OS 331.62 CDCl 3 : 4.06 (s, 2H), 7.09 (s, 1H), 7.37 (d, J = 8.7 Hz, 2H), 7.62 (d, J = 8.4 Hz, 2H). 27. C 15 H 15 BrCl 2 N 2 O 2 S 438.17 CDCl 3 : 1.10 (d, J = 6.3 Hz, 6H), 2.10-2.24 (m, 1H), 3.81 (d, J = 6.3 Hz, 2H), 4.11 (s, 2H), 7.16 (s, 1H), 7.76 (s, 2H), 9.56 (br s, 1H) 28 C 11 H 8 Br 2 N 2 O 2 360.00 DMSO-d 6 : 4.11 (s, 2H), 7.42 (s, 1H), 7.73 (d, J = 8.1 Hz, 2H), 7.86 (d, J = 8.1 Hz, 2H), 11.56 (br s, 1H)
General Procedure for the Preparation of 2-amino-4-aryl Thiazoles:
Method 1
[0165] A solution of acetophenone derivative (1.0 eq) in glacial acetic acid (5 vol) was added liquid bromine (1.0 eq) at 0° C. and reaction mixture was stirred at room temperature for 2 h. The reaction mixture was diluted with water and extracted with ethyl acetate, washed with brine and dried over Na 2 SO 4 . The crude product obtained upon concentration was dissolved in dry THF (10 vol) and thiourea (2.0 eq) was added and refluxed for overnight. The reaction mixture was diluted with ethyl acetate, washed with sodium thiosulfate solution and organic layer was treated with 1N HCl to result salt formation of the amine. The precipitated salt was collected by filtration. The salt was then treated with saturated solution of NaHCO 3 to re-generate the amine. The mixture was extracted with dichloromethane (2×50 ml) and the combined organic extracts were washed with water and brine. The solvent was evaporated under reduced pressure to afford the 2-amino-4-aryl-thiazole derivative.
Method 2
[0166] A solution of acetophenone derivative (1.0 equiv.), thiourea (2.0 equiv.) and iodine (1.0 equiv.) in dry ethanol (5 vol) was refluxed for 24 h. The reaction mixture was diluted with ethyl acetate and the layers were separated. The organic layer was washed with sodium thiosulfate solution to remove iodine. The ethyl acetate solution was treated with 1N HCl and precipitated salt collected by filtration. The free amine was re-generated as described in Method 1 given above.
[0167] All the 2-amino-4-aryl-thiazole derivatives were prepared by either Method 1 or Method 2 starting from appropriate aryl alkyl ketones. Structure information and characterization data for selected intermediates are given in Table 2.
[0000]
TABLE 2
Structural details and 1 H NMR data of selected 2-aminothiazole intermediates
S
Mol. Formula
No
Structure
(Mol. Wt.)
1 H NMR (δ ppm, 300 MHz)
1.
C 9 H 7 BrN 2 S (255.14)
DMSO-d 6 : 7.61 (d, J = 8.1, 2H); 7.46 (d, J = 7.8, 2H); 6.70 (s, 1H); 4.99 (br. s, 2H).
2.
C 9 H 7 ClN 2 S (210.68)
DMSO-d 6 : 7.78 (d, J = 8.4, 2H); 7.39 (d, J = 7.8, 2H); 7.07 (br. s, 2H); 7.05 (s, 1H).
3.
C 10 H 7 F 3 N 2 S (244.24)
DMSO-d 6 : 7.97 (d, J = 7.8, 2H); 7.69 (d, J = 8.1, 2H); 7.24 (s, 1H); 7.16 (br. s, 2H).
4.
C 10 H 7 F 3 N 2 S (244.24)
CDCl 3 : 8.12-8.06 (m, 1H); 7.91 (d, J = 6.9, 1H); 7.50-7.42 (m, 2H); 6.79 (s, 1H); 5.02 (br. s, 2H).
5.
C 10 H 6 F 4 N 2 S 262.24
CDCl 3 : 7.68-7.61 (m, 2H); 7.36 (t, J = 7.8, 1H); 7.10 (d, J = 7.8, 1H), 6.75 (s, 1H); 5.08 (br s, 2H).
6.
C 13 H 16 N 2 S (232.25)
DMSO-d 6 : 7.68 (d, J = 7.8, 2H); 7.13 (d, J = 8.1, 2H); 7.03 (br. s, 2H); 6.92 (s, 1H); 2.43 (d, J = 6.9, 2H); 1.86-1.76 (m, 1H); 0.86 (d, J = 6.6, 6H)
7.
C 9 H 6 F 2 N 2 S (212.22)
CDCl 3 : 8.04-7.95 (m, 1H); 6.93-6.80 (m, 3H); 5.04 (br. s, 2H).
8.
C 10 H 6 F 4 N 2 S 262.23
DMSO-d 6 : 7.87-7.74 (m, 3H); 7.40 (s, 1H); 7.22 (br. s, 2H).
9.
C 10 H 6 F 4 N 2 OS (278.23)
DMSO-d 6 : 7.92-7.85 (m, 2H); 7.50 (t, J = 8.7, 1H); 7.18 (br. s, 3H).
10.
C 10 H 6 F 4 N 2 OS (278.23)
DMSO-d 6 : 7.87-7.80 (m, 1H); 7.73 (d, J = 8.7, 1H); 7.55 (d, J = 8.1, 1H); 7.24 (s, 1H); 7.18 (br. s, 2H).
11.
C 11 H 8 F 4 N 2 OS (292.25)
CDCl 3 : 7.57-7.46 (m, 2H), 7.02 (t, J = 8.4, 1H); 6.66 (s, 1H); 5.08 (br. s, 2H); 4.43 (q, J = 8.4, 2H)
12.
C 10 H 6 F 4 N 2 S (262.23)
DMSO-d 6 : 8.14 (d, J = 6.6, 2H); 7.52 (t, J = 8.7, 1H); 7.24 (s, 1H); 7.20 (br. s, 2H).
13.
C 10 H 5 F 5 N 2 S (280.22)
DMSO-d 6 : 8.35-8.21 (m, 1H); 7.48- 7.35 (m, 1H); 7.21 (br. s, 2H); 7.05 (s, 1H).
14
C 10 H 6 F 4 N 2 S 262.23
CDCl 3 : 8.36-8.29 (m, 1H); 7.73-7.65 (m, 1H); 7.58-7.50 (m, 1H); 7.26 (br. s, 2H); 7.13 (s, 1H)
15
C 10 H 7 F 3 N 2 OS 260.24
DMSO-d 6 : 7.75-7.62 (m, 2H); 7.33 (t, J = 8.1, 1H); 7.23 (t, J = 73.2, 1H); 7.12 (br. s, 3H)
16
C 9 H 6 F 2 N 2 S 212.22
CDCl 3 : 7.30-7.20 (m, 2H); 6.80-6.74 (m, 1H); 6.68-6.60 (m, 1H), 5.06 (br s, 2H)
17
C 10 H 6 F 4 N 2 S 262.23
CDCl 3 : 8.28-8.21 (m, 1H); 7.51 (t, J = 6.9, 1H); 7.27 (t, J = 7.5, 1H); 7.10 (s, 1H), 5.04 (br s, 2H)
18
C 10 H 5 F 5 N 2 S 280.22
CDCl 3 : 7.94-7.82 (m, 1H); 7.42-7.32 (m, 1H); 7.18-7.10 (m, 1H); 5.09 (br s, 2H)
19
C 11 H 7 F 5 N 2 OS 310.24
DMSO-d 6 : 7.59 (s, 1H); 7.55 (s, 1H); 7.21 (s, 1H); 7.16 (br. s, 2H); 4.82 (q, J = 9.0, 2H).
20
C 10 H 6 F 4 N 2 OS 278.23
DMSO-d 6 : 7.65 (d, J = 9.0, 2H); 7.48 (s, 1H); 7.24 (t, J = 72.3, 1H); 7.20 (br. s, 2H).
21
C 10 H 6 F 4 N 2 OS 262.23
DMSO-d 6 : 7.97-7.87 (m, 1H); 7.62- 7.52 (m, 1H); 7.41 (s, 1H); 7.23 (br. s, 2H).
22
C 14 H 16 F 2 N 2 OS 298.35
DMSO-d 6 : 1.00 (s, 9H), 3.76 (s, 2H), 7.12-7.18 (m, 1H + 2H), 7.48-7.58 (m, 2H)
23
C 10 H 6 F 4 N 2 S 262.23
CDCl 3 : 5.00 (br s, 2H); 7.16 (s, 1H); 7.37 (d, J = 11.7, 1H); 7.44 (d, J = 8.4, 1H); 8.18 (t, J = 7.8, 1H).
24
C 9 H 6 F 2 N 2 S (212.22)
CDCl 3 : 7.60-7.53 (m, 1H); 7.48-7.43 (m, 1H); 7.18-7.07 (m, 1H); 6.66 (s, 1H); 4.98 (br. s, 2H).
25
C 14 H 16 F 2 N 2 OS 298.35
DMSO-d 6 : 1.00 (s, 9H), 3.76 (s, 2H), 7.12-7.18 (m, 1H + 2H), 7.48-7.58 (m, 2H)
5-(4-Bromophenyl)isoxazol-3-amine used for the preparation of Examples 33, 65 and 84 is purchased from Aldrich. 5-(Trifluoromethoxy)-1,3-benzothiazol-2-amine used for the preparation of Example 66 is also purchased from Aldrich.
[0168] For further illustration of methods of preparing the compounds of the present invention, the following examples are disclosed below.
EXAMPLES
General Procedure for the Preparation of Examples
Method A:
[0169] To a stirred mixture of pyrrolo[3,2-d]pyrimidinedione (Intermediates 1-6, 1.0 equiv.) or pyrazolo[4,3-d]pyrimidinedione (Intermediates 9-10, 1.0 equiv.) and NaH (1.5 equiv.) in dry DMF (10 ml/g) was added 2-bromo-N-phenyl-1,3-thiazol-2-yl acetamide (1.1 equiv.) at 0° C., the reaction mixture was warmed to room temperature and stirred for 30 min. The reaction mixture was heated to 80° C. for overnight. After this time, the reaction mixture was concentrated under reduced pressure and the residue purified by silica gel column chromatography by using 2% methanol in chloroform to afford the product.
Method B:
[0170] To a stirred solution of (1,3,7-Trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetic acid (Intermediate 7, 1.0 equiv.) or 2,5,7-Trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetic acid (Intermediate 8, 1.0 equiv.) in 1,2-dichloroethane was added EDCI (1.2 equiv.), HOBt (0.3 equiv.) and 4-dimethylaminopyridine (0.1 equiv.) and the mixture was stirred at room temperature for 10-15 min. An appropriate amine (1.0 equiv.) was then added and mixture was stirred at the same temperature for 48 h. The solvent was evaporated under reduced pressure and the residue obtained was diluted with methanol and stirred at room temperature for 30 min. The solid separated out was collected by filtration. The solid product was further purified by recrystallization from isopropanol or methanol to give the desired products.
Example 1
N-[4-(2,4-Difluorophenyl)-1,3-thiazol-2-yl]-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0171]
[0172] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(2,4-difluorophenyl)-1,3-thiazol-2-yl]acetamide (111 mg, 0.330 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 60 mg of the product as a white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.21-7.27 (m, 1H), 7.36-7.42 (m, 2H), 7.52 (s, 1H), 8.03-8.10 (m, 1H), 12.70 (br s, 1H); APCI-MS (m/z) 432.20 (M+H) + .
Example 2
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide
[0173]
[0174] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(4-fluoro-3-trifluoromethylphenyl)-1,3-thiazol-2-yl]acetamide (128 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.36 (s, 1H), 7.58-7.66 (m, 1H), 7.88 (s, 1H), 8.24-8.32 (m, 2H), 12.74 (br s, 1H); APCI-MS (m/z) 480.16 (M−H).
Example 3
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide
[0175]
[0176] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(3-fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-yl]acetamide (128 mg, 0.334 mmol) in the presence of NaH (10 mg, 0.418 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as a white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.33 (s, 2H), 6.24 (s, 1H), 7.36 (s, 1H), 7.86 (d, J=7.8 Hz, 1H), 7.90-8.01 (m, 3H), 12.77 (br s, 1H); APCI-MS (m/z) 482.07 (M+H) + .
Example 4
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-chloro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide
[0177]
[0178] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (30 mg, 0.167 mmol) with 2-bromo-N-[4-(4-chloro-3-trifluoromethylphenyl)-1,3-thiazol-2-yl]acetamide (80 mg, 0.200 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 38 mg of the product as an off-white solid; 1 H NMR (δ ppm, CDCl 3 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (s, 2H), 6.22 (s, 1H), 7.35 (s, 1H), 7.80 (d, J=8.4 Hz, 1H), 7.94 (s, 2H), 8.20 (d, J=8.4 Hz, 1H), 8.34 (s, 1H), 12.74 (br s, 1H). APCI-MS (m/z) 498.14 (M+H) + .
Example 5
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-[4-(2,3,4-trichlorophenyl)-1,3-thiazol-2-yl]acetamide
[0179]
[0180] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(2,3,4-trichlorophenyl)-1,3-thiazol-2-yl]acetamide (134 mg, 0.334 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 37 mg of the product as an off-white solid; 1 H NMR (6 ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.70 (s, 1H), 7.77 (s, 2H), 12.74 (br s, 1H). APCI-MS (m/z) 498.14 (M+H) + .
Example 6
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(2-methylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide
[0181]
[0182] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-(2-methylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.334 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 45 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 0.98 (d, J=6.9 Hz, 6H), 1.96-2.04 (m, 1H), 3.17 (s, 3H), 3.33 (s, 3H), 3.91 (d, J=6.3 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.35 (s, 1H), 7.65 (d, J=9.0 Hz, 2H), 7.77 (s, 1H), 12.68 (br s, 1H); APCI-MS (m/z) 504.11 (M+H) + .
Example 7
N-{4-[3,5-Difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0183]
[0184] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{-4-[3,5-difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}acetamide (140 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 0.92 (d, J=6.6 Hz, 6H), 1.60 (d, J=6.3 Hz, 2H), 1.75-1.85 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 4.15 (d, J=6.3 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.35 (s, 1H), 7.63 (s, 1H), 7.66 (s, 1H), 7.77 (s, 1H), 12.68 (br s, 1H); ESI-MS (m/z) 516.41 [M−H].
Example 8
N-{[4-(2,2-Dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0185]
[0186] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (25 mg, 0.139 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (70 mg, 0.167 mmol) in the presence of NaH (8 mg, 0.333 mmol) in dry DMF (5.0 mL) to give 29 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 3.17 (s, 3H), 3.39 (s, 3H), 3.81 (s, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.63 (s, 1H), 7.67 (s, 1H), 7.77 (s, 1H), 12.68 (br s, 1H); APCI-MS (m/z) 518.10 [M+H] + .
Example 9
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[2,4-difluorophenyl-3-trifluoromethyl]-1,3-thiazol-2-yl}acetamide
[0187]
[0188] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{-4-[2,4-difluorophenyl-3-trifluoromethyl]-1,3-thiazol-2-yl}acetamide (134 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 60 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.40 (s, 3H), 5.33 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.48-7.58 (m, 1H), 7.66 (s, 1H), 8.28-8.38 (m, 1H), 12.75 (br s, 1H); APCI-MS (m/z) 500.02 (M+H) + .
Example 10
N-{4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0189]
[0190] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (45 mg, 0.251 mmol) with 2-bromo-N-{4-[4-(difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (125 mg, 0.313 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 20 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.28 (t, J=72.3 Hz, 1H), 7.35 (s, 1H), 7.79 (d, J=9.6 Hz, 2H), 7.90 (s, 1H), 12.73 (br s, 1H); ESI-MS (m/z) 498.08 (M+H) + .
Example 11
N-{-4-[3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0191]
[0192] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (29 mg, 0.166 mmol) with 2-bromo-N-{-4-[3,5-difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (60 mg, 0.139 mmol) in the presence of NaH (5.0 mg, 0.208 mmol) in dry DMF (5.0 mL) to give 20 mg of the product as a white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 4.86 (q, J=8.7 Hz, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.69 (s, 1H), 7.72 (s, 1H), 7.83 (s, 1H), 12.70 (br s, 1H); ESI-MS (m/z) 530.11 (M+H) + .
Example 12
N-{-4-[3,5-Difluoro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0193]
[0194] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (30 mg, 0.167 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (89 mg, 0.200 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 18 mg of the product as a white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz): 2.73-2.84 (m, 2H), 3.17 (s, 3H), 3.39 (s, 3H), 4.32-4.38 (m, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.66 (s, 1H), 7.69 (s, 1H), 7.80 (s, 1H), 12.70 (br s, 1H); APCI-MS (m/z): 542.20 [M−H].
Example 13
N-{4-[3,5-Dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0195]
[0196] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.110 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (23 mg, 0.128 mmol) in the presence of NaH (7 mg, 0.291 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.08 (s, 9H), 3.17 (s, 3H), 3.39 (s, 3H), 3.67 (s, 2H), 5.32 (s, 2H), 6.22 (s, 2H), 7.35 (s, 1H), 7.85 (s, 1H), 8.00 (s, 2H), 12.68 (br s, 1H); APCI-MS (m/z) 550.20 [M+H] + .
Example 14
N-{4-[3,5-Dichloro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0197]
[0198] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (160 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as a white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.85-2.92 (m, 2H), 3.17 (s, 3H), 3.39 (s, 3H), 4.18-4.23 (m, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.88 (s, 1H), 8.00-8.08 (m, 2H), 12.71 (br s, 1H); APCI-MS (m/z) 576.23 (M+H) + .
Example 15
N-{4-[3,5-Dichloro-4-(3,3,4,4,4-pentafluorobutoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0199]
[0200] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(3,3,4,4,4-pentafluorobutoxy)phenyl]-1,3-thiazol-2-yl}acetamide (176 mg, 0.332 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 58 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.80-2.86 (m, 2H), 3.17 (s, 3H), 3.39 (s, 3H), 4.25-4.32 (m, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.88 (s, 1H), 8.03 (s, 2H), 12.70 (br s, 1H); ESI-MS (m/z) 626.18 (M+H) + .
Example 16
N-{4-[3-Chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0201]
[0202] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (33 mg, 0.184 mmol) with 2-bromo-N-{4-[3-chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (70 mg, 0.156 mmol) in the presence of NaH (11 mg, 0.458 mmol) in dry DMF (5.0 mL) to give 11 mg of the product as an off-white solid; 1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 4.84 (q, J=8.7 Hz, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.82-7.91 (m, 3H), 12.71 (br s, 1H); APCI-MS (m/z) 546.03 (M+H) + .
Example 17
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(cyclopropylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide
[0203]
[0204] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-(cyclopropylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 39 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 0.24-0.30 (m, 2H), 0.50-0.56 (m, 2H), 1.15-1.21 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 3.97 (d, J=7.5 Hz, 2H), 5.32 (s, 2H), 6.23 (s, 2H), 7.35 (s, 1H), 7.60-7.66 (m, 2H), 7.77 (s, 1H), 12.68 (br s, 1H); APCI-MS (m/z) 502.13 (M+H) + .
Example 18
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide
[0205]
[0206] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-(cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (139 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 44 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 1.82-1.90 (m, 4H), 2.00-2.06 (m, 2H), 2.65-2.70 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 4.07-4.13 (m, 2H), 5.32 (s, 2H), 6.20-6.26 (m, 1H), 7.34 (s, 1H), 7.63 (d, J=8.7 Hz, 2H), 7.77 (s, 1H), 12.67 (br s, 1H); APCI-MS (m/z) 516.11 (M+H) + .
Example 19
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(cyclobutylmethoxy)-3,5-dichlorophenyl]-1,3-thiazol-2-yl}acetamide
[0207]
[0208] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (45 mg, 0.251 mmol) with 2-bromo-N-{4-[4-(cyclobutylmethoxy)-3,5-dichlorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.301 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as an off-white solid; 1 H NMR ((δ ppm, 300 MHz, DMSO-d 6 ) 1.90-1.99 (m, 4H), 2.04-2.10 (m, 2H), 2.72-2.80 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 4.00 (d, J=6.3 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.36 (s, 1H), 7.85 (s, 1H), 8.00 (s, 2H), 12.68 (br s, 1H); ESI-MS (m/z) 548.15 (M+H) + .
Example 20
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3,5-difluoro-4-[2-(trifluoromethyl)benzyloxy]phenyl)-1,3-thiazol-2-yl}acetamide
[0209]
[0210] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-[2-(trifluoromethyl)benzyloxy]phenyl]-1,3-thiazol-2-yl}acetamide (170 mg, 0.335 mmol) in the presence of NaH (17 mg, 0.419 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (s, 2H), 5.35 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.65-7.68 (m, 3H), 7.84-7.80 (m, 4H), 12.69 (br s, 1H); APCI-MS (m/z) 606.35 (M+H) + .
Example 21
2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3,5-difluoro-4-[4-(trifluoromethyl)benzyloxy]phenyl)-1,3-thiazol-2-yl}acetamide
[0211]
[0212] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (33 mg, 0.184 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-[4-(trifluoromethyl)benzyloxy)phenyl]-1,3-thiazol-2-yl}acetamide (112 mg, 0.221 mmol) in the presence of NaH (11 mg, 0.276 mmol) in dry DMF (3.0 mL) to give 25 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (br s, 4H), 6.22 (s, 1H), 7.35 (s, 1H), 7.70-7.72 (m, 4H), 7.78-7.80 (m, 3H), 12.68 (br s, 1H); ESI-MS (m/z) 606.15 (M+H) + .
Example 22
N-[4-(3-Fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0213]
[0214] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (45 mg, 0.232 mmol) with 2-bromo-N-{4-[3-fluoro-4-trifluoromethylphenyl]-1,3-thiazol-2-yl}acetamide (107 mg, 0.279 mmol) in the presence of NaH (13 mg, 0.555 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.27 (s, 3H), 3.17 (s, 3H), 3.36 (s, 3H), 5.34 (s, 2H), 6.07 (s, 1H), 7.85-7.91 (m, 1H), 7.94-8.05 (m, 3H), 12.82 (br s, 1H); ESI-MS (m/z) 496.23 (M+H) + .
Example 23
N-{4-[3-Bromo-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0215]
[0216] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[3-bromo-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (158 mg, 0.333 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.39 (s, 3H), 4.91 (d, J=8.7 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.30-7.38 (m, 2H), 7.69 (s, 1H), 7.89-7.95 (m, 1H), 8.17 (m, 1H), 12.65 (br s, 1H); APCI-MS (m/z) 572.27 (M+H) + .
Example 24
N1-{4-[3,5-Difluoro-4-(2,2-dimethylprop oxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0217]
[0218] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (130 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.625 mmol) in dry DMF (5.0 mL) to give 55 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 1.01 (s, 9H), 2.26 (s, 3H), 3.17 (s, 3H), 3.34 (s, 3H), 3.80 (s, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.63 (s, 1H), 7.66 (s, 1H), 7.77 (s, 1H), 12.74 (br s, 1H); ESI-MS (m/z) 532.24 (M+H) + .
Example 25
N-{4-[2,4-Difluoro-3-trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0219]
[0220] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[2,4-difluoro-3-trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (124 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.625 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.27 (s, 3H), 3.16 (s, 3H), 3.34 (s, 3H), 5.34 (s, 2H), 6.07 (s, 1H), 7.47-7.57 (m, 1H), 7.66 (s, 1H), 8.28-8.38 (m, 1H), 12.80 (br s, 1H); APCI-MS (m/z) 514.08 (M+H) + .
Example 26
N-[4-(3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0221]
[0222] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-(3,5-difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl}acetamide (133 mg, 0.308 mmol) in the presence of NaH (16 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 60 mg of the product as a white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.26 (s, 3H), 3.16 (s, 3H), 3.34 (s, 3H), 4.80-4.90 (m, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.71 (d, J=9.3 Hz, 2H), 7.83 (s, 1H), 12.75 (br s, 1H); ESI-MS (m/z) 544.55 (M+H) + .
Example 27
N-[4-(4-Cyclobutylmethoxy-3,5-difluorophenyl)-1,3-thiazol-2-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0223]
[0224] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[4-Cyclobutylmethoxy-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (129 mg, 0.308 mmol) in the presence of NaH (16 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as an off-white solid; 1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 1.82-1.88 (m, 4H), 2.00-2.06 (m, 2H), 2.26 (s, 3H), 2.65-2.70 (m, 1H), 3.17 (s, 3H), 3.33 (s, 3H), 4.10 (d, J=6.6 Hz, 2H), 5.33 (s, 2H), 6.06 (s, 1H), 7.63 (d, J=8.7 Hz, 2H), 7.77 (s, 1H), 12.71 (br s, 1H); APCI-MS (m/z) 530.16 (M+H) + .
Example 28
N-{4-[3-Chloro-4-(2,2-dimethylpropoxy)-5-fluorophenyl]-1,3-thiazol-2-yl]}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0225]
[0226] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)-5-fluorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.04 (s, 9H), 2.26 (s, 3H), 3.17 (s, 3H), 3.34 (s, 3H), 3.78 (s, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.70-7.86 (m, 3H), 12.74 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 548.12 (M+H) + .
Example 29
N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl]}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0227]
[0228] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (140 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 70 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.08 (s, 9H), 2.27 (s, 3H), 3.17 (s, 3H), 3.33 (s, 3H), 3.67 (s, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.85 (s, 1H), 8.00 (s, 2H), 12.73 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 564.22 (M+H) + .
Example 30
N-{4-[3-Chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl]}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0229]
[0230] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (139 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.26 (s, 3H), 3.16 (s, 3H), 3.33 (s, 3H), 4.84 (q, J=8.7 Hz, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.80-7.90 (m, 3H), 12.75 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 560.10 (M+H) + .
Example 31
N-{4-[4-(2,2-Dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0231]
[0232] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}acetamide (124 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 55 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.06 (s, 9H), 2.26 (s, 3H), 3.17 (s, 3H), 3.36 (s, 3H), 3.75 (s, 2H), 5.32 (s, 2H), 6.07 (s, 1H), 7.22 (t, J=8.4 Hz, 1H), 7.59 (s, 1H), 7.65-7.75 (m, 2H), 12.77 (br s, 1H, exchangeable with D 2 O); APCI-MS (m/z) 514.16 (M+H) + .
Example 32
N-{4-[3-Chloro-4-(2,2-dimethylprop oxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0233]
[0234] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (129 mg, 0.308 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 85 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz): 1.04 (s, 9H), 2.27 (s, 3H), 3.17 (s, 3H), 3.36 (s, 3H), 3.76 (s, 2H), 5.32 (s, 2H), 6.07 (s, 1H), 7.19 (d, J=8.7 Hz, 1H), 7.62 (s, 1H), 7.82 (d, J=8.4 Hz, 1H), 7.96 (s, 1H), 12.69 (br s, 1H, exchangeable with D 2 O); APCI-MS (m/z) 530.26 (M+H) + .
Example 33
N-[5-(4-bromophenyl)isoxazol-3-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0235]
[0236] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-[5-(4-bromophenyl)isoxazol-3-yl]acetamide (111 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.26 (s, 3H), 3.18 (s, 3H), 3.34 (s, 3H), 5.27 (s, 2H), 6.05 (s, 1H), 7.35 (s, 1H), 7.72 (d, J=8.7 Hz, 2H), 7.82 (d, J=8.7 Hz, 2H), 11.56 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 472.08 (M+H) + .
Example 34
N-{4-[3,5-Difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0237]
[0238] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 3 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (130 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 2.29 (s, 3H), 3.16 (s, 3H), 3.59 (s, 3H), 3.80 (s, 2H), 5.25 (s, 2H), 7.12 (s, 1H), 7.63 (d, J=9.6 Hz, 2H), 7.76 (s, 1H), 12.63 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 532.18 (M+H) + .
Example 35
N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide
[0239]
[0240] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 3 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (119 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 90 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.29 (s, 3H), 3.16 (s, 3H), 3.59 (s, 3H), 5.26 (s, 2H), 7.12 (s, 1H), 7.82-8.00 (m, 4H), 12.71 (br s, 1H, exchangeable with D 2 O); APCI-MS (m/z) 494.30 (M−H) − .
Example 36
2-(7-Bromo-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide
[0241]
[0242] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 4 (50 mg, 0.193 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (97 mg, 0.232 mmol) in the presence of NaH (11 mg, 0.289 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 3.17 (s, 3H), 3.67 (s, 3H), 3.80 (s, 2H), 5.32 (s, 2H), 7.54 (s, 1H), 7.63 (d, J=9.3 Hz, 2H), 7.80 (s, 1H), 12.70 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 594.17 (M−H) − .
Example 37
2-(7-Bromo-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide
[0243]
[0244] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 4 (50 mg, 0.193 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (89 mg, 0.232 mmol) in the presence of NaH (11 mg, 0.289 mmol) in dry DMF (5.0 mL) to give 50 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.68 (s, 3H), 5.33 (s, 2H), 7.55 (s, 1H), 7.87 (d, J=7.8 Hz, 1H), 7.91-8.02 (m, 3H), 12.79 (br s, 1H, exchangeable with D 2 O); APCI-MS (m/z) 560.12 (M+H) + .
Example 38
N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-{7-[(dimethylamino)methyl]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl}acetamide
[0245]
[0246] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 5 (40 mg, 0.169 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (77 mg, 0.203 mmol) in the presence of NaH (10 mg, 0.250 mmol) in dry DMF (4.0 mL) to give 35 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.15 (s, 3H), 3.17 (s, 3H), 3.32 (s, 2H, overlapped with residual DMSO peak), 3.71 (s, 3H), 5.29 (s, 2H), 7.24 (s, 1H), 7.86-8.01 (m, 4H), 12.84 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 539.12 (M+H) + .
Example 39
N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-{7-[(dimethylamino)methyl]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl}acetamide
[0247]
[0248] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 5 (50 mg, 0.211 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (106 mg, 0.253 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 2.16 (s, 3H), 3.17 (s, 3H), 3.34 (s, 2H, overlapped with residual DMSO peak), 3.71 (s, 3H), 3.80 (s, 3H), 5.28 (s, 2H), 7.24 (s, 1H), 7.65 (d, J=9.6 Hz, 2H), 7.76 (s, 1H), 12.66 (br s, 1H, exchangeable with D 2 O); APCI-MS (m/z) 575.02 (M+H) + .
Example 40
N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-{7-[(diethylamino)methyl]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl}acetamide
[0249]
[0250] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 6 (50 mg, 0.189 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (86 mg, 0.224 mmol) in the presence of NaH (11 mg, 0.250 mmol) in dry DMF (5.0 mL) to give 50 mg of the product as a white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 0.96 (t, J=6.9 Hz, 6H), 2.47-2.53 (m, 4H, overlapped with residual DMSO peak), 3.17 (s, 3H), 3.50 (s, 2H), 3.75 (s, 3H), 5.29 (s, 2H), 7.27 (s, 1H), 7.83-8.02 (m, 4H), 12.76 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 567.00 (M+H) + .
Example 41
N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide
[0251]
[0252] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (80 mg, 0.318 mmol) with 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (84 mg, 0.318 mmol) in the presence of EDCI hydrochloride (74 mg, 0.381 mmol), HOBt (13 mg, 0.096 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (4 mL) to give 52 mg of the product as an off white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.21 (s, 3H), 3.73 (s, 3H), 3.80 (s, 3H), 3.95 (s, 2H), 6.35 (s, 1H), 7.82-8.02 (m, 4H), 12.62 (br s, 1H, exchangeable with D 2 O); APCI-MS (m/z) 496.26 (M+H) + .
Example 42
N-[4-(3,5-Difluoro-4-(2,2-dimethylprop oxy)phenyl)-1,3-thiazol-2-yl]-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide
[0253]
[0254] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (100 mg, 0.398 mmol) with 4-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-amine (118 mg, 0.398 mmol) in the presence of EDCI hydrochloride (91 mg, 0.475 mmol), HOBt (16 mg, 0.118 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (5 mL) to give 40 mg of the product as an off white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 3.21 (s, 3H), 3.73 (s, 3H), 3.80 (s, 5H), 3.93 (s, 2H), 6.35 (s, 1H), 7.64 (d, J=9.6 Hz, 2H), 7.67 (s, 1H), 12.53 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 532.24 (M+H) + .
Example 43
N-{4-[2,4-Difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide
[0255]
[0256] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (100 mg, 0.398 mmol) with 4-[2,4-difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (111 mg, 0.398 mmol) in the presence of EDCI hydrochloride (91 mg, 0.475 mmol), HOBt (16 mg, 0.118 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (5 mL) to give 35 mg of the product as an off white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.21 (s, 3H), 3.73 (s, 3H), 3.81 (s, 3H), 3.95 (s, 2H), 6.35 (s, 1H), 7.51 (d, J=9.9 Hz, 1H), 8.32 (q, J=6.3 Hz, 1H), 12.61 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 514.09 (M+H) + .
Example 44
N-{4-[3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide
[0257]
[0258] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (100 mg, 0.398 mmol) with 4-[3,5-difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-amine (123 mg, 0.398 mmol) in the presence of EDCI hydrochloride (91 mg, 0.475 mmol), HOBt (16 mg, 0.118 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (5 mL) to give 70 mg of the product as an off white solid; 1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.21 (s, 3H), 3.73 (s, 3H), 3.80 (s, 5H), 3.94 (s, 2H), 4.85 (q, J=8.7 Hz, 2H), 6.35 (s, 1H), 7.69 (d, J=9.3 Hz, 2H), 7.82 (s, 1H), 12.55 (br s, 1H, exchangeable with D 2 O); ESI-MS (m/z) 544.11 (M+H) + .
Example 45
N-[4-(4-Isobutylphenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0259]
[0260] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-(4-isobutylphenyl)-1,3-thiazol-2-amine (183 mg, 0.793 mmol) in the presence of EDCI hydrochloride (181 mg, 0.952 mmol), HOBt (32 mg, 0.238 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2 dichloroethane (8 ml) to give 32 mg of the product as a white solid; 1 H NMR (300 MHz, CDCl 3 ): δ 0.90 (d, J=6.6 Hz, 6H), 2.49 (d, J=5.1 Hz, 2H), 3.46 (s, 3H), 3.50 (s, 3H), 3.99 (s, 3H), 4.16 (s, 2H), 7.08 (s, 1H), 7.18 (d, J=7.8 Hz, 2H), 7.74 (d, J=8.4, 2H), 11.11 (br s, 1H); APCI-MS (m/z): 513.03 (M+H) + .
Example 46
N-[4-(4-Chlorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0261]
[0262] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(4-chlorophenyl)-1,3-thiazol-2-amine (208 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (8 ml) to give 35 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.16 (s, 3H), 3.36 (s, 3H), 3.84 (s, 3H), 4.39 (s, 2H), 7.50 (d, J=8.4 Hz, 2H), 7.72 (s, 1H), 7.92 (d, J=9.0 Hz, 2H), 12.74 (br s, 1H); APCI-MS (m/z) 445.08 (M+H) + .
Example 47
N-{4-[4-(Trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0263]
[0264] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-[4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (193 mg, 0.793 mmol) in the presence of EDCI hydrochloride (182 mg, 0.951 mmol), HOBt (32 mg, 0.237 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2-dichloroethane (7.9 ml) to give 13.4 mg of the product as an off-white solid; 1 H NMR (300 MHz, CDCl 3 ): δ 3.48 (s, 3H), 3.50 (s, 3H), 4.01 (s, 3H), 4.16 (s, 2H), 7.24 (s, 1H), 7.65 (d, J=7.8, 2H), 7.95 (d, J=7.8, 2H), 11.21 (br s, 1H); APCI-MS (m/z): 479.08 (M+H) + .
Example 48
N-{4-[3-(Trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0265]
[0266] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (243 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (8 ml) to give 75 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.70 (s, 2H), 7.91 (s, 1H), 8.23-8.29 (m, 2H), 12.80 (br s, 1H); APCI-MS (m/z) 479.09 (M+H) + .
Example 49
N-{4-[3-(Trifluoromethoxy)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0267]
[0268] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-[3-(trifluoromethoxy)phenyl]-1,3-thiazol-2-amine (206 mg, 0.793 mmol) in the presence of EDCI hydrochloride (181 mg, 0.952 mmol), HOBt (32 mg, 0.238 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2 dichloroethane (8 ml) to give 14 mg of the product as a white solid; 1 H NMR (300 MHz, CDCl 3 ): δ 3.48 (s, 3H), 3.50 (s, 3H), 4.00 (s, 3H), 4.16 (s, 2H), 7.18 (s, 2H), 7.42 (t, J=8.1 Hz, 1H), 7.70-7.80 (m, 2H), 11.24 (br s, 1H); ESI-MS (m/z): 495.06 (M+H) + .
Example 50
N-[4-(2,4-Difluorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0269]
[0270] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(2,4-difluorophenyl)-1,3-thiazol-2-amine (210 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 60 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.23 (t, J=8.4 Hz, 1H), 7.39 (t, J=9.0 Hz, 1H), 7.52 (s, 1H), 8.06 (q, J=8.7 Hz, 1H), 12.76 (br s, 1H); APCI-MS (m/z) 447.08 (M+H) + .
Example 51
N-[4-(3,4-Difluorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0271]
[0272] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(3,4-difluorophenyl)-1,3-thiazol-2-amine (210 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 26 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.23 (d, J=9.0 Hz, 1H), 7.61 (d, J=7.5 Hz, 2H), 7.91 (s, 1H), 12.79 (br s, 1H); APCI-MS (m/z) 447.00 (M+H) + .
Example 52
N-[4-(3,5-Difluorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0273]
[0274] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(3,5-difluorophenyl)-1,3-thiazol-2-amine (210 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 36 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.23 (d, J=9.0 Hz, 1H), 7.61 (d, J=7.5 Hz, 2H), 7.91 (s, 1H), 12.79 (br s, 1H); APCI-MS (m/z) 447.00 (M+H) + .
Example 53
N-{4-[4-Fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0275]
[0276] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 45 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.62 (t, J=9.0 Hz, 1H), 7.88 (s, 1H), 8.24-8.30 (m, 2H), 12.80 (br s, 1H); APCI-MS (m/z) 497.05 (M+H) + .
Example 54
N-[4-(3-Fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0277]
[0278] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(3-fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-amine (259 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2-dichloroethane (9.9 ml) to give 80 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.86-8.05 (m, 4H), 12.84 (br s, 1H); ESI-MS (m/z): 497.09 (M+H) + .
Example 55
N-{4-[2-Fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0279]
[0280] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2-fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 35 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.41 (s, 2H), 7.54 (t, J=7.8 Hz, 1H), 7.72 (s, 1H), 7.78 (t, J=6.9 Hz, 1H), 8.33 (t, J=7.5 Hz, 1H), 12.83 (br s, 1H); APCI-MS (m/z) 497.00 (M+H) + .
Example 56
N-{4-[2-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0281]
[0282] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2-dichloroethane (9.9 ml) to give 32 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.35 (s, 3H), 3.85 (s, 3H), 4.41 (s, 2H), 7.70-7.86 (m, 3H), 7.26 (t, J=7.8 Hz, 1H), 12.85 (br s, 1H); APCI-MS (m/z) 497.09 (M+H) + .
Example 57
N-{4-[2-Fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0283]
[0284] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2-fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 80 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.56-7.65 (m, 1H), 7.72 (s, 1H), 7.76-7.82 (m, 1H), 8.38-8.44 (m, 1H), 12.84 (br s, 1H); APCI-MS (m/z) 497.10 (M+H) + .
Example 58
N-{4-[3-Fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0285]
[0286] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[3-fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (275 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.19 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2 dichloroethane (8 ml) to give 12 mg of the product as a white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.61 (t, J=9.9 Hz, 1H), 7.82 (s, 1H), 8.00-8.06 (m, 2H), 12.78 (br s, 1H); APCI-MS (m/z) 513.11 (M+H) + .
Example 59
N-{4-[3-Fluoro-4-(trifluoromethoxy)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0287]
[0288] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-[3-fluoro-4-(trifluoromethoxy)phenyl]-1,3-thiazol-2-amine (220 mg, 0.793 mmol) in the presence of EDCI hydrochloride (181 mg, 0.952 mmol), HOBt (32 mg, 0.238 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2 dichloroethane (8 ml) to give 16 mg of the product as a white solid; 1 H NMR (300 MHz, CDCl 3 ): δ 3.49, 3.50 (2s, 6H), 4.01 (s, 3H), 4.15 (s, 2H), 7.15 (s, 1H), 7.27-7.35 (m, 1H), 7.61 (d, J=8.1 Hz, 1H), 7.67-7.73 (m, 1H), 11.18 (br s, 1H); ESI-MS (m/z): 495.06 (M+H) + .
Example 60
N-{4-[4-Fluoro-3-(trifluoromethoxy)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0289]
[0290] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-fluoro-3-(trifluoromethoxy)phenyl]-1,3-thiazol-2-amine (275 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 90 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.61 (t, J=8.7 Hz, 1H), 7.82 (s, 1H), 8.00-8.07 (m, 2H), 12.78 (br s, 1H); APCI-MS (m/z) 513.11 (M+H) + .
Example 61
N-{4-[4-(Difluoromethoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0291]
[0292] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-(difluoromethoxy)-3-fluorophenyl]-1,3-thiazol-2-amine (258 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 40 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.29 (t, J=72.9 Hz, 1H), 7.45 (t, J=8.4 Hz, 1H), 7.78 (s, 2H), 7.86-7.92 (m, 1H), 12.77 (br s, 1H); ESI-MS (m/z) 495.08 (M+H) + .
Example 62
N-{4-[2,3-difluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0293]
[0294] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2,3-difluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (277 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 53 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.33 (s, 3H), 3.85 (s, 3H), 4.41 (s, 2H), 7.72-7.79 (m, 1H), 7.84 (s, 1H), 7.99-8.05 (m, 1H), 12.87 (br s, 1H); ESI-MS (m/z) 515.10 (M+H)
Example 63
N-{4-[2,4-Difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0295]
[0296] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2,4-difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (279 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (9.69 mg, 0.099 mmol) in 1,2-dichloroethane (8 ml) to give 122 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMF-d 7 ): δ 3.22 (s, 3H), 3.42 (s, 3H), 3.97 (s, 3H), 4.58 (s, 2H), 7.52 (t, J=8.4 Hz, 1H), 7.71 (s, 1H), 8.43 (q, J=9.0 Hz, 1H), 12.80 (br s, 1H); APCI-MS (m/z) 515.07 (M+H) + .
Example 64
N-{4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0297]
[0298] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-amine (273 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2-dichloroethane (9.9 ml) to give 40 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.28 (t, J=72.3 Hz, 1H), 7.80 (d, J=9.0 Hz, 2H), 7.91 (s, 1H), 12.80 (br s, 1H); APCI-MS (m/z) 513.00 (M+H) + .
Example 65
N-[5-(4-Bromophenyl)isoxazol-3-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0299]
[0300] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 5-(4-bromophenyl)isoxazol-3-amine (237 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 30 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.18 (s, 3H), 3.34 (s, 3H), 3.84 (s, 3H), 4.33 (s, 2H), 7.35 (s, 1H), 7.73 (d, J=8.1 Hz, 2H), 7.83 (d, J=8.7 Hz, 2H), 11.58 (br s, 1H); APCI-MS (m/z) 473.05 (M+H) + .
Example 66
N-[5-(Trifluoromethoxy)-1,3-benzothiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0301]
[0302] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 5-(trifluoromethoxy)-1,3-benzothiazol-2-amine (234 mg, 0.992 mmol) in the presence of EDCI hydrochloride (458 mg, 2.389 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 200 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.86 (s, 3H), 4.45 (s, 2H), 7.44 (d, J=8.7 Hz, 1H), 7.86 (d, J=8.7 Hz, 1H), 8.13 (s, 1H), 12.94 (br s, 1H); APCI-MS (m/z) 469.10 (M+H) + .
Example 67
N-[4-(4-Chlorophenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0303]
[0304] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (150 mg, 0.823 mmol) with 2-bromo-N-[4-(4-chlorophenyl)-1,3-thiazol-2-yl]acetamide (328 mg, 0.988 mmol) in the presence of NaH (50 mg, 1.235 mmol) in dry DMF (3.0 mL) to give 30 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.22 (s, 3H), 3.44 (s, 3H), 5.50 (s, 2H), 7.51 (d, J=8.1 Hz, 2H), 7.73 (s, 1H), 7.89 (s, 1H), 7.93 (d, J=8.4 Hz, 2H), 12.77 (br s, 1H); APCI-MS (m/z): 431.09 (M+H) + .
Example 68
2-(4,6-Dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide
[0305]
[0306] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (62 mg, 0.344 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (110 mg, 0.287 mmol) in the presence of NaH (17 mg, 0.430 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 3.21 (s, 3H), 3.43 (s, 3H), 5.51 (s, 2H), 7.84-8.02 (m, 5H), 12.85 (br s, 1H); APCI-MS (m/z) 481.22 (M−H) − .
Example 69
N-{4-[4-(2,2-Dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0307]
[0308] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}acetamide (107 mg, 0.277 mmol) in the presence of NaH (17 mg, 0.415 mmol) in dry DMF (5.0 mL) to give 50 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.02 (s, 9H), 3.22 (s, 3H), 3.44 (s, 3H), 3.75 (s, 2H), 5.49 (s, 2H), 7.22 (t, J=8.4 Hz, 1H), 7.61 (s, 1H), 7.65-7.75 (m, 2H), 7.89 (s, 1H), 12.72 (br s, 1H); APCI-MS (m/z) 501.45 (M+H) + .
Example 70
N-{4-[3-Chloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0309]
[0310] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (167 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.04 (s, 9H), 3.22 (s, 3H), 3.43 (s, 3H), 3.76 (s, 2H), 5.49 (s, 2H), 7.19 (d, J=8.7 Hz, 1H), 7.63 (s, 1H), 7.81 (d, J=8.7 Hz, 1H), 7.88 (s, 1H), 7.95 (s, 1H), 12.72 (br s, 1H); APCI-MS (m/z) 517.17 (M+H) + .
Example 71
N-{4-[2,4-Difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0311]
[0312] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (100 mg, 0.600 mmol) with 2-bromo-N-{4-[2,4-difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (289 mg, 0.720 mmol) in the presence of NaH (36 mg, 0.900 mmol) in dry DMF (3.0 mL) to give 38 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.22 (s, 3H), 3.44 (s, 3H), 5.51 (s, 2H), 7.53 (t, J=9.9 Hz, 1H), 7.69 (s, 1H), 7.89 (s, 1H), 8.30-8.38 (m, 1H), 12.84 (br s, 1H); APCI-MS (m/z): 501.24 (M+H) + .
Example 72
N-{4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0313]
[0314] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.331 mmol) with 2-bromo-N-{4-[4-(difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (110 mg, 0.276 mmol) in the presence of NaH (17 mg, 0.414 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 3.22 (s, 3H), 3.43 (s, 3H), 5.50 (s, 2H), 7.28 (t, J=72.3 Hz, 1H), 7.80 (d, J=9.3 Hz, 1H), 7.89 (s, 1H), 7.92 (s, 1H), 12.82 (br s, 1H); APCI-MS (m/z) 499.20 (M+H) + .
Example 73
N-{4-[3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0315]
[0316] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (130 mg, 0.700 mmol) with 2-bromo-N-[4-(3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl]acetamide (302 mg, 0.700 mmol) in the presence of NaH (42 mg, 1.050 mmol) in dry DMF (3.0 mL) to give 73 mg of the product as a white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.21 (s, 3H), 3.43 (s, 3H), 4.86 (q, J=9.0 Hz, 2H), 5.50 (s, 2H), 7.71 (d, J=9.9 Hz, 2H), 7.85 (s, 1H), 7.89 (s, 1H), 12.80 (br s, 1H); APCI-MS (m/z): 531.11 (M+H) + .
[0317] Further eluting gave 30 mg of N-[4-(3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[4,3-d]pyrimidin-2-yl)acetamide; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.26 (s, 3H), 3.36 (s, 3H), 4.86 (q, J=9.0 Hz, 2H), 5.38 (s, 2H), 7.70 (d, J=8.7 Hz, 2H), 7.88 (s, 1H), 8.08 (s, 1H), 12.85 (br s, 1H); APCI-MS (m/z) 529.10 (M−H) − .
Example 74
N-[4-(3,5-Difluoro-4-isobutoxyphenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0318]
[0319] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-(3,5-difluoro-4-isobutoxyphenyl)-1,3-thiazol-2-yl}acetamide (162 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 25 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 0.98 (d, J=6.9 Hz, 6H), 1.98-2.04 (m, 1H), 3.22 (s, 3H), 3.43 (s, 3H), 3.91 (d, J=6.6 Hz, 2H), 5.50 (s, 2H), 7.62-7.68 (m, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.77 (br s, 1H); APCI-MS (m/z) 505.13 (M+H) + .
Example 75
N-[4-(3,5-Dichloro-4-isobutoxyphenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0320]
[0321] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-(3,5-dichloro-4-isobutoxyphenyl)-1,3-thiazol-2-yl}acetamide (175 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 45 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.05 (d, J=6.6 Hz, 6H), 2.05-2.15 (m, 1H), 3.25 (s, 3H), 3.35 (s, 3H), 3.79 (d, J=6.0 Hz, 2H), 5.37 (s, 2H), 7.90 (s, 1H), 8.00 (s, 2H), 8.08 (s, 1H), 12.84 (br s, 1H); APCI-MS (m/z) 505.13 (M+H) + .
Example 76
N-{4-[3,5-Difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0322]
[0323] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (50 mg, 0.286 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}acetamide (100 mg, 0.238 mmol) in the presence of NaH (14 mg, 0.357 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 0.92 (d, J=6.9 Hz, 6H), 1.55-1.62 (m, 2H), 1.76-1.86 (m, 1H), 3.22 (s, 3H), 3.43 (s, 3H), 4.15 (t, J=6.6 Hz, 2H), 5.50 (s, 2H), 7.62-7.68 (m, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.77 (br s, 1H); APCI-MS (m/z) 519.18 (M+H) + .
Example 77
N-{4-[3,5-Dichloro-4-isobutoxyphenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0324]
[0325] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-[4-(3,5-difluoro-4-isobutoxyphenyl)-1,3-thiazol-2-yl]acetamide (180 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 45 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 0.96 (d, J=6.9 Hz, 6H), 1.64-1.73 (m, 2H), 1.83-1.92 (m, 1H), 3.25 (s, 3H), 3.36 (s, 3H), 4.04 (t, J=6.6 Hz, 2H), 5.37 (s, 2H), 7.90 (s, 1H), 8.01 (s, 2H), 8.07 (s, 1H), 12.84 (br s, 1H); APCI-MS (m/z) 551.24 (M+H) + .
Example 78
N-{4-[4-(2,2-Dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0326]
[0327] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (150 mg, 0.800 mmol) with 2-bromo-N-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl)-1,3-thiazol-2-yl]acetamide (400 mg, 0.96 mmol) in the presence of NaH (48 mg, 1.20 mmol) in dry DMF (3.0 mL) to give 52 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.22 (s, 3H), 3.43 (s, 3H), 3.80 (s, 2H), 5.50 (s, 2H), 7.65 (d, J=9.3 Hz, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.78 (br s, 1H); APCI-MS (m/z): 519.14 (M+H) + .
Example 79
N-{4-[3,5-Dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0328]
[0329] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (80 mg, 0.444 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (219 mg, 0.488 mmol) in the presence of NaH (27 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.08 (s, 9H), 3.22 (s, 3H), 3.43 (s, 3H), 3.67 (s, 2H), 5.50 (s, 2H), 7.85-7.91 (m, 2H), 8.00 (s, 2H), 12.77 (br s, 1H); APCI-MS (m/z) 551.16 (M+H) + .
Example 80
N-{4-[3-Chloro-4-(2,2-dimethylprop oxy)-5-fluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0330]
[0331] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (70 mg, 0.389 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)-5-fluorophenyl]-1,3-thiazol-2-yl}acetamide (203 mg, 0.466 mmol) in the presence of NaH (23 mg, 0.586 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.04 (s, 9H), 3.21 (s, 3H), 3.43 (s, 3H), 3.78 (s, 2H), 5.49 (s, 2H), 7.75-7.91 (m, 4H), 12.77 (br s, 1H); APCI-MS (m/z) 535.23 (M+H) + .
Example 81
N-{4-[4-(Cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0332]
[0333] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (100 mg, 0.555 mmol) with 2-bromo-N-{4-[4-(cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (278 mg, 0.666 mmol) in the presence of NaH (33 mg, 0.832 mmol) in dry DMF (5.0 mL) to give 55 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.78-1.92 (m, 4H), 2.00-2.06 (m, 2H), 2.65-2.72 (m, 1H), 3.22 (s, 3H), 3.43 (s, 3H), 4.10 (d, J=6.9 Hz, 2H), 5.50 (s, 2H), 7.62-7.68 (m, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.77 (br s, 1H); APCI-MS (m/z) 517.15 (M+H) + .
Example 82
N-[4-(3,5-Difluoro-4-(2,2-dimethylprop oxy)phenyl)-1,3-thiazol-2-yl]-2-(3,4,6-trimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0334]
[0335] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 10 (50 mg, 0.257 mmol) with 2-bromo-N-[4-(3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl)]-1,3-thiazol-2-yl}acetamide (118 mg, 0.283 mmol) in the presence of NaH (12 mg, 0.308 mmol) in dry DMF (5.0 mL) to give 19 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.01 (s, 9H), 2.50 (s, 3H), 3.21 (s, 3H), 3.58 (s, 3H), 3.80 (s, 2H), 5.41 (s, 2H), 7.64 (d, J=9.3 Hz, 2H), 7.87 (s, 1H), 12.74 (br s, 1H); APCI-MS (m/z) 533.16 (M+H) + .
Example 83
N-[4-(3,5-Dichloro-4-(2,2-dimethylpropoxy)phenyl)-1,3-thiazol-2-yl]-2-(3,4,6-trimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0336]
[0337] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 10 (50 mg, 0.257 mmol) with 2-bromo-N-[4-(3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl)]-1,3-thiazol-2-yl}acetamide (127 mg, 0.283 mmol) in the presence of NaH (15 mg, 0.385 mmol) in dry DMF (5.0 mL) to give 25 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 1.07 (s, 9H), 2.50 (s, 3H), 3.21 (s, 3H), 3.58 (s, 3H), 3.67 (s, 2H), 5.42 (s, 2H), 7.87 (s, 1H), 8.00 (s, 2H), 12.74 (br s, 1H); APCI-MS (m/z) 565.32 (M+H) + .
Example 84
N-[5-(4-Bromophenyl)isoxazol-3-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7,-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide
[0338]
[0339] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-[5-(4-bromophenyl)isoxazol-3-yl]acetamide (144 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as an off-white solid; 1 H NMR (300 MHz, DMSO-d 6 ) δ 3.22 (s, 3H), 3.43 (s, 3H), 5.42 (s, 2H), 7.33 (s, 1H), 7.72 (d, J=8.7 Hz, 2H), 7.85 (d, J=8.1 Hz, 2H), 8.88 (s, 1H), 11.60 (br s, 1H); APCI-MS (m/z) 459.08 (M+H) + .
Example 85
N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide
[0340]
[0341] To a stirred solution of 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-amine (Intermediate 11) (104 mg, 0.428 mmol) in dry toluene (4 ml), sodium hydride (60% dispersion in mineral oil, (12 mg, 1.401 mmol) was added and reaction mixture was stirred for 30 min at room temperature. Step 6 of Intermediate 8 (100 mg, 0.356 mmol) was added to the above reaction mixture and heated to reflux for 48 h. The reaction mixture quenched into water and extracted with ethyl acetate and the combined organic layers were washed with brine, dried over Na 2 SO 4 . Solvent was evaporated and residue obtained was purified by SiO 2 column chromatography using 2% methanol in chloroform to give 23 mg of the product as off white solid; 1 H NMR (300 MHz, DMSO-d 6 ): δ 3.18 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.30 (s, 2H), 7.62 (s, 1H), 7.70-7.81 (m, 3H), 11.76 (br s, 1H), 11.94 (br s, 1H); APCI-MS (m/z): 480.17 (M+H) + .
Pharmacological Activity
[0342] The illustrative examples of the present invention are screened for TRPA1 activity according to a modified procedure described in (a) Tóth, A. et al., Life Sciences, 2003, 73, 487-498. (b) McNamara C, R. et al., Proc. Natl. Acad. Sci. U.S.A., 2007, 104, 13525-13530. The screening of the compounds can be carried out by other methods and procedures known to persons skilled in the art.
Screening for TRPA1 Antagonist Using the 45 Calcium Uptake Assay
[0343] The inhibition of TRPA1 receptor activation was measured as inhibition of allyl isothiocyanate (AITC) induced cellular uptake of radioactive calcium. Test compounds were dissolved in DMSO to prepare 10 mM stock solution and then diluted using plain medium with 0.1% BSA and 1.8 mM CaCl 2 to get desired concentration. Final concentration of DMSO in the reaction was 0.5% (v/v). Human TRPA1 expressing CHO cells were grown in F-12 DMEM medium with 10% FBS, 1% penicillin-streptomycin solution, 400 pg/ml of G-418. Cells were seeded 24 h prior to the assay in 96 well plates so as to get ˜50,000 cells per well on the day of experiment. Cells were treated with test compounds for 10 min followed by addition of AITC at a final concentration of 30 μM and 5 μCi/ml 45 Ca +2 for 3 min. Cells were washed and lysed using buffer containing 1% Triton X-100, 0.1% deoxycholate and 0.1% SDS. Radioactivity in the lysate was measured in Packard Top count after addition of liquid scintillant. Concentration response curves were plotted as a % of maximal response obtained in the absence of test antagonist. IC 50 value was calculated from concentration response curve by nonlinear regression analysis using GraphPad PRISM software.
[0344] The compounds prepared were tested using the above assay procedure and the results obtained are given in Table 3. Percentage inhibition at concentrations of 1.0 μM and 10.0 μM are given in the table along with IC 50 (nM) details for selected examples. The IC 50 (nM) values of the compounds are set forth in Table 3 wherein “A” refers to an IC 50 value of less than 50 nM, “B” refers to IC 50 value in range of 50.01 to 100.0 nM and “C” refers to an IC 50 values above 100.0 nM.
[0000]
TABLE 3
In-vitro screening results of compounds of invention
Percentage inhibition
Human
Examples
at 1.0 μM
at 10.0 μM
IC 50 value (range)
1
23.05
21.39
—
2
35.44
79.51
—
3
94.43
98.77
A
4
34.39
89.77
—
5
55.26
82.29
—
6
42.37
52.84
—
7
35.52
37.28
—
8
91.92
100.00
A
9
60.70
91.28
—
10
91.00
95.30
B
11
96.26
98.07
A
12
97.37
95.97
A
13
86.45
98.82
B
14
92.52
92.54
A
15
76.50
92.50
B
16
94.96
97.14
A
17
33.54
49.94
—
18
38.44
38.71
—
19
72.12
76.86
—
20
22.59
67.70
—
21
11.16
16.23
—
22
81.41
99.41
A
23
87.43
92.21
B
24
93.92
99.43
A
25
68.31
94.76
—
26
95.26
98.27
A
27
87.58
99.15
A
28
99.51
99.68
A
29
95.58
97.08
A
30
93.56
100.00
A
31
87.44
95.35
B
32
92.81
96.32
A
33
0.00
28.30
—
34
88.81
97.01
C
35
64.74
96.79
—
36
35.59
70.11
—
37
52.90
95.44
—
38
57.01
97.80
—
39
4.89
21.09
—
40
48.49
86.22
—
41
37.99
86.55
—
42
41.10
63.14
—
43
30.13
41.58
—
44
27.08
77.03
—
45
93.46
98.87
B
46
89.26
96.58
C
47
98.98
99.45
A
48
92.84
97.51
B
49
52.26
88.46
—
50
0.00
19.84
—
51
57.54
79.68
—
52
37.75
64.81
—
53
97.25
98.63
A
54
97.73
99.61
A
55
92.23
99.15
B
56
96.20
98.16
A
57
43.04
49.81
—
58
94.63
99.25
A
59
97.57
99.33
A
60
93.42
97.19
A
61
86.05
98.33
B
62
90.31
95.76
A
63
95.07
99.74
A
64
97.78
98.29
A
65
12.49
24.64
—
66
45.05
71.55
—
67
57.60
98.43
—
68
91.34
99.43
C
69
97.27
99.75
A
70
91.47
98.76
A
71
78.25
99.28
B
72
85.88
97.67
C
73
99.06
99.91
A
74
92.10
98.78
A
75
99.34
100
A
76
84.32
95.60
C
77
89.48
99.58
B
78
100
99.65
A
79
100
99.99
A
80
99.99
100
A
81
93.95
99.97
A
82
92.85
98.95
B
83
75.59
95.02
A
84
17.24
83.90
—
85
44.10
78.19
— | The invention described herein relates to novel fused pyrimidinediones derivatives of formula (I) which are TRPA (Transient Receptor Potential subfamily A) modulators. In particular, compounds described herein are useful for treating or preventing diseases, conditions and/or disorders modulated by TRPA1 (Transient Receptor Potential subfamily A, member 1). This invention also provides processes for preparing compounds described herein, intermediates used in their synthesis, pharmaceutical compositions thereof, and methods for treating or preventing diseases, conditions and/or disorders modulated by TRPA1. | Summarize the key points of the given document. | [
"RELATED APPLICATIONS [0001] This application claims the benefit of Indian Patent Application Nos. 665/MUM/2009 filed on Mar. 23, 2009;",
"2211/MUM/2009 filed on Sep. 23, 2009;",
"2212/MUM/2009 filed on Sep. 23, 2009;",
"2891/MUM/2009 filed on Dec. 15, 2009;",
"2892/MUM/2009 filed on Dec. 15, 2009 and U.S. Provisional Application Nos 61/171,355 filed on Apr. 21, 2009;",
"61/251,944 filed on Oct. 15, 2009;",
"61/253,263 filed on Oct. 20, 2009;",
"61/294,463 filed on Jan. 12, 2010 and 61/300,241 filed on Feb. 1, 2010 all of which are hereby incorporated by reference.",
"TECHNICAL FIELD [0002] The present patent application relates to fused pyrimidinedinedione derivatives with transient receptor potential ankyrin1 (TRPA1) activity.",
"BACKGROUND OF THE INVENTION [0003] The transient receptor potential (TRP) channels or receptors are pain receptors.",
"They have been classified into seven subfamilies: TRPC (canonical), TRPV (vanilloid), TRPM (melastatin), TRPP (polycystin), TRPML (mucolipin), TRPA (ankyrin, ANKTM1) and TRPN (NOMPC) families.",
"The TRPC family can be divided into 4 subfamilies (i) TRPC1 (ii) TRPC2 (iii) TRPC3, TRPC6, TRPC7 and (iv) TRPC4, TRPC5 based on sequence functional similarities.",
"Currently the TRPV family has 6 members.",
"TRPV5 and TRPV6 are more closely related to each other than to TRPV1, TRPV2, TRPV3 or TRPV4.",
"TRPA1 is most closely related to TRPV3 and is more closely related to TRPV1 and TRPV2 than to TRPV5 and TRPV6.",
"The TRPM family has 8 members.",
"Constituents include the following: the founding member TRPM1 (melastatin or LTRPC1), TRPM3 (KIAA1616 or LTRPC3), TRPM7 (TRP-PLIK, ChaK(1), LTRPC7), TRPM6 (ChaK2), TRPM2 (TRPC7 or LTRPC2), TRPM8 (TRP-p8 or CMR1), TRPM5 (MTR1 or LTRPC5) and TRPM4 (FLJ20041 or LTRPC4).",
"The TRPML family consists of the mucolipins, which include TRPML1 (mucolipin 1), TRPML2 (mucolipin 2) and TRPML3 (mucolipin 3).",
"The TRPP family consists of two groups of channels: those predicted to have six transmembrane domains and those that have eleven.",
"TRPP2 (PKD2), TRPP3 (PKD2L1), TRPP5 (PKD2L2) are all predicted to have six transmembrane domains.",
"TRPP1 (PKD1, PC1), PKD-REJ and PKD-1L1 are all thought to have eleven transmembrane domains.",
"The sole mammalian member of the TRPA family is ANKTM1.",
"[0004] It is believed TRPA1 is expressed in nociceptive neurons.",
"Nociceptive neurons of the nervous system sense the peripheral damage and transmit pain signals.",
"TRPA1 is membrane bound and most likely acts as a heterodimeric voltage gated channel.",
"It is believed to have a particular secondary structure, its N-terminus is lined with a large number of ankyrin repeats which are believed to form a spring-like edifice.",
"TRPA1 is activated by a variety of noxious stimuli, including cold temperatures (activated at 17° C.), pungent natural compounds (e.g., mustard, cinnamon and garlic) and environmental irritants (MacPherson L J et al, Nature, 2007, 445;",
"541-545).",
"Noxious compounds activate TRPA1 ion channels through covalent modification of cysteines to form covalently linked adducts.",
"Variety of endogenous molecules produced during tissue inflammation/injury have been identified as pathological activators of TRPA1 receptor.",
"These include hydrogen peroxide which is produced due to oxidative stress generated during inflammation, alkenyl aldehyde 4-HNE—an intracellular lipid peroxidation product and cyclopentenone prostaglandin 15dPGJ2 which is produced from PGD2 during inflammation/allergic response.",
"TRPA1 is also activated in receptor dependant fashion by Bradykinin (BK) which is released during tissue injury at peripheral terminals [0005] The difference between TRPA1 and other TRP receptors is that TRPA1 ligand binding persists for hours due to which the physiological response (e.g., pain) is greatly prolonged.",
"Hence to dissociate the electrophile, an effective antagonist is required.",
"[0006] WO 2009/158719, WO 2009/002933, WO 2008/0949099, WO 2007/073505, WO 2004/055054 and WO 2005/089206 describe the TRP channels as the targets for the treatment of pain and related conditions.",
"[0007] In efforts to discover better analgesics for the treatment of both acute and chronic pain and to develop treatments for various neuropathic and nociceptive pain states, there exists a need for a more effective and safe therapeutic treatment of diseases, conditions and/or disorders modulated by TRPA1.",
"SUMMARY OF THE INVENTION Definitions [0008] The present invention relates to compounds of the formula (I): [0000] [0009] or a pharmaceutically acceptable salt thereof, [0010] wherein, [0011] Z 1 is NR a or CR a ;",
"[0012] Z 2 is NR b or CR b ;",
"[0013] Z 3 is N or C;",
"[0014] with the proviso that when Z 2 is CR b then both Z 1 and Z 3 are not nitrogen at the same time;",
"[0015] at each occurrence, R a and R b which may be same or different, are independently selected from hydrogen, hydroxyl, cyano, halogen, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, —(CR x R y ) n OR x , —COR x , —COOR x , —CONR x R y , —S(O) m NR x R y , —NR x R y , —NR x (CR x R y ) n OR x , —(CH 2 ) n NR x R y , —(CH 2 ) n CHR x R y , —(CH 2 )NR x R y , —NR x (CR x R y ) n CONR x R y , —(CH 2 ) n NHCOR x , —(CH 2 ) n NH(CH 2 ) n SO 2 R x and (CH 2 ) n NHSO 2 R x ;",
"[0016] alternatively either of R a or R b is absent;",
"[0017] R 1 and R 2 , which may be same or different, are independently selected from hydrogen, hydroxyl, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, arylalkyl, (CR x R y ) n OR x , COR x , COOR x , CONR x R y , (CH 2 ) n NR x R y , (CH 2 ) n CHR x R y , (CH 2 )NR x R y and (CH 2 ) n NHCOR x ;",
"[0018] R 3 is selected from hydrogen, substituted or unsubstituted alkyl, alkenyl, haloalkyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl;",
"[0019] L is a linker selected from —(CR x R y ) n —, —O—(CR x R y ) n —, —C(O)—, —NR x —, —S(O) n NR x —, —NR x (CR x R y ) n — and —S(O) m NR x (CR x R y ) n ;",
"[0020] U is selected from substituted or unsubstituted aryl, substituted or unsubstituted five membered heterocycles selected from the group consisting of thiazole, isothiazole, oxazole, isoxazole, thiadiazole, oxadiazole, pyrazole, imidazole, furan, thiophene, pyrroles, 1,2,3-triazoles and 1,2,4-triazole;",
"and substituted or unsubstituted six membered heterocycles selected from the group consisting of pyrimidine, pyridine and pyridazine;",
"[0021] V is selected from hydrogen, cyano, nitro, —NR x R y , halogen, hydroxyl, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, haloalkyl, haloalkoxy, cycloalkylalkoxy, aryl, arylalkyl, biaryl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl, —C(O)OR x , —OR x , —C(O)NR x R y , —C(O)R x and —SO 2 NR x R y ;",
"or U and V together may form an optionally substituted 3 to 7 membered saturated or unsaturated cyclic ring, that may optionally include one or more heteroatoms selected from O, S and N;",
"[0022] at each occurrence, R x and R y are independently selected from the group consisting of hydrogen, hydroxyl, halogen, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl;",
"and [0023] at each occurrence ‘m’ and ‘n’ are independently selected from 0 to 2, both inclusive.",
"[0024] According to one embodiment, there is provided a compound of the formula (Ia): [0000] [0025] or a pharmaceutically acceptable salt thereof, [0026] wherein, [0027] R 1 and R 2 which may be same or different, are independently selected from hydrogen, hydroxyl, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, arylalkyl, (CR x R y ) n OR x , COR x , COOR x , CONR x R y , (CH 2 ) n NR x R y , (CH 2 ) n CHR x R y , (CH 2 )NR x R y and (CH 2 ) n NHCOR x ;",
"[0028] U is selected from substituted or unsubstituted aryl, substituted or unsubstituted five membered heterocycles selected from the group consisting of thiazole, isothiazole, oxazole, isoxazole, thiadiazole, oxadiazole, pyrazole, imidazole, furan, thiophene, pyrroles, 1,2,3-triazoles and 1,2,4-triazole;",
"and substituted or unsubstituted six membered heterocycles selected from the group consisting of pyrimidine, pyridine and pyridazine;",
"[0029] V is selected from hydrogen, cyano, nitro, —NR x R y , halogen, hydroxyl, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, haloalkyl, haloalkoxy, cycloalkylalkoxy, aryl, arylalkyl, biaryl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl, —C(O)OR x , —OR x , —C(O)NR x R y , —C(O)R x and —SO 2 NR x R y ;",
"or U and V together may form an optionally substituted 3 to 7 membered saturated or unsaturated cyclic ring, which may optionally include one or more heteroatoms selected from O, S and N;",
"[0030] at each occurrence, R a and R b which may be same or different, are independently selected from hydrogen, hydroxyl, cyano, halogen, substituted or unsubstituted alkyl, haloalkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, —(CR x R y ) n OR x , —COR x , —COOR x , —CONR x R y , —S(O) m NR x R y , —NR x R y , —NR x (CR x R y ) n OR x , —(CH 2 ) n NR x R y , —(CH 2 ) n CHR x R y , —(CH 2 )NR x R y , —NR x (CR x R y ) n CONR x R y , —(CH 2 ) n NHCOR x , —(CH 2 ) n NH(CH 2 ) n SO 2 R x and (CH 2 ) n NHSO 2 R x ;",
"[0031] at each occurrence, R x and R y are independently selected from hydrogen, hydroxyl, halogen, substituted or unsubstituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclic ring and heterocyclylalkyl;",
"[0032] at each occurrence ‘m’ and ‘n’ are independently selected from 0 to 2, both inclusive.",
"[0033] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.",
"[0034] According to another embodiment, specifically provided are compounds of the formula (Ia) in which R a is hydrogen, halogen (for example bromine), alkyl (for example methyl) or alkylaminoalkyl (for example dimethylaminomethyl or diethylaminomethyl).",
"[0035] According to one embodiment, specifically provided are compounds of the formula (Ia) in which R b is hydrogen or alkyl for example methyl.",
"[0036] According to yet another embodiment, specifically provided are compounds of the formula (Ia) in which R 1 and R 2 are independently hydrogen or alkyl for example methyl.",
"[0037] According to yet another embodiment, specifically provided are compounds of the formula (Ia) in which U is substituted or unsubstituted heterocycle, preferably thiazole or isoxazole.",
"[0038] According to yet another embodiment, specifically provided are compounds of the formula (Ia) in which V is substituted or unsubstituted aryl, preferably phenyl.",
"In this embodiment the substitutents on phenyl may be one or more are independently selected from halogen (for example F, Cl or Br), haloalkyl (for example CF 3 ), alkoxy (for example methoxy, ethoxy, OCH 2 CH(CH 3 ) 2 , OCH 2 C(CH 3 ) 3 or OCH 2 CH 2 CH(CH 3 ) 2 ), haloalkoxy (for example OCHF 2 , OCF 3 , OCH 2 CF 3 , OCH 2 CH 2 CF 3 or OCH 2 CH 2 CF 2 CF 3 ), cycloalkylalkoxy (for example cyclopropylmethoxy, cyclobutylmethoxy or cyclopentylmethoxy) and, substituted or unsubstituted arylalkoxy (for example trifluoromethylbenzyloxy).",
"[0039] According to one embodiment, there is provided a compound of the formula (Ib): [0000] [0040] or a pharmaceutically acceptable salt thereof, wherein, [0041] U, V, R 1 , R 2 , R a and R b are as defined herein above.",
"[0042] According to one embodiment, there is provided a compound of the formula (Ic): [0000] [0043] or a pharmaceutically acceptable salt thereof, wherein, [0044] U, V, R 1 , R 2 , R a and R b are as defined herein above.",
"[0045] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.",
"[0046] According to another embodiment, specifically provided are compounds of the formula (Ic) in which R a is hydrogen or alkyl (for example methyl).",
"[0047] According to one embodiment, specifically provided are compounds of the formula (Ic) in which R b is hydrogen.",
"[0048] According to yet another embodiment, specifically provided are compounds of the formula (Ic) in which R 1 and R 2 are independently hydrogen or alkyl (for example methyl).",
"[0049] According to yet another embodiment, specifically provided are compounds of the formula (Ic) in which U is substituted or unsubstituted heterocycle, preferably thiazole.",
"[0050] According to yet another embodiment, specifically provided are compounds of the formula (Ic) in which V is substituted or unsubstituted aryl, preferably phenyl.",
"In this embodiment the substitutents on phenyl may be one or more and are independently selected from halogen (for example F, Cl or Br), haloalkyl (for example CF 3 ), alkoxy (for example OCH 2 C(CH 3 ) 3 or haloalkoxy (for example OCH 2 CF 3 ).",
"[0051] According to one embodiment, there is provided a compound of the formula (Id): [0000] or a pharmaceutically acceptable salt thereof, wherein, [0053] R 1 , R 2 , R b , U and V are as defined herein above;",
"[0054] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.",
"[0055] According to one embodiment, specifically provided are compounds of the formula (Id) in which R 1 and R 2 are alkyl, preferably methyl.",
"[0056] According to another embodiment, specifically provided are compounds of the formula (Id) in which R b is hydrogen or (C 1 -C 4 ) alkyl, preferably methyl.",
"[0057] According to yet another embodiment, specifically provided are compounds of the formula (Id) in which ‘U’ is substituted or unsubstituted five membered heterocycle, preferably thiazole or isoxazole.",
"[0058] According to yet another embodiment, specifically provided are compounds of the formula (Id) in which ‘V’ is substituted or unsubstituted aryl, preferably phenyl.",
"In this embodiment the substituents on phenyl may be one or more and are independently selected from halogen (for example F, Cl or Br), cyano, alkyl (for example t-butyl or iso-butyl), haloalkyl (for example CF 3 ) and haloalkoxy (for example OCHF 2 , OCF 3 or OCH 2 CF 3 ).",
"[0059] According to yet another embodiment, specifically provided are compounds of the formula (Id) in which U and V together form an optionally substituted fused ring system which may optionally include one or more heteroatoms selected from O, S and N. In this embodiment the fused ring system is benzothiazole and the optional substituent is haloalkoxy (for example OCF 3 ).",
"[0060] According to one embodiment, there is provided a compound of the formula (Ie): [0000] [0061] or a pharmaceutically acceptable salt thereof, wherein, [0062] R 1 , R 2 , R a , U and V are as defined herein above;",
"[0063] According to one embodiment, there is provided a compound of the formula (If): [0000] [0064] or a pharmaceutically acceptable salt thereof, wherein, [0065] R 1 , R 2 , R a , U and V are as defined herein above;",
"[0066] The embodiments below are illustrative of the present invention and are not intended to limit the claims to the specific embodiments exemplified.",
"[0067] According to one embodiment, specifically provided are compounds of the formula (If) in which R 1 and R 2 are methyl.",
"[0068] According to another embodiment, specifically provided are compounds of the formula (If) in which R a is hydrogen or (C 1 -C 4 ) alkyl.",
"[0069] According to yet another embodiment, specifically provided are compounds of the formula (If) in which ‘U’ is substituted or unsubstituted five membered heterocycle, preferably thiazole or oxazole.",
"[0070] According to yet another embodiment, specifically provided are compounds of the formula (If) in which ‘V’ is substituted or unsubstituted aryl, preferably phenyl.",
"In this embodiment one or more substituents on phenyl may be same or different and are independently selected from halogen (for example F, Cl or Br), cyano, alkyl, haloalkyl (for example CF 3 ), alkoxy [for example OCH 2 CH(CH 3 ) 2 , OCH 2 CH 2 CH(CH 3 ) 2 or OCH 2 C(CH 3 ) 3 ], cycloalkylalkoxy (for example cyclobutylmethoxy) and haloalkoxy (for example OCHF 2 , OCF 3 , OCH 2 CF 3 or OCH 2 CH 2 CF 3 ).",
"[0071] Particularly contemplated are compounds of the formulas (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) which possess IC 50 of less than 250 nM, preferably, less than 100 nM, more preferably, less than 50 nM with respect to TRPA1 activity as measured by method as described in the present patent application.",
"[0072] It should be understood that the compounds of the formulas (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) structurally encompasses all stereoisomers, enantiomers and diastereomers and pharmaceutically acceptable salts that may be contemplated from the chemical structure of the genera described herein.",
"[0073] In accordance with another aspect, the present patent application provides a pharmaceutical composition that includes at least one compound described herein and at least one pharmaceutically acceptable excipient (such as a pharmaceutically acceptable carrier or diluent).",
"Preferably, the pharmaceutical composition comprises a therapeutically effective amount of at least one compound described herein.",
"The compounds described in the present patent application may be associated with a pharmaceutically acceptable excipient (such as a carrier or a diluent) or be diluted by a carrier, or enclosed within a carrier which can be in the form of a capsule, sachet, paper or other container.",
"[0074] The compounds and pharmaceutical compositions described herein are useful for modulating TRPA1 receptors, wherein modulation is believed to be related to a variety of disease states.",
"[0075] In accordance with another aspect, the present patent application further provides a method of inhibiting TRPA1 receptors in a subject in need thereof by administering to the subject one or more compounds described herein in the amount effective to cause inhibition of such receptor.",
"DETAILED DESCRIPTION OF THE INVENTION [0076] The terms “halogen”",
"or “halo”",
"includes fluorine, chlorine, bromine or iodine.",
"[0077] The term “alkyl”",
"refers to a straight or branched hydrocarbon chain radical consisting solely of carbon and hydrogen atoms, containing no unsaturation, having from one to eight carbon atoms, and which is attached to the rest of the molecule by a single bond, e.g., methyl, ethyl, n-propyl, 1-methylethyl (isopropyl), n-butyl, n-pentyl and 1,1-dimethylethyl (tert-butyl).",
"The term “C 1-6 alkyl”",
"refers to an alkyl chain having 1 to 6 carbon atoms.",
"Unless set forth or recited to the contrary, all alkyl groups described herein may be straight chain or branched, substituted or unsubstituted [0078] The term “alkenyl”",
"refers to an aliphatic hydrocarbon group containing a carbon-carbon double bond and which may be a straight or branched chain having 2 to about 10 carbon atoms, e.g., ethenyl, 1-propenyl, 2-propenyl (allyl), iso-propenyl, 2-methyl-1-propenyl, 1-butenyl and 2-butenyl.",
"Unless set forth or recited to the contrary, all alkenyl groups described herein may be straight chain or branched, substituted or unsubstituted.",
"[0079] The term “alkynyl”",
"refers to a straight or branched chain hydrocarbyl radical having at least one carbon-carbon triple bond and having 2 to about 12 carbon atoms (with radicals having 2 to about 10 carbon atoms being preferred) e.g., ethynyl, propynyl and butynyl.",
"Unless set forth or recited to the contrary, all alkynyl groups described herein may be straight chain or branched, substituted or unsubstituted.",
"[0080] The term “alkoxy”",
"refers to a straight or branched, saturated aliphatic hydrocarbon radical bonded to an oxygen atom that is attached to a core structure.",
"Examples of alkoxy groups include but are not limited to methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tert-butoxy, pentoxy, 3-methyl butoxy and the like.",
"Unless set forth or recited to the contrary, all alkoxy groups described herein may be straight chain or branched, substituted or unsubstituted.",
"[0081] The term “haloalkyl”",
"and “haloalkoxy”",
"means alkyl or alkoxy, as the case may be, substituted with one or more halogen atoms, where alkyl and alkoxy groups are as defined above.",
"The term “halo”",
"is used herein interchangeably with the term “halogen”",
"means F, Cl, Br or I. Examples of “haloalkyl”",
"include but are not limited to trifluoromethyl, difluoromethyl, 2,2,2-trifluoroethyl, pentafluoroethyl, pentachloroethyl 4,4,4-trifluorobutyl, 4,4-difluorocyclohexyl, chloromethyl, dichloromethyl, trichloromethyl, 1-bromoethyl and the like.",
"Examples of “haloalkoxy”",
"include but are not limited to fluoromethoxy, difluoromethoxy, trifluoromethoxy, 2,2,2-trifluoroethoxy, pentafluoroethoxy, pentachloroethoxy, chloromethoxy, dichloromethoxy, trichloromethoxy, 1-bromoethoxy and the like.",
"Unless set forth or recited to the contrary, all “haloalkyl”",
"and “haloalkoxy”",
"groups described herein may be straight chain or branched, substituted or unsubstituted.",
"[0082] The term “cycloalkyl”",
"denotes a non-aromatic mono or multicyclic ring system of 3 to about 12 carbon atoms, such as cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.",
"Examples of multicyclic cycloalkyl groups include, but are not limited to, perhydronapththyl, adamantyl and norbornyl groups, bridged cyclic groups or spirobicyclic groups, e.g., spiro(4,4) non-2-yl.",
"Unless set forth or recited to the contrary, all cycloalkyl groups described herein may be substituted or unsubstituted.",
"[0083] The term “cycloalkylalkyl”",
"refers to a cyclic ring-containing radical having 3 to about 8 carbon atoms directly attached to an alkyl group.",
"The cycloalkylalkyl group may be attached to the main structure at any carbon atom in the alkyl group that results in the creation of a stable structure.",
"Non-limiting examples of such groups include cyclopropylmethyl, cyclobutylethyl and cyclopentylethyl.",
"Unless set forth or recited to the contrary, all cycloalkylalkyl groups described herein may be substituted or unsubstituted.",
"[0084] The term “cycloalkylalkoxy”",
"is used to denote alkoxy substituted with cycloalkyl, wherein ‘alkoxy’ and ‘cycloalkyl’ are as defined above (either in the broadest aspect or a preferred aspect).",
"Examples of cycloalkylalkoxy groups include cyclopropylmethoxy, 1- or 2-cyclopropylethoxy, 1-, 2- or 3-cyclopropylpropoxy, 1-, 2-, 3- or 4-cyclopropyl-butoxy, cyclobutylmethoxy, 1- or 2-cyclobutylethoxy, 1-, 2- or 3-cyclobutylpropoxy, 1-, 2-, 3- or 4-cyclobutylbutoxy, cyclopentylmethoxy, 1- or 2-cyclopentylethoxy, 1-, 2- or 3-cyclopentylpropoxy, 1-, 2-, 3- or 4-cyclopentylbutoxy, cyclohexylmethoxy, 1- or 2-cyclohexylethoxy and 1-, 2- or 3-cyclohexylpropoxy.",
"Preferably, ‘cycloalkylalkoxy’ is (C 3-6 )cycloalkyl-(C 1-6 )alkoxy.",
"Unless set forth or recited to the contrary, all cycloalkylalkoxy groups described herein may be substituted or unsubstituted.",
"[0085] The term “cycloalkenyl”",
"refers to a cyclic ring-containing radical having 3 to about 8 carbon atoms with at least one carbon-carbon double bond, such as cyclopropenyl, cyclobutenyl and cyclopentenyl.",
"Unless set forth or recited to the contrary, all cycloalkenyl groups described herein may be substituted or unsubstituted.",
"[0086] The term “aryl”",
"means a carbocyclic aromatic system containing one, two or three rings wherein such rings may be fused.",
"If the rings are fused, one of the rings must be fully unsaturated and the fused ring(s) may be fully saturated, partially unsaturated or fully unsaturated.",
"The term “fused”",
"means that a second ring is present (ie, attached or formed) by having two adjacent atoms in common (i.e., shared) with the first ring.",
"The term “fused”",
"is equivalent to the term “condensed.”",
"The term “aryl”",
"embraces aromatic radicals such as phenyl, naphthyl, tetrahydronaphthyl, indane and biphenyl.",
"Unless set forth or recited to the contrary, all aryl groups described herein may be substituted or unsubstituted.",
"[0087] The term “arylalkyl”",
"refers to an aryl group as defined above directly bonded to an alkyl group as defined above, e.g., —CH 2 C 6 H 5 or —C 2 H 4 C 6 H 5 .",
"Unless set forth or recited to the contrary, all arylalkyl groups described herein may be substituted or unsubstituted.",
"[0088] The term “heterocyclic ring”",
"refers to a stable 3- to 15-membered ring radical which consists of carbon atoms and from one to five heteroatoms selected from nitrogen, phosphorus, oxygen and sulfur.",
"For purposes of this invention, the heterocyclic ring radical may be a monocyclic, bicyclic or tricyclic ring system, which may include fused, bridged or spiro ring systems and the nitrogen, phosphorus, carbon, oxygen or sulfur atoms in the heterocyclic ring radical may be optionally oxidized to various oxidation states.",
"In addition, the nitrogen atom may be optionally quaternized;",
"and the ring radical may be partially or fully saturated (i.e., heterocyclic or heteroaryl).",
"Examples of such heterocyclic ring radicals include, but are not limited to, azetidinyl, acridinyl, benzodioxolyl, benzodioxanyl, benzofuranyl, carbazolyl, cinnolinyl, dioxolanyl, indolizinyl, naphthyridinyl, perhydroazepinyl, phenazinyl, phenothiazinyl, phenoxazinyl, phthalazinyl, pyridyl, pteridinyl, purinyl, quinazolinyl, quinoxalinyl, quinolinyl, isoquinolinyl, tetrazolyl, imidazolyl, tetrahydroisoqinolyl, piperidinyl, piperazinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolidinyl, 2-oxoazepinyl, azepinyl, pyrrolyl, 4-piperidonyl, pyrrolidinyl, pyrazinyl, pyrimidinyl, pyridazinyl, oxazolyl, oxazolinyl, oxazolidinyl, triazolyl, indanyl, isoxazolyl, isoxazolidinyl, morpholinyl, thiazolyl, thiazolinyl, thiazolidinyl, isothiazolyl, quinuclidinyl, isothiazolidinyl, indolyl, isoindolyl, indolinyl, isoindolinyl, octahydroindolyl, octahydroisoindolyl, quinolyl, isoquinolyl, decahydroisoquinolyl, benzimidazolyl, thiadiazolyl, benzopyranyl, benzothiazolyl, benzooxazolyl, furyl, tetrahydrofuryl, tetrahydropyranyl, thienyl, benzothienyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiamorpholinyl sulfone, dioxaphospholanyl, oxadiazolyl, chromanyl and isochromanyl.",
"The heterocyclic ring radical may be attached to the main structure at any heteroatom or carbon atom that results in the creation of a stable structure.",
"Unless set forth or recited to the contrary, all heterocyclic ring described herein may be substituted or unsubstituted.",
"[0089] The term “heterocyclyl”",
"refers to a heterocyclic ring radical as defined above.",
"The heterocyclyl ring radical may be attached to the main structure at any heteroatom or carbon atom that results in the creation of a stable structure.",
"Unless set forth or recited to the contrary, all heterocyclyl groups described herein may be substituted or unsubstituted.",
"[0090] The term “heterocyclylalkyl”",
"refers to a heterocyclic ring radical directly bonded to an alkyl group.",
"The heterocyclylalkyl radical may be attached to the main structure at any carbon atom in the alkyl group that results in the creation of a stable structure.",
"Unless set forth or recited to the contrary, all heterocyclylalkyl groups described herein may be substituted or unsubstituted.",
"[0091] The term “heteroaryl”",
"refers to an aromatic heterocyclic ring radical.",
"The heteroaryl ring radical may be attached to the main structure at any heteroatom or carbon atom that results in the creation of a stable structure.",
"Unless set forth or recited to the contrary, all heteroaryl groups described herein may be substituted or unsubstituted.",
"[0092] The term “heteroarylalkyl”",
"refers to a heteroaryl ring radical directly bonded to an alkyl group.",
"The heteroarylalkyl radical may be attached to the main structure at any carbon atom in the alkyl group that results in the creation of a stable structure.",
"Unless set forth or recited to the contrary, all heteroarylalkyl groups described herein may be substituted or unsubstituted.",
"[0093] Unless otherwise specified, the term “substituted”",
"as used herein refers to substitution with any one or more or any combination of the following substituents: hydroxy, halogen, carboxyl, cyano, nitro, oxo (═O), thio (═S), substituted or unsubstituted alkyl, substituted or unsubstituted haloalkyl, substituted or unsubstituted alkoxy, substituted or unsubstituted haloalkoxy, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenylalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted amino, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted or unsubstituted heterocyclylalkyl ring, substituted or unsubstituted heteroarylalkyl, substituted or unsubstituted heterocyclic ring, substituted or unsubstituted guanidine, —COOR x′ , —C(O)R x′ , —C(S)R x′ , —C(O)NR x′ R y′ , —C(O)ONR x′ R y′ , —NR x′ CONR y′ R z′ , —N(R x′ )SOR y′ , —N(R x′ )SO 2 R y′ , —(═N—N(R x′ )R y′ ), —NR x′ C(O)OR y′ , —NR x′ R y′ , —NR x′ C(O)R y′ , —NR x′ C(S)R y′ , —NR x′ C(S)NR y′ R z′ , —SONR x′ R y′ , —SO 2 NR x′ R y′ , —OR x′ , —OR x′ C(O)NR y′ R z′ , —OR x′ C(O)OR y′ , —OC(O)R x′ , —OC(O)NR x′ R y′ , —R x′ NR y′ C(O)R z′ , —R x′ OR y′ , —R x′ C(O)OR y′ , —R x′ C(O)NR y′ R z′ , —R x′ C(O)R y′ , —R x′ OC(O)R y′ , —SR x′ , —SOR x′ , —SO 2 R x′ and —ONO 2 , wherein R x′ , R y′ and R z′ are independently selected from hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted alkoxy, substituted or unsubstituted alkenyl, substituted or unsubstituted alkynyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkenyl, substituted or unsubstituted amino, substituted or unsubstituted aryl, substituted or unsubstituted heteroaryl, substituted heterocyclylalkyl ring, substituted or unsubstituted heteroarylalkyl or substituted or unsubstituted heterocyclic ring.",
"[0094] The term “treating”",
"or “treatment”",
"of a state, disorder or condition includes;",
"(a) preventing or delaying the appearance of clinical symptoms of the state, disorder or condition developing in a subject that may be afflicted with or predisposed to the state, disorder or condition but does not yet experience or display clinical or subclinical symptoms of the state, disorder or condition;",
"(b) inhibiting the state, disorder or condition, i.e., arresting or reducing the development of the disease or at least one clinical or subclinical symptom thereof;",
"or (c) relieving the disease, i.e., causing regression of the state, disorder or condition or at least one of its clinical or subclinical symptoms.",
"[0095] The term “subject”",
"includes mammals (especially humans) and other animals, such as domestic animals (e.g., household pets including cats and dogs) and non-domestic animals (such as wildlife).",
"[0096] A “therapeutically effective amount”",
"means the amount of a compound that, when administered to a subject for treating a state, disorder or condition, is sufficient to effect such treatment.",
"The “therapeutically effective amount”",
"will vary depending on the compound, the disease and its severity and the age, weight, physical condition and responsiveness of the subject to be treated.",
"[0097] The compounds described in the present patent application may form salts.",
"Non-limiting examples of pharmaceutically acceptable salts forming part of this patent application include salts derived from inorganic bases salts of organic bases, salts of chiral bases, salts of natural amino acids and salts of non-natural amino acids.",
"[0098] Certain compounds of the present invention, including compounds of formula (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) are capable of existing in stereoisomeric forms (e.g. diastereomers and enantiomers).",
"The present invention includes these stereoisomeric forms (including diastereomers and enantiomers) and mixtures of them.",
"The various stereoisomeric forms of the compounds of the present invention may be separated from one another by methods known in the art or a given isomer may be obtained by stereospecific or asymmetric synthesis.",
"Tautomeric forms and mixtures of compounds described herein are also contemplated.",
"Pharmaceutical Compositions [0099] The pharmaceutical composition of the present patent application includes at least one compound described herein and at least one pharmaceutically acceptable excipient (such as a pharmaceutically acceptable carrier or diluent).",
"Preferably, the pharmaceutical composition includes the compound(s) described herein in an amount sufficient to inhibit TRPA1 in a subject (e.g., a human).",
"The inhibitory activity of compounds falling within the formulas (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) may be measured by an assay provided below.",
"[0100] The compound of the present invention may be associated with a pharmaceutically acceptable excipient (such as a carrier or a diluent) or be diluted by a carrier, or enclosed within a carrier which can be in the form of a capsule, sachet, paper or other container.",
"[0101] The pharmaceutical compositions may be prepared by techniques known in the art.",
"For example, the active compound can be mixed with a carrier, or diluted by a carrier, or enclosed within a carrier, which may be in the form of an ampoule, capsule, sachet, paper, or other container.",
"When the carrier serves as a diluent, it may be a solid, semi-solid, or liquid material that acts as a vehicle, excipient, or medium for the active compound.",
"The active compound can be adsorbed on a granular solid container, for example, in a sachet.",
"[0102] The pharmaceutical compositions may be in conventional forms, for example, capsules, tablets, aerosols, solutions, suspensions or products for topical application.",
"Methods of Treatment [0103] The compounds and pharmaceutical compositions of the present invention can be administered to treat any disorder, condition, or disease treatable by inhibition of TRPA1.",
"For instance, the compounds and pharmaceutical compositions of the present invention are suitable for treatment or prophylaxis of the following diseases, conditions and disorders mediated or associated with the activity of TRPA1 receptors: pain, chronic pain, complex regional pain syndrome, neuropathic pain, postoperative pain, rheumatoid arthritic pain, osteoarthritic pain, back pain, visceral pain, cancer pain, algesia, neuralgia, migraine, neuropathies, diabetic neuropathy, sciatica, HIV-related neuropathy, post-herpetic neuralgia, fibromyalgia, nerve injury, ischaemia, neurodegeneration, stroke, post stroke pain, multiple sclerosis, respiratory diseases, asthma, cough, COPD, inflammatory disorders, oesophagitis, gastroeosophagal reflux disorder (GERD), irritable bowel syndrome, inflammatory bowel disease, pelvic hypersensitivity, urinary incontinence, cystitis, burns, psoriasis, eczema, emesis, stomach duodenal ulcer and pruritus.",
"The connection between therapeutic effect and inhibition of TRPA1 is illustrated, for example, in Story G M et al, Cell, 2003, 112, 819-829;",
"McMahon S B and Wood J N, Cell, 2006, 124, 1123-1125;",
"Voorhoeve P M et al.",
", Cell, 2006, 124, 1169-1181;",
"Wissenbach U, Niemeyer B A and Flockerzi V, Biology of the Cell, 2004, 96, 47-54;",
"Dayne Y O, Albert Y H &",
"Michael X, Expert Opinion on Therapeutic Targets, 2007, 11(3), 391-401 and the references cited therein.",
"[0104] Pain can be acute or chronic.",
"While acute pain is usually self-limiting, chronic pain persists for 3 months or longer and can lead to significant changes in a patient's personality;",
"lifestyle, functional ability and overall quality of life (K.",
"M. Foley, Pain , in Cecil Textbook of Medicine;",
"J. C. Bennett &",
"F. Plum (eds.), 20th ed.",
", 1996, 100-107).",
"The sensation of pain can be triggered by any number of physical or chemical stimuli and the sensory neurons which mediate the response to this harmful stimulus are termed as “nociceptors.”",
"Nociceptors are primary sensory afferent (C and Aδ fibers) neurons that are activated by a wide variety of noxious stimuli including chemical, mechanical, thermal and proton (pH<6) modalities.",
"Nociceptors are the nerves which sense and respond to parts of the body which suffer from damage.",
"They signal tissue irritation, impending injury, or actual injury.",
"When activated, they transmit pain signals (via the peripheral nerves as well as the spinal cord) to the brain.",
"[0105] Chronic pain can be classified as either nociceptive or neuropathic.",
"Nociceptive pain includes tissue injury-induced pain and inflammatory pain such as that associated with arthritis.",
"Neuropathic pain is caused by damage to the sensory nerves of the peripheral or central nervous system and is maintained by aberrant somatosensory processing.",
"The pain is typically well localized, constant and often with an aching or throbbing quality.",
"Visceral pain is the subtype of nociceptive pain that involves the internal organs.",
"It tends to be episodic and poorly localized.",
"Nociceptive pain is usually time limited, meaning when the tissue damage heals, the pain typically resolves (arthritis is a notable exception in that it is not time limited).",
"General Methods of Preparation [0106] The compounds described herein, including compounds of general formula (I), (Ia), (Ib), (Ic), (Id), (Ie) and (If) and specific examples, can be prepared by techniques known to one in the art, for example, through the reaction scheme depicted in Schemes 1-12.",
"Furthermore, in the following schemes, where specific acids, bases, reagents, coupling agents, solvents etc.",
"are mentioned, it is understood that other suitable acids, bases, reagents, coupling agents etc.",
"may be used and are included within the scope of the present invention.",
"Modifications to reaction conditions, for example, temperature, duration of the reaction or combinations thereof are envisioned as part of the present invention.",
"The compounds obtained by using the general reaction scheme may be of insufficient purity.",
"These compounds can be purified by any of the methods for purification of organic compounds known in the art, for example, crystallization or silica gel or alumina column chromatography using different solvents in suitable ratios.",
"All possible stereo isomers are envisioned within the scope of this invention.",
"[0107] An approach for the synthesis of 2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide of the general formula (Ia-1) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 1.",
"The starting substituted uracil derivative of formula (1), wherein R 1 and R 2 are alkyl (e.g., methyl, ethyl) are available commercially or can be prepared by reaction of 1,3-dialkylurea and acetic anhydride or by condensation of monosubstituted urea and ethyl acetoacetate according to methods known in the art (Egg, H. et al.",
"Synthesis, 1982, 1071-1073;",
"Senda S. et al.",
"Chem.",
"Pharm.",
"Bull.",
", 1972, 6, 404-408).",
"Nitro derivative of general formula (2) can be prepared by nitration of uracil derivative of formula (1) using mixture of sulphuric acid and fuming nitric acid followed by condensation with DMF-dimethyl acetal in a suitable solvent (e.g., DMF, THF).",
"Reductive cyclization of compound of formula (2) using 10% Pd—C under hydrogen atmosphere in suitable solvent (e.g., EtOH, MeOH) affords compound of general formula (3).",
"Alkylation of compound of formula (3) using appropriate electrophile of a general formula (4) [prepared from haloacetyl halide and appropriate substituted amine as described in Ohkubo M. et al.",
", Chem.",
"Pharm.",
"Bull.",
", 1995, 43(9), 1497-1504] in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compound of general formula (Ia-1).",
"[0000] [0108] An approach for the synthesis of compounds of the general formula (Ia-2) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 2.",
"Compounds of general formula (3) is converted to a compound of formula (6) by using suitable amine of formula (5) [wherein R and R′ are alkyl (e.g., methyl, ethyl)] and formaldehyde as described by Tsupak, E. B. et al.",
"in Chemistry of Heterocyclic Compounds, 1994, 30(9), 1077-1082.",
"Alternatively, the intermediate (6) can be prepared by formylation of compound of formula (3) using mixture of phosphorous oxychloride and dimethyl formamide to give compound of formula (7) followed by reductive amination of the formyl group using a suitable amine of formula (5).",
"Alkylation of compound of formula (6) using appropriate electrophile of a general formula (4) in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compounds of general formula (Ia-2).",
"[0000] [0109] An approach for the synthesis of compounds of the general formula (Ia-3) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 2.",
"Deoxygenation of formyl pyrrole of formula (7) with suitable reducing system (e.g., triethylsilane/trifluoroacetic acid) affords methylpyrrole of formula (8).",
"Alkylation of compound of formula (8) using appropriate electrophile of a general formula (4) in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compounds of the general formula (Ia-3).",
"[0110] An approach for the synthesis of compounds of the general formula (Ia-4) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 3.",
"Halogenation of compound of formula (3) with suitable halogenating agent (e.g., N-bromosuccinimide, N-iodosuccinimide, bromine) gives corresponding halogenated compound of formula (9).",
"Alkylation of compound of formula (9) using appropriate electrophile of a general formula (4) in the presence of a suitable base (e.g., NaH, K 2 CO 3 ) affords compounds of general formula (Ia-4).",
"[0000] [0111] An approach for the synthesis of compounds of the general formula (Ia-5) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 4.",
"1,3,6-trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione of the formula (12) can be prepared by the reaction of 5-amino-1,3-dimethyluracil of the formula (10) with propargyl bromide in a suitable solvent such as MeOH followed by cyclization of the intermediate (11) at elevated temperature as described in Townsend, L. B. et al.",
", J. Heterocyclic Chem.",
", 1975, 12, 711-716 and Kawahara, N. et al.",
", Chem.",
"Pharm.",
"Bull.",
", 1985, 33(11), 4740-4748.",
"Alkylation of compound of formula (12) with an appropriate electrophile of a general formula (4) affords compounds of general formula (Ia-5).",
"[0000] [0112] A general approach for the synthesis of 2,4-dioxo-2,3,4,6-tetrahydro-1H-pyrrolo[3,4-d]pyrimidin-5-yl)acetamide of the general formula (Ib-1) where R 1 , R 2 , R b , U and V are as defined herein above is depicted in Scheme 5.",
"The formyl derivative of formula (13) can be prepared by formylation of uracil derivative of formula (1) [Senda, S. et al.",
", Yakugaku Zasshi, 1971, 91, 1372] followed by bromination of formyl derivative thus formed.",
"Cyclization of formyl derivative of formula (13) [as described in Senda, S. et al.",
", Synthesis, 1978, 463-465] with amine of the formula (19) in suitable solvent (e.g., EtOAc) followed by halogenation using suitable halogenating reagent (e.g., N-bromosuccinimide, N-iodosuccinimide, Br 2 in acetic acid) gives halopyrrole of general formula (14).",
"Halopyrrole of formula (14) on reaction with allyl boronic acid pinacol ester of the formula (15) in the presence of a palladium catalyst, such as bis(triphenylphosphine)palladium dichloride or tetrakis(triphenylphosphine) palladium(0) gives allyl pyrrole of the formula (16) [procedure is similar to the Suzuki-Miyaura Coupling described by Kotha, et al.",
", Synlett, 2005, 12, 1877-1890].",
"Transformation of allyl pyrrole of formula (16) into corresponding aldehyde can be accomplished by methods known in the art [e.g., Postema, M. H. D. et al.",
", in J. Org.",
"Chem.",
", 2003, 68, 4748-4754].",
"Further oxidation of aldehyde thus formed can be carried out by oxidation methods well known in the literature to give corresponding carboxylic acid of general formula (17).",
"Coupling of carboxylic acid (17) with appropriate amines of formula (18) using a standard amide coupling method gives compounds of general formula (Ib-1).",
"[0000] [0113] A general approach for the synthesis of 2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide of the general formula (Ic-1) where R a is an alkyl group, R 1 , R 2 , U and V are as defined above is depicted in Scheme 6.",
"Reaction of 6-chlorouracil derivative of the formula (20) with amino ester of formula (21) followed by cyclization gives pyrrolidinone of formula (22) [Similar procedure described by Edstrom, E. D. et al.",
", J. Org.",
"Chem.",
", 1995, 60, 5069-5076].",
"Pyrrolidinone of formula (22) can be converted to halopyrrole of formula (23) (wherein X is halogen) using triflic anhydride or hydrazine followed by iodine.",
"Halopyrrole of formula (23) on reaction with allyl boronic acid pinacol ester of the formula (15) in the presence of a palladium catalyst, such as bis(triphenylphosphine)palladium dichloride or tetrakis(triphenylphosphine) palladium(0) gives allyl pyrrole of the formula (24).",
"Transformation of allyl pyrrole of formula (24) to the corresponding aldehyde followed by further oxidation of aldehyde thus formed can be carried out by oxidation methods well known in the literature to give corresponding carboxylic acid of general formula (25).",
"Coupling of carboxylic acid of formula (25) with appropriate amines of formula (18) by using a standard amide coupling method gives compounds of general formula (Ic-1).",
"[0000] [0114] An alternative approach for the synthesis of compounds of the general formula (Ic-1) is described in Scheme 7.",
"Reaction of commercially available 6-aminouracil derivative of the formula (26) with chloroacetaldehyde dimethyl acetal gives pyrrole derivative (as described by Noell, C. W. et al.",
", J. Het.",
"Chem.",
", 1964, 34-41) which upon alkylation with appropriate alkylating agent (R a X) gives compound of formula (27).",
"Compound of formula (27) can be converted into α-keto ester of general formula (28) using oxalyl chloride followed by reaction of acid chloride thus formed with anhydrous protic solvent (e.g., methanol, ethanol, tert-butanol).",
"Deoxygenation of α-keto ester of general formula (28) with triethylsilane in the presence of trifluoroacetic acid affords ester of general formula (29) [similar procedure described by Han, Q. et al.",
", J. Med.",
"Chem.",
", 2000, 43, 4398-4415].",
"Acidic hydrolysis of ester of formula (29) gives corresponding carboxylic acid of formula (25).",
"Coupling of carboxylic acid of formula (25) with appropriate amines of formula (18) by using a standard amide coupling method give compounds of general formula (Ic-1).",
"[0000] [0115] An approach for the synthesis of compounds of the general formula (Id-1) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 8.",
"The synthesis starts from known 6-hydrazino-1,3-dimethyluracil (30) which is readily prepared by the displacement of halogen of 6-chloro-1,3-dialkyuracil of the formula (20) with hydrazine hydrate according to the known procedure.",
"The cyclisation of compound of the formula (30) with acetic anhydride gave pyrazole of the formula (31).",
"The deacetylation followed by selective N-alkylation of pyrazole (31) with dimethyl sulfate afforded compounds of the formula (33) (Pfleiderer, W. et al.",
", Justus Liebigs Ann Chem.",
"1958, 615, 42-47).",
"The reaction of compound of formula (33) with dimethyl carbonate in presence of a strong base (e.g. NaH) under reflux conditions gives ester of the formula (34).",
"Hydrolysis of ester (34) with aqueous acid afforded the desired pyrazolo[3,4-d]pyrimidinedione acetic acid of the formula (35).",
"The coupling of compound of formula (35) with respective amines of formula (18) by using a standard amide coupling method gives compounds of general formula (Id-1).",
"[0000] [0116] An approach for the synthesis of compounds of the general formula (Ie) where R 1 , R 2 , U and V are as defined herein above is also depicted in Scheme 9.",
"Synthesis starts from readily available 1,3-dialkylbarbituric acid of the formula (36).",
"The known 6-chloro-5-formyl-1,3-dimethyluracil of formula (37) wherein R 1 and R 2 are methyl is prepared according to a reported procedure (Singh, J. S. et al.",
", Synthesis, 1988, 342-344).",
"The reaction of 6-chloro-5-formyl-1,3-dimethyluracil (37) with hydroxylamine in methanol followed by dehydration with phosphorous oxychloride give 6-chloro-5-cyano-1,3-dimethyluracil of formula (38).",
"The cyclisation of compounds of the formula (38) with alkylhydrazine of the formula (39) in the presence of suitable base afforded amino pyrazole of the formula (40).",
"The amino pyrazole (40) on diazotization followed by halide substitution with copper halide (such as copper bromide or copper iodide) gives a halide derivative of the formula (41) (wherein X is halogen).",
"Suzuki-Miyaura coupling reaction of aryl halide of formula (41) with allyl boronic acid pinacol ester of the formula (15) as described by Kotha et al.",
", Synlett, 2005, 12, 1877-1890) gives allyl pyrazole of the formula (42).",
"This can be converted to pyrazolo[3,4-d]pyrimidinylacetic acid of the formula (43) by oxidative cleavage methods well known in the literature.",
"The coupling of carboxylic acid of the formula (43) with respective amines of formula (18) by using a standard amide coupling method can give compounds of general formula (Ie).",
"[0000] [0117] An approach for the synthesis of compounds of the general formula (If-1) where R 1 , R 2 , U and V are as defined herein above is depicted in Scheme 10.",
"The approach described is similar to that described by Papesch, P. et al.",
", J. Org.",
"Chem.",
", 1965, 30, 199-203.",
"Compound of the formula (44) was prepared by nitration of pyrimidine-2,4(1H,3H)-dione of the formula (1) followed by reduction (Egg, H. et al.",
", Synthesis, 1982, 12, 1071-1073).",
"The compound of the formula (44) was transformed into the compound of the formula (45) by diazotization followed by in situ cyclisation with base (eg.",
"NaOH).",
"The compound of the formula (45) on alkylation with suitable 2-halo-acetamide of general formula (4) in the presence of a suitable base (e.g. Cs 2 CO 3 , NaH etc.) and a suitable solvent (e.g. DMF, THF, DMSO etc.) gives compound of general formula (If-1).",
"[0000] [0118] The 2-haloacetamides of formula (53) (wherein R z is selected from alkyl, cyano, halogen, haloalkyl, alkoxy, haloalkoxy, cycloalkylalkoxy and arylalkoxy, and ‘p’ is selected from 0 to 5) required for the synthesis of compound of the present invention can be prepared according to methods known to one skilled in the art (Carroll, L. et al.",
", J. Am.",
"Chem.",
"Soc.",
", 1950, 72, 3722-3725;",
"Ohkubo, M. et al.",
", Chem.",
"Pharm.",
"Bull.",
", 1995, 43(9), 1497-1504).",
"Thus, acylation of an aryl, heteroaryl or aryl alkyl amine with bromoacetyl bromide in the presence of a suitable base such as triethylamine or pyridine gives N-substituted bromoacetamide of the general formula (53) (Scheme 11).",
"[0119] A few of aniline derivatives, arylalkylamines and 2-amino-4-arylthiazoles (52) were commercially available.",
"Many of the disubstituted and trisubstituted arylaminothiazoles were prepared from appropriate aryl alkyl ketones.",
"Commercially unavailable aryl alkyl ketones were prepared from the corresponding benzoic acids as shown in Scheme 11.",
"Substituted benzoic acid of the formula (46) was converted to the corresponding acetophenone in three steps as shown in Scheme 11.",
"Thus, acid (46) was converted to the corresponding acid chloride (47) using oxalyl chloride in the presence of catalytic amounts of DMF in dry dichloromethane.",
"Alternatively, this transformation can be carried out using excess thionyl chloride.",
"The acid chloride (47) was converted to corresponding Weinreb amide (48) by treating with N,O-dimethyl hydroxylamine hydrochloride in the presence of a suitable base such as triethylamine.",
"Addition of methyl magnesium iodide to Weinreb amide (48) gives acetophenone derivative of the formula (49).",
"In addition, commercially unavailable aryl alkyl ketones were prepared from mono or di-substituted phenol (50) as depicted in Scheme 11.",
"Thus, acetylation of phenol (50) with acetic anhydride followed by Fries rearrangement of the ester formed in the presence of Lewis acid (e.g. AlCl 3 ) affords corresponding hydroxyacetophenone of general formula (51).",
"Alkylation of hydroxyacetophenone of general formula (51) with suitable alkyl halide in suitable base (e.g., NaH, Cs 2 CO 3 ) and suitable solvent (e.g., DMSO, THF, DMF) gives acetophenone derivative of general formula (49).",
"[0120] The aryl alkyl ketone of the formula (49) is converted to 2-aminothiazole of the formula (52) in one step by its reaction with thiourea in the presence of iodine in ethanol.",
"This conversion is similar to the one described by Carroll, K. et al.",
", J. Am.",
"Chem.",
"Soc.",
"1950, 3722;",
"and Naik, S., J.;",
"Halkar, U. P., ARKIVOC, 2005, xiii, 141-149.",
"Alternatively, 2-aminothiazoles of the formula (52) can be prepared by the reaction of compounds of formula (49) with bromine in acetic acid to give the alpha halo intermediate, which on reaction with thiourea in THF at reflux condition give compounds of the formula (52).",
"The compound of the formula (52) is converted to 2-bromo-N-thiazolyl acetamide of the formula (53) by acylation with bromoacetyl bromide in the presence of a suitable base (e.g., pyridine or triethylamine) and in a suitable solvent (e.g., THF, DMF).",
"[0000] [0121] 5-Aryl-1H-imidazol-2-amines of the formula (55) were prepared as shown in Scheme 12.",
"The reaction of acetophenones of the formula (49) (wherein R z and ‘p’ are as defined above in scheme 11) with bromine in acetic acid to give the alpha bromo intermediate, which on reaction with acetyl guanidine in acetonitrile at reflux condition give compounds of the formula (54).",
"The deacetylation of (54) in the presence of catalytic amount of concentrated sulphuric acid using suitable solvent afforded desired 5-Aryl-1H-imidazol-2-amine of the formula (55).",
"(This is similar to procedure reported by Thomas, L. et al.",
", J. Org.",
"Chem.",
", 1994, 59, 7299-7305).",
"[0000] [0122] The intermediates and examples described in the present invention are prepared using the procedure described below.",
"However, it is understood that these intermediates and examples can be prepared by alternate approaches which are within the scope of the present invention.",
"EXPERIMENTAL [0123] Unless otherwise stated, work-up includes distribution of the reaction mixture between the organic and aqueous phase indicated within parentheses, separation of layers and drying the organic layer over sodium sulphate, filtration and evaporation of the solvent.",
"Purification, unless otherwise mentioned, includes purification by silica gel chromatographic techniques, generally using ethyl acetate/petroleum ether mixture of a suitable polarity as the mobile phase.",
"Use of a different eluent system is indicated within parentheses.",
"The following abbreviations are used in the text: DMSO-d 6 : Hexadeuterodimethyl sulfoxide;",
"DMF: N,N-dimethylformamide, M.P.: Melting point;",
"J: Coupling constant in units of Hz;",
"RT or rt: room temperature (22-26° C.).",
"Aq.",
": aqueous AcOEt: ethyl acetate;",
"equiv.",
"or eq.",
": equivalents.",
"Intermediate 1 1,3-Dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione [0124] [0125] Step 1 1,3,6-Trimethyl-5-nitrouracil: A mixture of concentrated H 2 SO 4 (7.0 mL) and fuming HNO 3 (7.0 mL) was cooled to 0-5° C. and 1,3,6-trimethylpyrimidine-2,4(1H,3H)-dione (3.5 g, 22.702 mmol) was gradually added to the reaction mixture.",
"After stirring for 2 h. at the same temperature the reaction mixture was partitioned between ethyl acetate (200 mL) and water (100 mL).",
"The organic layer was washed with brine (2×50 mL), dried (Na 2 SO 4 ) and evaporated under reduced pressure.",
"Crude product obtained was purified by column chromatography to give 1.30 g of the product as yellow solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.38 (s, 3H), 3.20 (s, 3H), 3.40 (s, 3H);",
"APCI-MS (m/z) 198.30 (M−H).",
"[0126] Step 2 1,3-Dimethyl-6-[2-(dimethylamino)vinyl]-5-nitrouracil: To a solution of Step 1 intermediate, 1,3,6-Trimethyl-5-nitrouracil (0.60 g, 3.012 mmol) in dry N,N-dimethylformamide (5.0 mL) was added N,N-dimethylformamide dimethyl acetal (0.53 g, 4.447 mmol) and the reaction mixture was stirred at room temperature for 2 h. After this time, diethyl ether was added to the reaction mixture and the precipitate was collected by filtration and washed with diethyl ether to give 0.45 g of the product as brownish solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.98 (s, 6H), 3.16 (s, 3H), 3.40 (s, 3H), 4.78 (d, J=12.6 Hz, 1H), 7.05 (d, J=12.6 Hz, 1H);",
"APCI-MS (m/z) 255.11 (M+H) + .",
"[0127] Step 3 1,3-Dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: To a solution of Step 2 intermediate (0.40 g, 1.573 mmol) in MeOH (80 mL) was added 10% Pd—C (0.2 g) and the mixture was stirred under a hydrogen atmosphere at room temperature for 2 h. The mixture was filtered through a celite bed and was thoroughly washed with MeOH (50 mL).",
"The filtrate was collected and evaporated and the residue thus obtained was purified by column chromatography to afford 0.120 g of the desired compound as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.23 (s, 3H), 3.38 (s, 3H), 6.17 (s, 1H), 7.25 (s, 1H), 12.09 (s, 1H);",
"APCI-MS (m/z) 180.28 (M+H) + .",
"Intermediate 2 1,3,6-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione [0128] [0129] Step 1 5-Amino-1,3-dimethylpyrimidine-2,4(1H,3H)-dione: To a stirred solution of 1,3-dimethyl-5-nitropyrimidine-2,4(1H,3H)-dione (2.0 g, 10.802 mmol) in methanol (200 mL), 10% Pd—C (0.500 g) was added under hydrogen atmosphere and the reaction mixture was stirred at room temperature for 2 h. Reaction mixture was filtered through a celite bed and washed with methanol.",
"The filtrate was collected and concentrated under reduced pressure to give 1.5 g of the product.",
"[0130] Step 2 1,3-Dimethyl-5-(prop-2-yn-1-ylamino)pyrimidine-2,4(1H,3H)-dione: To a stirred solution of Step 1 intermediate (1.4 g, 9.023 mmol) in 1:1 mixture of dichloromethane and methanol (28 mL) was added propargyl bromide (1.4 mL) and the mixture was stirred at room temperature for 2 h. Reaction mixture was filtered through celite bed and washed with methanol.",
"The filtrate was concentrated under reduced pressure to give 500 mg of the product.",
"[0131] Step 3 1,3,6-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: A solution of Step 2 intermediate (500 mg, 2.587 mmol) in dry N,N-dimethylformamide (20 mL) was refluxed for 40 h under nitrogen atmosphere.",
"The excess of solvent was evaporated and the residue obtained was purified by silica gel column chromatography by using 5% methanol in chloroform to obtain 200 mg of the product as a yellow solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.26 (s, 3H), 3.21 (s, 3H), 3.33 (s, 3H), 5.91 (s, 1H), 11.84 (br s, 1H);",
"ESI-MS (m/z) 194.28 (M+H) + .",
"Intermediate 3 1,3,7-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione [0132] [0133] Step 1 1,3-Dimethyl-2,4-dioxo-2,3,4,5-tetrahydro-1H-pyrrolo[3,2-d]pyrimidine-7-carbaldehyde: At a temperature of 5-10° C., phosphorous oxychloride (1.84 ml, 20.087 mmol) was mixed with N,N-dimethylformamide (2 mL).",
"Then a solution of Intermediate 1 (600 mg, 3.348 mmol) in N,N-dimethylformamide (3 mL) was added while stirring.",
"The reaction mixture was held for 2 h at 95° C., cooled and poured onto ice (10 g).",
"The precipitate formed was filtered off and recrystallised from water to give 300 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.25 (s, 3H), 3.75 (s, 3H), 8.06 (s, 1H), 9.79 (s, 1H), 13.15 (br s, 1H);",
"APCI-MS (m/z) 208.20 (M+H) + .",
"[0134] Step 2 1,3,7-Trimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: To a stirred and cooled (−10° C.) solution of trifluoroacetic acid (5 mL) was added triethylsilane (294 mg, 2.528 mmol) followed by portionwise addition of Step 1 intermediate (150 mg, 0.723 mmol).",
"The reaction mixture was warmed to room temperature and stirred for another 1 h. Reaction mixture was diluted with ethyl acetate (25 mL) and water (25 mL).",
"Two layers were separated.",
"The aqueous layer was extracted with ethyl acetate (2×25 mL).",
"The combined organic layers were washed with water (25 mL), dried (Na 2 SO 4 ) and filtered.",
"The filtrate was evaporated to give 110 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.27 (s, 3H), 3.22 (s, 3H), 3.56 (s, 3H), 7.03 (s, 1H), 11.75 (br s, 1H);",
"APCI-MS (m/z) 194.28 (M+H) + .",
"Intermediate 4 7-Bromo-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione [0135] [0136] To a solution of Intermediate 1 (500 mg, 2.800 mmol) in acetic acid (5 mL) was added a solution of bromine (430 mg, 2.700 mmol) in acetic acid (5 mL) dropwise with stirring, after which water (1.2 mL) was added.",
"The reaction mixture was stirred for another 20 min and diluted with two volumes of cold water.",
"After 3 h, the precipitate was filtered off and washed with diethyl ether to afford 400 mg of the product as a white solid;",
"1 H NMR (6 ppm, 300 MHz, DMSO-d 6 ) 3.23 (s, 3H), 3.65 (s, 3H), 7.42 (s, 1H), 12.59 (br s, 1H);",
"APCI-MS (m/z) 258.19 (M+H) + .",
"Intermediate 5 7-[(Dimethylamino)methyl]-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione [0137] [0138] To a mixture of 50% dimethyl amine (0.4 mL), acetic acid (0.4 mL) and 38% formaldehyde (0.4 mL) were added, after which Intermediate 1 (0.4 g, 2.232 mmol) was added.",
"The reaction mixture was refluxed for 10 min and then held for 20 min at 90° C. Reaction mixture was cooled to room temperature and diluted with water (25 mL).",
"Two layers were separated.",
"The aqueous layer was extracted with ethyl acetate (2×25 mL).",
"The combined organic layers were washed with water (25 mL), dried (Na 2 SO 4 ) and filtered.",
"The filtrate was evaporated to give a crude product which was recrystallised from acetonitrile to give 97 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.08 (s, 6H), 3.23 (s, 3H), 3.30 (s, 2H), 3.69 (s, 3H), 7.13 (s, 1H), 11.93 (br s, 1H);",
"APCI-MS (m/z) 237.00 (M+H) + .",
"Intermediate 6 7-[(Diethylamino)methyl]-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione [0139] [0140] To a stirred solution of diethyl amine (52 mg, 0.723 mmol) in dichloromethane (5 mL) Intermediate 3, Step 1 (150 mg, 0.723 mmol) was added portionwise followed by the addition of sodium triacetoxyborohydried (230 mg, 1.085 mmol) at room temperature.",
"After stirring for 24 h, the excess of solvent was evaporated and the crude product obtained was purified by column chromatography by using 1% methanol in chloroform to afford 130 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 0.93 (t, J=7.2 Hz, 6H), 2.40-2.56 (m, 4H), 3.23 (s, 3H), 3.48 (s, 2H), 3.73 (s, 3H), 7.18 (s, 1H), 11.92 (br s, 1H);",
"APCI-MS (m/z) 265.00 (M+H) + .",
"Intermediate 7 (1,3,7-Trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetic acid [0141] [0142] Step 1 1,3-Dimethyl-1H-pyrrolo[2,3-d]pyrimidine-2,4(3H,7H)-dione: (374-ABK-023) To a stirred solution of chloroacetaldehyde dimethyl acetal (26.0 g, 208.717 mmol) in water (60 mL) concentrated hydrochloric acid (4 mL) was added at room temperature and the reaction mixture was stirred at near boiling until a homogeneous solution was obtained.",
"Solution of sodium acetate (8.0 g, 97.525 mmol) was then added.",
"The resulting mixture was then added to a stirred solution consisting of 6-amino-1,3-dimethyl uracil (20.0 g, 128.907 mmol) and sodium acetate (16.0 g, 195.051) in water (100 mL) at 90° C. All solid material was dissolved, then after 10 min.",
"a precipitate was started to form.",
"The reaction mixture was stirred for another 30 min.",
"at the same temperature.",
"The reaction mixture was cooled to room temperature and solid obtained was filtered, washed with water (2×250 mL) and then acetone (2×150 mL).",
"The solid obtained was dried in oven at 65° C. to obtain 7.81 g of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.42 (s, 3H), 6.35 (s, 1H), 6.77 (s, 1H), 11.71 (br s, 1H);",
"APCI-MS (m/z) 180.25 (M+H) + .",
"[0143] Step 2 7-[(Dimethylamino)methyl]-1,3-dimethyl-1H-pyrrolo[3,2-d]pyrimidine-2,4(3H,5H)-dione: To a stirred solution of sodium hydroxide (3.4 g, 84.830 mmol) in water (80 mL) was added Step 1 intermediate (7.6 g, 42.415 mmol) at room temperature and the reaction mixture was stirred for 30 min.",
"Dimethyl sulfate (10.7 g, 84.830 mmol) was added dropwise to the reaction mixture and stirred for another 4 h. Solid was precipitated out and collected by filtration, washed with water.",
"The crude solid obtained was purified by column chromatography by using 3% methanol in chloroform to obtain 5.4 g of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.70 (s, 3H), 3.90 (s, 3H), 6.32 (s, 1H), 6.69 (s, 1H);",
"APCI-MS (m/z) 194.21 (M+H) + .",
"[0144] Step 3 Methyl oxo(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetate: To a well stirred solution of oxalyl chloride (1.6 g, 12.939 mmol) in dichloromethane (10 mL) was added Step 2 intermediate (1.0 g, 5.176 mmol) in small portions at −10° C. and the resulting mixture was stirred overnight at room temperature.",
"The excess of solvent was removed under vacuum and the residue was again taken in dichloromethane (10 mL).",
"The reaction mixture was cooled to −10° C. and dry methanol (10 mL) was added dropwise over a period of 10-15 min.",
"The resulting reaction mixture was stirred overnight at room temperature.",
"Excess of solvent was evaporated under vacuum.",
"The residue obtained was basified with saturated solution of NaHCO 3 (25 mL) and extracted with ethyl acetate (2×50 mL).",
"The combined organic layers were washed with water (25 mL), brine (25 mL) and dried (Na 2 SO 4 ).",
"The crude product obtained after evaporation of the solvent was purified by silica gel column chromatography by using 5% methanol in chloroform to give 1.1 g of the product as a pale yellow solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.62 (s, 3H), 3.72 (s, 6H), 3.83 (s, 2H), 6.29 (s, 1H);",
"APCI-MS (m/z) 266.23 (M+H) + .",
"[0145] Step 4 Methyl (1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetate: To a stirred solution of triethylsilane (364 mg, 3.133 mmol) in trifluoroacetic acid (4.0 mL) was added Step 3 intermediate (250 mg, 0.892 mmol) slowly at −10° C. The resulting mixture was warmed slowly to room temperature.",
"After overnight stirring at room temperature, excess of solvent was removed under reduced pressure and the residue obtained was neutralized with saturated solution of NaHCO 3 (15 mL).",
"Two layers were separated after the addition of ethyl acetate (25 mL).",
"The aqueous layer was extracted with ethyl acetate (2×25 mL).",
"The combined organic layers were washed with water (25 mL) and brine (25 mL).",
"The crude product obtained was purified by silica gel column chromatography by using 20% ethyl acetate in petroleum ether to give 147 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.20 (s, 3H), 3.65-3.72 (m, 8H), 6.29 (s, 1H), 12.62 (br s, 1H);",
"APCI-MS (m/z) 252.38 (M+H) + .",
"[0146] Step 5 (1,3,7-Trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetic acid: A mixture of Step 4 intermediate (130 mg, 0.491 mmol) and concentrated hydrochloric acid (4 mL) was heated at 60° C. for 2 h. The excess of hydrochloric acid was evaporated under reduced pressure and the residue obtained was purified by silica gel column chromatography using 5% methanol in chloroform to obtain 94 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.21 (s, 3H), 3.65-3.72 (m, 8H), 6.29 (s, 1H), 12.62 (br s, 1H);",
"APCI-MS (m/z) 252.38 (M+H) + .",
"Intermediate 8 2,5,7-Trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetic acid [0147] [0148] Step 1 6-Chloro-1,3-dimethylpyrimidine-2,4(1H,3H)-dione: To a stirred solution of 1,3-dimethylbarbituric acid (20.0 g, 128.09 mmol) in water (10 ml), phosphorous oxychloride (80 ml) was added slowly in externally cooling condition and then the reaction was slowly warmed to room temperature.",
"After refluxing for 3 h the reaction mixture was allowed to cool to 0° C. and quenched with ice cold water (350 ml).",
"The reaction mixture was extracted with chloroform (2×200 ml) and the combined organic extracts were washed with water (2×100 ml), dried over Na 2 SO 4 and concentrated.",
"The residue obtained was purified by silica gel column chromatography using 5% ethyl acetate in chloroform to obtain 21g of the product as a pale brown solid;",
"1 H NMR (300 MHz , CDCl 3 ) δ 3.33 (s, 3H), 3.57 (s, 3H), 5.94 (s, 1H).",
"[0149] Step 2 6-Hydrazino-1,3-dimethylpyrimidine-2,4(1H,3H)-dione: A mixture of Step 1 intermediate (17 g, 97.34 mmol) and hydrazine hydrate (119 ml) in isopropyl alcohol (280 ml) were refluxed for 1 h. The excess of solvent was removed under reduced pressure, solid obtained was filtered, washed with methanol (25 ml) and dried to obtain 8.1 g of the product as white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.09 (s, 3H), 3.21 (s, 3H), 4.37 (br s, 2H), 5.10 (s, 1H), 8.02 (br s, 1H).",
"[0150] Step 3 1-Acetyl-3,5,7-trimethyl-1H-pyrazolo[3,4-d]pyrimidine-4,6(5H,7H)-dione: A mixture of Step 2 intermediate (8.0 g, 47.01 mmol) and acetic anhydride (40 ml) in dry pyridine (78 ml) were refluxed for 3 h. The reaction mixture was cooled to 0° C. and acidified with 1N HCl (200 ml).",
"The solid obtained was collected by filtration, washed with 1 N HCl (25 ml), water (25 ml) and dried to give 6.9 g of the product as a white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 2.71 (s, 3H), 2.96 (s, 3H), 3.37 (s, 3H), 3.50 (s, 3H).",
"[0151] Step 4 3,5,7-Trimethyl-1H-pyrazolo[3,4-d]pyrimidine-4,6(5H,7H)-dione: Step 3 above intermediate (6.9 g, 29.211 mmol) was refluxed in 1 N sodium hydroxide (69 ml) for 10 min.",
"The reaction mixture was cooled to room temperature and poured into ice water and stirred for 2 h. The precipitated solid was collected by filtration and dried to give 5.1 g of the desired product as off-white solid;",
"1 H NMR (300 MHz, CF 3 CO 2 D): δ 3.05 (s, 3H), 3.78 (s, 3H), 3.93 (s, 3H).",
"[0152] Step 5 2,3,5,7-Tetramethyl-2H-pyrazolo[3,4-d]pyrimidine-4,6(5H,7H)-dione: A solution of Step 4 intermediate (5.2 g, 26.77 mmol) in 1 N sodium hydroxide (52 ml) was added dimethylsulphate (5.2 ml) and stirred at room temperature for 1 h. The reaction mixture was diluted with water and the solid precipitated out was filtered, washed with water and dried to give 3.85 g of the product as off white solid;",
"1 H NMR (300 MHz, CDCl 3 ): δ 2.59 (s, 3H), 3.36 (s, 3H), 3.48 (s, 3H), 3.79 (s, 3H).",
"[0153] Step 6 Methyl (2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetate: To a stirred solution of Step 5 intermediate (3.8 g, 18.24 mmol) in dimethylcarbonate (91 ml) was added sodium hydride (60% dispersion in mineral oil, 4.5 g, 187.5 mmol) at room temperature.",
"The reaction mixture was heated to reflux for overnight.",
"The reaction mixture was cooled to room temperature, quenched into 1N HCl (200 ml), extracted with ethyl acetate (2×250 ml) and the combined organic layers were washed with water (2×250 ml), dried over Na 2 SO 4 and concentrated.",
"The residue obtained was triturated in hexane, solid obtained was filtered to give 5.5 g of the product as a white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.37 (s, 3H), 3.50 (s, 3H), 3.82 (s, 5H), 3.90 (s, 3H).",
"[0154] Step 7 (2,5,7-Trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetic acid: A mixture of Step 6 intermediate (1.0 g, 3.755 mmol) and 6 N H 2 SO 4 (9.3 ml) in dioxane (9.3 ml) stirred at reflux temperature for 2 h to give a homogeneous pale yellow solution.",
"This solution was cooled, diluted with water and extracted with ethyl acetate (2×50 ml).",
"The combined organic layers were washed with water, dried over Na 2 SO 4 and concentrated.",
"The residue obtained was triturated in diethyl ether, solid obtained was collected by filtration to give 330 mg of the product as a white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.34 (s, overlapping with DMSO, 3H), 3.79 (s, 3H), 4.11 (s, 2H), 12.95 (br s, 1H) and 1 H NMR (300 MHz, CDCl 3 ): δ 3.39 (s, 3H), 3.50 (s, 3H), 3.88 (s, 3H), 4.10 (s, 2H).",
"Intermediate 9 4,6-Dimethyl-1H-pyrazolo[4,3-d]pyrimidine-5,7(4H,6H)-dione [0155] [0156] Step 1 5-Amino-1,3,6-trimethylpyrimidine-2,4(1H,3H)-dione: To a stirred suspension of 5-nitro-1,3,6-trimethylpyrimidine-2,4(1H,3H)-dione (4.2 g, 20.084 mmol) in 1:1 mixture of methanol and toluene (200 ml) was added 10% Pd—C (1.2 g).",
"The reaction mixture was stirred under hydrogen atmosphere at room temperature overnight.",
"The mixture was then filtered over a celite bed and was thoroughly washed with methanol (200 ml).",
"The filtrate was collected and evaporated to give viscous residue which was then purified by column chromatography to afford 4.1 g of the product as an off-white solid.",
"[0157] Step 2 4,6-Dimethyl-1H-pyrazolo[4,3-d]pyrimidine-5,7(4H,6H)-dione: To a stirred solution of Step 1 intermediate (4.0 g, 23.634 mmol) in a mixture of ice (24g) and concentrated HCl (5 ml) was added a solution of sodium nitrite (1.42 g, 20.580 mmol) in water (5 ml).",
"The resulting suspension was stirred below 10° C. for 30 min.",
"The solid formed at this stage was removed by filtration and the filtrate was added slowly with continuous stirring to 20% aq.",
"NaOH (20 ml) by maintaining the temperature below 10° C. After addition the basic solution was filtered and neutralized with hydrochloric acid (5 N HCl).",
"The precipitate separated was filtered and dried to get 300 mg of the product as dark orange solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.45 (s, 3H), 3.52 (s, 3H), 7.53 (s, 1H).",
"Intermediate 10 3,4,6-Trimethyl-1H-pyrazolo[4,3-d]pyrimidine-5,7(4H,6H)-dione [0158] [0159] The title compound was prepared in 2 steps from 6-ethyl-1,3-dimethyl-5-nitropyrimidine-2,4(1H,3H)-dione (3.5 g, 16.279 mmol) as described in intermediate 9 to give 110 mg of the product as a white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 2.62 (s, 3H), 3.45 (s, 3H), 3.67 (s, 3H), 11.59 (br s, 1H);",
"ESI-MS (m/z) 193.31 (M−H).",
"Intermediate 11 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-amine [0160] [0161] Step 1 N-{-4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-yl}acetamide: To a stirred solution of 2-bromo-1-[3-fluoro-4-(trifluoromethyl)phenyl]ethanone (4.5 g, 15.73 mmol) in acetonitrile (45 ml) was added acetyl guanidine (2.38 g, 23.60 mmol).",
"The reaction mixture was stirred and refluxed for overnight.",
"The solvent was evaporation under reduced pressure and diluted with water and extracted with ethyl acetate (75 ml×3) and organic layers were washed with brine, dried (Na 2 SO 4 ) and filtered.",
"The filtrate was concentrated under reduced pressure and the residue obtained after the evaporation of the solvent was purified by silica gel column chromatography using 2% methanol in chloroform to obtain 1.15 g of the product as a yellow solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 2.07 (s, 3H), 7.58 (s, 1H), 7.69-7.78 (m, 3H), 11.31 (br s, 1H), 11.91 (br s, 1H).",
"[0162] Step 2 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-amine: To a stirred solution of Step 1 intermediate (1.1 g, 3.829 mmol) in a mixture of methanol (20 ml) and water (20 ml) was added conc.",
"H 2 SO 4 (2 ml) and the resulting mixture was refluxed for 24 h. The reaction mixture was cooled to room temperature, saturated solution of potassium carnonate was added and extracted with ethyl acetate (2×50 ml).",
"The organic layers were combined and dried over Na 2 SO 4 and filtered.",
"The filtrate was concentrated under reduced pressure.",
"The residue obtained after the evaporation of the solvent was purified by silica gel column chromatography using 5% methanol in chloroform to obtain 290 mg of the product as a yellow solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 5.55 (br s, 2H), 7.32 (s, 1H), 7.59-7.67 (m, 3H), 11.30 (br s, 1H).",
"[0000] General Procedure for the Preparation of 2-halo N-thiazolyl Acetamide Derivatives [0163] To a stirred and cooled (0° C.) solution of appropriate thiazoleamine (1.0 equiv.) and pyridine (1.2 equiv.) in dichloromethane (5 volume) was added bromoacetyl bromide (1.2 eq.) over 5 min and the resulting mixture was allowed to warm to room temperature and then further stirred at room temperature for 2 h. The reaction mixture was diluted with dichloromethane (50 mL) and water (50 mL).",
"The layers were separated.",
"The aqueous layer was extracted with dichloromethane (2×50 mL) and the combined organic layers were washed with water (2×50 mL) followed by brine (50 mL), dried (Na 2 SO 4 ) and filtered.",
"The filtrate was concentrated under reduced pressure.",
"The residue obtained after the evaporation of the solvent was purified by silica gel column chromatography using 5-10% ethyl acetate in petroleum ether to obtain the desired product as an off-white solid.",
"[0164] Structure information and characterization data for selected 2-bromo-N-thiazolyl acetamide intermediates are given in Table 1.",
"[0000] TABLE 1 Structure and 1 H NMR data of selected 2-bromo-N-thiazolyl acetamides S Mol.",
"Formula/ 1 H NMR (δ ppm, DMSO-d 6 , No Structure Mass (m/z) 300 MHz) 1.",
"C 11 H 7 BrF 2 N 2 OS 333.98 (M + H) + 4.19 (s, 2H), 7.21 (t, J = 8.1 Hz, 1H), 7.37 (t, J = 9.3 Hz, 1H), 7.57 (s, 1H), 8.00-8.08 (m, 1H), 12.75 (br s, 1H) 2.",
"C 12 H 7 BrF 4 N 2 OS 382.35 (M + H) + 4.18 (s, 2H), 7.84 (d, J = 7.8 Hz, 1H), 7.91 (d, J = 8.7 Hz, 2H), 8.03 (s, 1H), 12.76 (br s, 1H).",
"C 12 H 7 BrF 4 N 2 OS 382.99 (M + H) + 4.20 (s, 2H), 7.84 (d, J = 7.8 Hz, 1H), 7.95 (d, J = 8.7 Hz, 2H), 8.06 (s, 1H), 12.82 (br s, 1H).",
"C 12 H 7 BrClF 3 N 2 OS 401.00 (M + H) + 4.18 (s, 2H), 7.88 (d, J = 7.2 Hz, 1H), 7.95 (d, J = 9.3 Hz, 1H), 8.18 (d, J = 7.8 Hz, 1H), 8.31 (s, 1H), 12.77 (br s, 1H).",
"C 11 H 6 BrCl 3 N 2 OS 399.05 (M + H) + 4.18 (s, 2H), 7.74-7.80 (m, 3H), 12.78 (br s, 1H).",
"C 15 H 15 BrF 2 N 2 O 2 S 405.13 (M + H) + 0.98 (d, J = 6.3 Hz, 6H), 1.93-2.00 (m, 1H), 3.91 (d, J = 6.3 Hz, 2H), 4.18 (s, 2H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.72 (br s, 1H) 7.",
"C 16 H 17 BrF 2 N 2 O 2 S 420.63 DMSO-d 6 : 0.92 (d, J = 6.9 Hz, 6H), 1.55-1.63 (m, 2H), 1.75-1.85 (m, 1H), 4.12-4.20 (m, 4H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.74 (br s, 1H) 8.",
"C 16 H 17 BrF 2 N 2 O 2 S 419.11 (M + H) + 1.00 (s, 9H), 3.80 (s, 2H), 4.18 (s, 2H), 7.62 (s, 1H), 7.66 (m, 1H), 7.82 (s, 1H), 12.73 (br s, 1H).",
"C 12 H 6 BrF 5 N 2 OS 400.02 (M + H) + 4.20 (s, 2H), 7.47-7.55 (m, 1H), 7.71 (s, 1H), 8.28-8.34 (m, 1H), 12.79 (br s, 1H).",
"10.",
"C 12 H 7 BrF 4 N 2 O 2 S 399.71 (M + H) + 4.18 (s, 2H), 7.25 (t, J = 71.7 Hz, 1H), 7.75 (d, J = 9.0 Hz, 2H), 7.93 (s, 1H), 12.73 (br s, 1H).",
"11.",
"C 13 H 8 BrF 5 N 2 O 2 S 430.18 (M + H) + 2.50-2.80 (m, 2H), 4.18 (s, 2H), 4.34 (t, J = 5.7 Hz, 2H), 7.63-7.70 (m, 2H), 7.85 (s, 1H), 12.74 (br s, 1H).",
"12.",
"C 14 H 10 BrF 5 N 2 O 2 S 445.01 (M + H) + 2.50-2.80 (m, 2H), 4.18 (s, 2H), 4.34 (t, J = 5.7 Hz, 2H), 7.63-7.70 (m, 2H), 7.85 (s, 1H), 12.74 (br s, 1H) 13.",
"C 16 H 17 BrCl 2 N 2 O 2 S 451.66 (M + H) + 1.07 (s, 9H), 3.67 (s, 2H), 4.18 (s, 2H), 7.90 (s, 1H), 7.99 (s, 2H), 12.72 (br s, 1H) 14.",
"C 14 H 10 BrCl 2 F 3 N 2 O 2 S 477.54 (M + H) + 2.79-2.89 (m, 2H), 4.16-4.22 (m, 4H), 7.90 (s, 1H), 7.99 (s, 2H), 12.70 (br s, 1H).",
"15.",
"C 15 H 10 BrCl 2 F 5 N 2 O 2 S 527.07 (M + H) + 2.81 (t, J = 6.0 Hz, 2H), 4.19 (s, 2H), 4.28 (t, J = 6.0 Hz, 2H), 7.93 (s, 1H), 8.02 (s, 2H), 12.75 (br s, 1H).",
"16.",
"C 13 H 8 BrClF 4 N 2 O 2 S 446.93 (M + H) + 4.19 (s, 2H), 4.80-4.90 (m, 2H), 7.71 (d, J = 9.3 Hz, 2H), 7.88 (s, 1H), 12.74 (br s, 1H) 17.",
"C 15 H 13 BrF 2 N 2 O 2 S 403.24 (M + H) + 0.23-0.30 (m, 2H), 0.50-0.56 (m, 2H), 1.17-1.22 (m, 1H), 3.97 (d, J = 6.9 Hz, 2H), 4.19 (s, 2H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.72 (br s, 1H) 18.",
"C 16 H 15 BrF 2 N 2 O 2 S 417.05 (M + H) + 1.82-1.90 (m, 4H), 1.90-2.05 (m, 2H), 2.65-2.71 (m, 1H), 4.10 (d, J = 6.3 Hz, 2H), 4.19 (s, 2H), 7.64 (d, J = 9.3 Hz, 2H), 7.82 (s, 1H), 12.72 (br s, 1H) 19.",
"C 16 H 15 BrCl 2 N 2 O 2 S 449.05 (M + H) + 1.85-1.95 (m, 4H), 2.04-2.10 (m, 2H), 2.72-2.79 (m, 1H), 4.00 (d, J = 6.3 Hz, 2H), 4.18 (s, 2H), 7.90 (s, 1H), 7.99 (s, 2H), 12.73 (br s, 1H).",
"20.",
"C 19 H 12 BrF 5 N 2 O 2 S 504.92 (M − H) 4.11 (s, 2H), 5.39 (s, 2H), 7.14 (s, 1H), 7.39-7.47 (m, 3H), 7.62 (t, J = 7.8 Hz, 1H), 7.68 (d, J = 7.8 Hz, 1H), 7.88 (d, J = 7.8 Hz, 1H), 9.62 (br s, 1H) 21.",
"C 19 H 12 BrF 5 N 2 O 2 S 507.16 (M + H) + 4.18 (s, 2H), 5.31 (s, 2H), 7.60-7.69 (m, 4H), 7.72-7.80 (m, 2H), 7.84 (s, 1H), 12.72 (br s, 1H).",
"22.",
"C 13 H 9 Br 2 F 3 N 2 O 2 S 473.03 (M + H) + 4.18 (s, 2H), 4.86-4.96 (m, 2H), 7.31 (d, J = 8.7 Hz, 1H), 7.75 (s, 1H), 7.91 (d, J = 9.0 Hz, 1H), 8.16 (s, 1H), 12.71 (br s, 1H).",
"23.",
"C 16 H 17 BrClFN 2 O 2 S 435.17 (M + H) + 3.78 (s, 2H), 4.18 (s, 2H), 7.76 (s, 1H), 7.80 (s, 1H), 7.85 (s, 1H), 12.73 (br s, 1H).",
"24.",
"C 16 H 18 BrFN 2 O 2 S 401.29 DMSO-d 6 : 1.02 (s, 9H), 3.74 (s, 2H), 4.18 (s, 2H), 7.22 (t, J = 8.7 Hz, 1H), 7.65-7.74 (m, 3H), 12.68 (br s, 1H) 25.",
"C 16 H 18 BrClN 2 O 2 S 417.75 DMSO-d 6 : 1.04 (s, 9H), 3.75 (s, 2H), 4.18 (s, 2H), 7.19 (d, J = 8.4 Hz, 1H), 7.67 (s, 1H), 7.81 (d, J = 8.7 Hz, 1H), 7.95 (s, 1H), 12.69 (br s, 1H) 26.",
"C 11 H 8 BrClN 2 OS 331.62 CDCl 3 : 4.06 (s, 2H), 7.09 (s, 1H), 7.37 (d, J = 8.7 Hz, 2H), 7.62 (d, J = 8.4 Hz, 2H).",
"27.",
"C 15 H 15 BrCl 2 N 2 O 2 S 438.17 CDCl 3 : 1.10 (d, J = 6.3 Hz, 6H), 2.10-2.24 (m, 1H), 3.81 (d, J = 6.3 Hz, 2H), 4.11 (s, 2H), 7.16 (s, 1H), 7.76 (s, 2H), 9.56 (br s, 1H) 28 C 11 H 8 Br 2 N 2 O 2 360.00 DMSO-d 6 : 4.11 (s, 2H), 7.42 (s, 1H), 7.73 (d, J = 8.1 Hz, 2H), 7.86 (d, J = 8.1 Hz, 2H), 11.56 (br s, 1H) General Procedure for the Preparation of 2-amino-4-aryl Thiazoles: Method 1 [0165] A solution of acetophenone derivative (1.0 eq) in glacial acetic acid (5 vol) was added liquid bromine (1.0 eq) at 0° C. and reaction mixture was stirred at room temperature for 2 h. The reaction mixture was diluted with water and extracted with ethyl acetate, washed with brine and dried over Na 2 SO 4 .",
"The crude product obtained upon concentration was dissolved in dry THF (10 vol) and thiourea (2.0 eq) was added and refluxed for overnight.",
"The reaction mixture was diluted with ethyl acetate, washed with sodium thiosulfate solution and organic layer was treated with 1N HCl to result salt formation of the amine.",
"The precipitated salt was collected by filtration.",
"The salt was then treated with saturated solution of NaHCO 3 to re-generate the amine.",
"The mixture was extracted with dichloromethane (2×50 ml) and the combined organic extracts were washed with water and brine.",
"The solvent was evaporated under reduced pressure to afford the 2-amino-4-aryl-thiazole derivative.",
"Method 2 [0166] A solution of acetophenone derivative (1.0 equiv.), thiourea (2.0 equiv.) and iodine (1.0 equiv.) in dry ethanol (5 vol) was refluxed for 24 h. The reaction mixture was diluted with ethyl acetate and the layers were separated.",
"The organic layer was washed with sodium thiosulfate solution to remove iodine.",
"The ethyl acetate solution was treated with 1N HCl and precipitated salt collected by filtration.",
"The free amine was re-generated as described in Method 1 given above.",
"[0167] All the 2-amino-4-aryl-thiazole derivatives were prepared by either Method 1 or Method 2 starting from appropriate aryl alkyl ketones.",
"Structure information and characterization data for selected intermediates are given in Table 2.",
"[0000] TABLE 2 Structural details and 1 H NMR data of selected 2-aminothiazole intermediates S Mol.",
"Formula No Structure (Mol.",
"Wt.) 1 H NMR (δ ppm, 300 MHz) 1.",
"C 9 H 7 BrN 2 S (255.14) DMSO-d 6 : 7.61 (d, J = 8.1, 2H);",
"7.46 (d, J = 7.8, 2H);",
"6.70 (s, 1H);",
"4.99 (br.",
"s, 2H).",
"C 9 H 7 ClN 2 S (210.68) DMSO-d 6 : 7.78 (d, J = 8.4, 2H);",
"7.39 (d, J = 7.8, 2H);",
"7.07 (br.",
"s, 2H);",
"7.05 (s, 1H).",
"C 10 H 7 F 3 N 2 S (244.24) DMSO-d 6 : 7.97 (d, J = 7.8, 2H);",
"7.69 (d, J = 8.1, 2H);",
"7.24 (s, 1H);",
"7.16 (br.",
"s, 2H).",
"C 10 H 7 F 3 N 2 S (244.24) CDCl 3 : 8.12-8.06 (m, 1H);",
"7.91 (d, J = 6.9, 1H);",
"7.50-7.42 (m, 2H);",
"6.79 (s, 1H);",
"5.02 (br.",
"s, 2H).",
"C 10 H 6 F 4 N 2 S 262.24 CDCl 3 : 7.68-7.61 (m, 2H);",
"7.36 (t, J = 7.8, 1H);",
"7.10 (d, J = 7.8, 1H), 6.75 (s, 1H);",
"5.08 (br s, 2H).",
"C 13 H 16 N 2 S (232.25) DMSO-d 6 : 7.68 (d, J = 7.8, 2H);",
"7.13 (d, J = 8.1, 2H);",
"7.03 (br.",
"s, 2H);",
"6.92 (s, 1H);",
"2.43 (d, J = 6.9, 2H);",
"1.86-1.76 (m, 1H);",
"0.86 (d, J = 6.6, 6H) 7.",
"C 9 H 6 F 2 N 2 S (212.22) CDCl 3 : 8.04-7.95 (m, 1H);",
"6.93-6.80 (m, 3H);",
"5.04 (br.",
"s, 2H).",
"C 10 H 6 F 4 N 2 S 262.23 DMSO-d 6 : 7.87-7.74 (m, 3H);",
"7.40 (s, 1H);",
"7.22 (br.",
"s, 2H).",
"C 10 H 6 F 4 N 2 OS (278.23) DMSO-d 6 : 7.92-7.85 (m, 2H);",
"7.50 (t, J = 8.7, 1H);",
"7.18 (br.",
"s, 3H).",
"10.",
"C 10 H 6 F 4 N 2 OS (278.23) DMSO-d 6 : 7.87-7.80 (m, 1H);",
"7.73 (d, J = 8.7, 1H);",
"7.55 (d, J = 8.1, 1H);",
"7.24 (s, 1H);",
"7.18 (br.",
"s, 2H).",
"11.",
"C 11 H 8 F 4 N 2 OS (292.25) CDCl 3 : 7.57-7.46 (m, 2H), 7.02 (t, J = 8.4, 1H);",
"6.66 (s, 1H);",
"5.08 (br.",
"s, 2H);",
"4.43 (q, J = 8.4, 2H) 12.",
"C 10 H 6 F 4 N 2 S (262.23) DMSO-d 6 : 8.14 (d, J = 6.6, 2H);",
"7.52 (t, J = 8.7, 1H);",
"7.24 (s, 1H);",
"7.20 (br.",
"s, 2H).",
"13.",
"C 10 H 5 F 5 N 2 S (280.22) DMSO-d 6 : 8.35-8.21 (m, 1H);",
"7.48- 7.35 (m, 1H);",
"7.21 (br.",
"s, 2H);",
"7.05 (s, 1H).",
"14 C 10 H 6 F 4 N 2 S 262.23 CDCl 3 : 8.36-8.29 (m, 1H);",
"7.73-7.65 (m, 1H);",
"7.58-7.50 (m, 1H);",
"7.26 (br.",
"s, 2H);",
"7.13 (s, 1H) 15 C 10 H 7 F 3 N 2 OS 260.24 DMSO-d 6 : 7.75-7.62 (m, 2H);",
"7.33 (t, J = 8.1, 1H);",
"7.23 (t, J = 73.2, 1H);",
"7.12 (br.",
"s, 3H) 16 C 9 H 6 F 2 N 2 S 212.22 CDCl 3 : 7.30-7.20 (m, 2H);",
"6.80-6.74 (m, 1H);",
"6.68-6.60 (m, 1H), 5.06 (br s, 2H) 17 C 10 H 6 F 4 N 2 S 262.23 CDCl 3 : 8.28-8.21 (m, 1H);",
"7.51 (t, J = 6.9, 1H);",
"7.27 (t, J = 7.5, 1H);",
"7.10 (s, 1H), 5.04 (br s, 2H) 18 C 10 H 5 F 5 N 2 S 280.22 CDCl 3 : 7.94-7.82 (m, 1H);",
"7.42-7.32 (m, 1H);",
"7.18-7.10 (m, 1H);",
"5.09 (br s, 2H) 19 C 11 H 7 F 5 N 2 OS 310.24 DMSO-d 6 : 7.59 (s, 1H);",
"7.55 (s, 1H);",
"7.21 (s, 1H);",
"7.16 (br.",
"s, 2H);",
"4.82 (q, J = 9.0, 2H).",
"20 C 10 H 6 F 4 N 2 OS 278.23 DMSO-d 6 : 7.65 (d, J = 9.0, 2H);",
"7.48 (s, 1H);",
"7.24 (t, J = 72.3, 1H);",
"7.20 (br.",
"s, 2H).",
"21 C 10 H 6 F 4 N 2 OS 262.23 DMSO-d 6 : 7.97-7.87 (m, 1H);",
"7.62- 7.52 (m, 1H);",
"7.41 (s, 1H);",
"7.23 (br.",
"s, 2H).",
"22 C 14 H 16 F 2 N 2 OS 298.35 DMSO-d 6 : 1.00 (s, 9H), 3.76 (s, 2H), 7.12-7.18 (m, 1H + 2H), 7.48-7.58 (m, 2H) 23 C 10 H 6 F 4 N 2 S 262.23 CDCl 3 : 5.00 (br s, 2H);",
"7.16 (s, 1H);",
"7.37 (d, J = 11.7, 1H);",
"7.44 (d, J = 8.4, 1H);",
"8.18 (t, J = 7.8, 1H).",
"24 C 9 H 6 F 2 N 2 S (212.22) CDCl 3 : 7.60-7.53 (m, 1H);",
"7.48-7.43 (m, 1H);",
"7.18-7.07 (m, 1H);",
"6.66 (s, 1H);",
"4.98 (br.",
"s, 2H).",
"25 C 14 H 16 F 2 N 2 OS 298.35 DMSO-d 6 : 1.00 (s, 9H), 3.76 (s, 2H), 7.12-7.18 (m, 1H + 2H), 7.48-7.58 (m, 2H) 5-(4-Bromophenyl)isoxazol-3-amine used for the preparation of Examples 33, 65 and 84 is purchased from Aldrich.",
"5-(Trifluoromethoxy)-1,3-benzothiazol-2-amine used for the preparation of Example 66 is also purchased from Aldrich.",
"[0168] For further illustration of methods of preparing the compounds of the present invention, the following examples are disclosed below.",
"EXAMPLES General Procedure for the Preparation of Examples Method A: [0169] To a stirred mixture of pyrrolo[3,2-d]pyrimidinedione (Intermediates 1-6, 1.0 equiv.) or pyrazolo[4,3-d]pyrimidinedione (Intermediates 9-10, 1.0 equiv.) and NaH (1.5 equiv.) in dry DMF (10 ml/g) was added 2-bromo-N-phenyl-1,3-thiazol-2-yl acetamide (1.1 equiv.) at 0° C., the reaction mixture was warmed to room temperature and stirred for 30 min.",
"The reaction mixture was heated to 80° C. for overnight.",
"After this time, the reaction mixture was concentrated under reduced pressure and the residue purified by silica gel column chromatography by using 2% methanol in chloroform to afford the product.",
"Method B: [0170] To a stirred solution of (1,3,7-Trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetic acid (Intermediate 7, 1.0 equiv.) or 2,5,7-Trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetic acid (Intermediate 8, 1.0 equiv.) in 1,2-dichloroethane was added EDCI (1.2 equiv.), HOBt (0.3 equiv.) and 4-dimethylaminopyridine (0.1 equiv.) and the mixture was stirred at room temperature for 10-15 min.",
"An appropriate amine (1.0 equiv.) was then added and mixture was stirred at the same temperature for 48 h. The solvent was evaporated under reduced pressure and the residue obtained was diluted with methanol and stirred at room temperature for 30 min.",
"The solid separated out was collected by filtration.",
"The solid product was further purified by recrystallization from isopropanol or methanol to give the desired products.",
"Example 1 N-[4-(2,4-Difluorophenyl)-1,3-thiazol-2-yl]-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0171] [0172] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(2,4-difluorophenyl)-1,3-thiazol-2-yl]acetamide (111 mg, 0.330 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 60 mg of the product as a white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.21-7.27 (m, 1H), 7.36-7.42 (m, 2H), 7.52 (s, 1H), 8.03-8.10 (m, 1H), 12.70 (br s, 1H);",
"APCI-MS (m/z) 432.20 (M+H) + .",
"Example 2 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide [0173] [0174] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(4-fluoro-3-trifluoromethylphenyl)-1,3-thiazol-2-yl]acetamide (128 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.36 (s, 1H), 7.58-7.66 (m, 1H), 7.88 (s, 1H), 8.24-8.32 (m, 2H), 12.74 (br s, 1H);",
"APCI-MS (m/z) 480.16 (M−H).",
"Example 3 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide [0175] [0176] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(3-fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-yl]acetamide (128 mg, 0.334 mmol) in the presence of NaH (10 mg, 0.418 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as a white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.33 (s, 2H), 6.24 (s, 1H), 7.36 (s, 1H), 7.86 (d, J=7.8 Hz, 1H), 7.90-8.01 (m, 3H), 12.77 (br s, 1H);",
"APCI-MS (m/z) 482.07 (M+H) + .",
"Example 4 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-chloro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide [0177] [0178] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (30 mg, 0.167 mmol) with 2-bromo-N-[4-(4-chloro-3-trifluoromethylphenyl)-1,3-thiazol-2-yl]acetamide (80 mg, 0.200 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 38 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, CDCl 3 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (s, 2H), 6.22 (s, 1H), 7.35 (s, 1H), 7.80 (d, J=8.4 Hz, 1H), 7.94 (s, 2H), 8.20 (d, J=8.4 Hz, 1H), 8.34 (s, 1H), 12.74 (br s, 1H).",
"APCI-MS (m/z) 498.14 (M+H) + .",
"Example 5 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-[4-(2,3,4-trichlorophenyl)-1,3-thiazol-2-yl]acetamide [0179] [0180] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-[4-(2,3,4-trichlorophenyl)-1,3-thiazol-2-yl]acetamide (134 mg, 0.334 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 37 mg of the product as an off-white solid;",
"1 H NMR (6 ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.40 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.70 (s, 1H), 7.77 (s, 2H), 12.74 (br s, 1H).",
"APCI-MS (m/z) 498.14 (M+H) + .",
"Example 6 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(2-methylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide [0181] [0182] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-(2-methylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.334 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 45 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 0.98 (d, J=6.9 Hz, 6H), 1.96-2.04 (m, 1H), 3.17 (s, 3H), 3.33 (s, 3H), 3.91 (d, J=6.3 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.35 (s, 1H), 7.65 (d, J=9.0 Hz, 2H), 7.77 (s, 1H), 12.68 (br s, 1H);",
"APCI-MS (m/z) 504.11 (M+H) + .",
"Example 7 N-{4-[3,5-Difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0183] [0184] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{-4-[3,5-difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}acetamide (140 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 0.92 (d, J=6.6 Hz, 6H), 1.60 (d, J=6.3 Hz, 2H), 1.75-1.85 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 4.15 (d, J=6.3 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.35 (s, 1H), 7.63 (s, 1H), 7.66 (s, 1H), 7.77 (s, 1H), 12.68 (br s, 1H);",
"ESI-MS (m/z) 516.41 [M−H].",
"Example 8 N-{[4-(2,2-Dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0185] [0186] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (25 mg, 0.139 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (70 mg, 0.167 mmol) in the presence of NaH (8 mg, 0.333 mmol) in dry DMF (5.0 mL) to give 29 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 3.17 (s, 3H), 3.39 (s, 3H), 3.81 (s, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.63 (s, 1H), 7.67 (s, 1H), 7.77 (s, 1H), 12.68 (br s, 1H);",
"APCI-MS (m/z) 518.10 [M+H] + .",
"Example 9 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[2,4-difluorophenyl-3-trifluoromethyl]-1,3-thiazol-2-yl}acetamide [0187] [0188] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{-4-[2,4-difluorophenyl-3-trifluoromethyl]-1,3-thiazol-2-yl}acetamide (134 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 60 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.40 (s, 3H), 5.33 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.48-7.58 (m, 1H), 7.66 (s, 1H), 8.28-8.38 (m, 1H), 12.75 (br s, 1H);",
"APCI-MS (m/z) 500.02 (M+H) + .",
"Example 10 N-{4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0189] [0190] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (45 mg, 0.251 mmol) with 2-bromo-N-{4-[4-(difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (125 mg, 0.313 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 20 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (s, 2H), 6.23 (s, 1H), 7.28 (t, J=72.3 Hz, 1H), 7.35 (s, 1H), 7.79 (d, J=9.6 Hz, 2H), 7.90 (s, 1H), 12.73 (br s, 1H);",
"ESI-MS (m/z) 498.08 (M+H) + .",
"Example 11 N-{-4-[3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0191] [0192] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (29 mg, 0.166 mmol) with 2-bromo-N-{-4-[3,5-difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (60 mg, 0.139 mmol) in the presence of NaH (5.0 mg, 0.208 mmol) in dry DMF (5.0 mL) to give 20 mg of the product as a white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 4.86 (q, J=8.7 Hz, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.69 (s, 1H), 7.72 (s, 1H), 7.83 (s, 1H), 12.70 (br s, 1H);",
"ESI-MS (m/z) 530.11 (M+H) + .",
"Example 12 N-{-4-[3,5-Difluoro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0193] [0194] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (30 mg, 0.167 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (89 mg, 0.200 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 18 mg of the product as a white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz): 2.73-2.84 (m, 2H), 3.17 (s, 3H), 3.39 (s, 3H), 4.32-4.38 (m, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.66 (s, 1H), 7.69 (s, 1H), 7.80 (s, 1H), 12.70 (br s, 1H);",
"APCI-MS (m/z): 542.20 [M−H].",
"Example 13 N-{4-[3,5-Dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0195] [0196] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.110 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (23 mg, 0.128 mmol) in the presence of NaH (7 mg, 0.291 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.08 (s, 9H), 3.17 (s, 3H), 3.39 (s, 3H), 3.67 (s, 2H), 5.32 (s, 2H), 6.22 (s, 2H), 7.35 (s, 1H), 7.85 (s, 1H), 8.00 (s, 2H), 12.68 (br s, 1H);",
"APCI-MS (m/z) 550.20 [M+H] + .",
"Example 14 N-{4-[3,5-Dichloro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0197] [0198] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(3,3,3-trifluoropropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (160 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as a white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.85-2.92 (m, 2H), 3.17 (s, 3H), 3.39 (s, 3H), 4.18-4.23 (m, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.88 (s, 1H), 8.00-8.08 (m, 2H), 12.71 (br s, 1H);",
"APCI-MS (m/z) 576.23 (M+H) + .",
"Example 15 N-{4-[3,5-Dichloro-4-(3,3,4,4,4-pentafluorobutoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0199] [0200] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(3,3,4,4,4-pentafluorobutoxy)phenyl]-1,3-thiazol-2-yl}acetamide (176 mg, 0.332 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 58 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.80-2.86 (m, 2H), 3.17 (s, 3H), 3.39 (s, 3H), 4.25-4.32 (m, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.88 (s, 1H), 8.03 (s, 2H), 12.70 (br s, 1H);",
"ESI-MS (m/z) 626.18 (M+H) + .",
"Example 16 N-{4-[3-Chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0201] [0202] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (33 mg, 0.184 mmol) with 2-bromo-N-{4-[3-chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (70 mg, 0.156 mmol) in the presence of NaH (11 mg, 0.458 mmol) in dry DMF (5.0 mL) to give 11 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.39 (s, 3H), 4.84 (q, J=8.7 Hz, 2H), 5.32 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.82-7.91 (m, 3H), 12.71 (br s, 1H);",
"APCI-MS (m/z) 546.03 (M+H) + .",
"Example 17 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(cyclopropylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide [0203] [0204] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-(cyclopropylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 39 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 0.24-0.30 (m, 2H), 0.50-0.56 (m, 2H), 1.15-1.21 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 3.97 (d, J=7.5 Hz, 2H), 5.32 (s, 2H), 6.23 (s, 2H), 7.35 (s, 1H), 7.60-7.66 (m, 2H), 7.77 (s, 1H), 12.68 (br s, 1H);",
"APCI-MS (m/z) 502.13 (M+H) + .",
"Example 18 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide [0205] [0206] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-(cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (139 mg, 0.334 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 44 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 1.82-1.90 (m, 4H), 2.00-2.06 (m, 2H), 2.65-2.70 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 4.07-4.13 (m, 2H), 5.32 (s, 2H), 6.20-6.26 (m, 1H), 7.34 (s, 1H), 7.63 (d, J=8.7 Hz, 2H), 7.77 (s, 1H), 12.67 (br s, 1H);",
"APCI-MS (m/z) 516.11 (M+H) + .",
"Example 19 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[4-(cyclobutylmethoxy)-3,5-dichlorophenyl]-1,3-thiazol-2-yl}acetamide [0207] [0208] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (45 mg, 0.251 mmol) with 2-bromo-N-{4-[4-(cyclobutylmethoxy)-3,5-dichlorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.301 mmol) in the presence of NaH (16 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as an off-white solid;",
"1 H NMR ((δ ppm, 300 MHz, DMSO-d 6 ) 1.90-1.99 (m, 4H), 2.04-2.10 (m, 2H), 2.72-2.80 (m, 1H), 3.17 (s, 3H), 3.39 (s, 3H), 4.00 (d, J=6.3 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.36 (s, 1H), 7.85 (s, 1H), 8.00 (s, 2H), 12.68 (br s, 1H);",
"ESI-MS (m/z) 548.15 (M+H) + .",
"Example 20 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3,5-difluoro-4-[2-(trifluoromethyl)benzyloxy]phenyl)-1,3-thiazol-2-yl}acetamide [0209] [0210] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[4-[2-(trifluoromethyl)benzyloxy]phenyl]-1,3-thiazol-2-yl}acetamide (170 mg, 0.335 mmol) in the presence of NaH (17 mg, 0.419 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (s, 2H), 5.35 (s, 2H), 6.23 (s, 1H), 7.35 (s, 1H), 7.65-7.68 (m, 3H), 7.84-7.80 (m, 4H), 12.69 (br s, 1H);",
"APCI-MS (m/z) 606.35 (M+H) + .",
"Example 21 2-(1,3-Dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3,5-difluoro-4-[4-(trifluoromethyl)benzyloxy]phenyl)-1,3-thiazol-2-yl}acetamide [0211] [0212] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (33 mg, 0.184 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-[4-(trifluoromethyl)benzyloxy)phenyl]-1,3-thiazol-2-yl}acetamide (112 mg, 0.221 mmol) in the presence of NaH (11 mg, 0.276 mmol) in dry DMF (3.0 mL) to give 25 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.39 (s, 3H), 5.32 (br s, 4H), 6.22 (s, 1H), 7.35 (s, 1H), 7.70-7.72 (m, 4H), 7.78-7.80 (m, 3H), 12.68 (br s, 1H);",
"ESI-MS (m/z) 606.15 (M+H) + .",
"Example 22 N-[4-(3-Fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0213] [0214] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (45 mg, 0.232 mmol) with 2-bromo-N-{4-[3-fluoro-4-trifluoromethylphenyl]-1,3-thiazol-2-yl}acetamide (107 mg, 0.279 mmol) in the presence of NaH (13 mg, 0.555 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.27 (s, 3H), 3.17 (s, 3H), 3.36 (s, 3H), 5.34 (s, 2H), 6.07 (s, 1H), 7.85-7.91 (m, 1H), 7.94-8.05 (m, 3H), 12.82 (br s, 1H);",
"ESI-MS (m/z) 496.23 (M+H) + .",
"Example 23 N-{4-[3-Bromo-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0215] [0216] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 1 (50 mg, 0.279 mmol) with 2-bromo-N-{4-[3-bromo-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (158 mg, 0.333 mmol) in the presence of NaH (10 mg, 0.416 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 3.17 (s, 3H), 3.39 (s, 3H), 4.91 (d, J=8.7 Hz, 2H), 5.32 (s, 2H), 6.22 (s, 1H), 7.30-7.38 (m, 2H), 7.69 (s, 1H), 7.89-7.95 (m, 1H), 8.17 (m, 1H), 12.65 (br s, 1H);",
"APCI-MS (m/z) 572.27 (M+H) + .",
"Example 24 N1-{4-[3,5-Difluoro-4-(2,2-dimethylprop oxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0217] [0218] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (130 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.625 mmol) in dry DMF (5.0 mL) to give 55 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 1.01 (s, 9H), 2.26 (s, 3H), 3.17 (s, 3H), 3.34 (s, 3H), 3.80 (s, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.63 (s, 1H), 7.66 (s, 1H), 7.77 (s, 1H), 12.74 (br s, 1H);",
"ESI-MS (m/z) 532.24 (M+H) + .",
"Example 25 N-{4-[2,4-Difluoro-3-trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0219] [0220] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[2,4-difluoro-3-trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (124 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.625 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.27 (s, 3H), 3.16 (s, 3H), 3.34 (s, 3H), 5.34 (s, 2H), 6.07 (s, 1H), 7.47-7.57 (m, 1H), 7.66 (s, 1H), 8.28-8.38 (m, 1H), 12.80 (br s, 1H);",
"APCI-MS (m/z) 514.08 (M+H) + .",
"Example 26 N-[4-(3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0221] [0222] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-(3,5-difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl}acetamide (133 mg, 0.308 mmol) in the presence of NaH (16 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 60 mg of the product as a white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 2.26 (s, 3H), 3.16 (s, 3H), 3.34 (s, 3H), 4.80-4.90 (m, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.71 (d, J=9.3 Hz, 2H), 7.83 (s, 1H), 12.75 (br s, 1H);",
"ESI-MS (m/z) 544.55 (M+H) + .",
"Example 27 N-[4-(4-Cyclobutylmethoxy-3,5-difluorophenyl)-1,3-thiazol-2-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0223] [0224] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[4-Cyclobutylmethoxy-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (129 mg, 0.308 mmol) in the presence of NaH (16 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as an off-white solid;",
"1 H NMR (δ ppm, 300 MHz, DMSO-d 6 ) 1.82-1.88 (m, 4H), 2.00-2.06 (m, 2H), 2.26 (s, 3H), 2.65-2.70 (m, 1H), 3.17 (s, 3H), 3.33 (s, 3H), 4.10 (d, J=6.6 Hz, 2H), 5.33 (s, 2H), 6.06 (s, 1H), 7.63 (d, J=8.7 Hz, 2H), 7.77 (s, 1H), 12.71 (br s, 1H);",
"APCI-MS (m/z) 530.16 (M+H) + .",
"Example 28 N-{4-[3-Chloro-4-(2,2-dimethylpropoxy)-5-fluorophenyl]-1,3-thiazol-2-yl]}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0225] [0226] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)-5-fluorophenyl]-1,3-thiazol-2-yl}acetamide (135 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.04 (s, 9H), 2.26 (s, 3H), 3.17 (s, 3H), 3.34 (s, 3H), 3.78 (s, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.70-7.86 (m, 3H), 12.74 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 548.12 (M+H) + .",
"Example 29 N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl]}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0227] [0228] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (140 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 70 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.08 (s, 9H), 2.27 (s, 3H), 3.17 (s, 3H), 3.33 (s, 3H), 3.67 (s, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.85 (s, 1H), 8.00 (s, 2H), 12.73 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 564.22 (M+H) + .",
"Example 30 N-{4-[3-Chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl]}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0229] [0230] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-chloro-5-fluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}acetamide (139 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.26 (s, 3H), 3.16 (s, 3H), 3.33 (s, 3H), 4.84 (q, J=8.7 Hz, 2H), 5.33 (s, 2H), 6.07 (s, 1H), 7.80-7.90 (m, 3H), 12.75 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 560.10 (M+H) + .",
"Example 31 N-{4-[4-(2,2-Dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0231] [0232] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}acetamide (124 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 55 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.06 (s, 9H), 2.26 (s, 3H), 3.17 (s, 3H), 3.36 (s, 3H), 3.75 (s, 2H), 5.32 (s, 2H), 6.07 (s, 1H), 7.22 (t, J=8.4 Hz, 1H), 7.59 (s, 1H), 7.65-7.75 (m, 2H), 12.77 (br s, 1H, exchangeable with D 2 O);",
"APCI-MS (m/z) 514.16 (M+H) + .",
"Example 32 N-{4-[3-Chloro-4-(2,2-dimethylprop oxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0233] [0234] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (129 mg, 0.308 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 85 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz): 1.04 (s, 9H), 2.27 (s, 3H), 3.17 (s, 3H), 3.36 (s, 3H), 3.76 (s, 2H), 5.32 (s, 2H), 6.07 (s, 1H), 7.19 (d, J=8.7 Hz, 1H), 7.62 (s, 1H), 7.82 (d, J=8.4 Hz, 1H), 7.96 (s, 1H), 12.69 (br s, 1H, exchangeable with D 2 O);",
"APCI-MS (m/z) 530.26 (M+H) + .",
"Example 33 N-[5-(4-bromophenyl)isoxazol-3-yl]-2-(1,3,6-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0235] [0236] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 2 (50 mg, 0.258 mmol) with 2-bromo-N-[5-(4-bromophenyl)isoxazol-3-yl]acetamide (111 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.26 (s, 3H), 3.18 (s, 3H), 3.34 (s, 3H), 5.27 (s, 2H), 6.05 (s, 1H), 7.35 (s, 1H), 7.72 (d, J=8.7 Hz, 2H), 7.82 (d, J=8.7 Hz, 2H), 11.56 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 472.08 (M+H) + .",
"Example 34 N-{4-[3,5-Difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0237] [0238] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 3 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (130 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 75 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 2.29 (s, 3H), 3.16 (s, 3H), 3.59 (s, 3H), 3.80 (s, 2H), 5.25 (s, 2H), 7.12 (s, 1H), 7.63 (d, J=9.6 Hz, 2H), 7.76 (s, 1H), 12.63 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 532.18 (M+H) + .",
"Example 35 N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)acetamide [0239] [0240] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 3 (50 mg, 0.258 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (119 mg, 0.310 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 90 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.29 (s, 3H), 3.16 (s, 3H), 3.59 (s, 3H), 5.26 (s, 2H), 7.12 (s, 1H), 7.82-8.00 (m, 4H), 12.71 (br s, 1H, exchangeable with D 2 O);",
"APCI-MS (m/z) 494.30 (M−H) − .",
"Example 36 2-(7-Bromo-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide [0241] [0242] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 4 (50 mg, 0.193 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (97 mg, 0.232 mmol) in the presence of NaH (11 mg, 0.289 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 3.17 (s, 3H), 3.67 (s, 3H), 3.80 (s, 2H), 5.32 (s, 2H), 7.54 (s, 1H), 7.63 (d, J=9.3 Hz, 2H), 7.80 (s, 1H), 12.70 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 594.17 (M−H) − .",
"Example 37 2-(7-Bromo-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl)-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide [0243] [0244] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 4 (50 mg, 0.193 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (89 mg, 0.232 mmol) in the presence of NaH (11 mg, 0.289 mmol) in dry DMF (5.0 mL) to give 50 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.17 (s, 3H), 3.68 (s, 3H), 5.33 (s, 2H), 7.55 (s, 1H), 7.87 (d, J=7.8 Hz, 1H), 7.91-8.02 (m, 3H), 12.79 (br s, 1H, exchangeable with D 2 O);",
"APCI-MS (m/z) 560.12 (M+H) + .",
"Example 38 N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-{7-[(dimethylamino)methyl]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl}acetamide [0245] [0246] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 5 (40 mg, 0.169 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (77 mg, 0.203 mmol) in the presence of NaH (10 mg, 0.250 mmol) in dry DMF (4.0 mL) to give 35 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 2.15 (s, 3H), 3.17 (s, 3H), 3.32 (s, 2H, overlapped with residual DMSO peak), 3.71 (s, 3H), 5.29 (s, 2H), 7.24 (s, 1H), 7.86-8.01 (m, 4H), 12.84 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 539.12 (M+H) + .",
"Example 39 N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-{7-[(dimethylamino)methyl]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl}acetamide [0247] [0248] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 5 (50 mg, 0.211 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (106 mg, 0.253 mmol) in the presence of NaH (15 mg, 0.375 mmol) in dry DMF (5.0 mL) to give 30 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 2.16 (s, 3H), 3.17 (s, 3H), 3.34 (s, 2H, overlapped with residual DMSO peak), 3.71 (s, 3H), 3.80 (s, 3H), 5.28 (s, 2H), 7.24 (s, 1H), 7.65 (d, J=9.6 Hz, 2H), 7.76 (s, 1H), 12.66 (br s, 1H, exchangeable with D 2 O);",
"APCI-MS (m/z) 575.02 (M+H) + .",
"Example 40 N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-{7-[(diethylamino)methyl]-1,3-dimethyl-2,4-dioxo-1,2,3,4-tetrahydro-5H-pyrrolo[3,2-d]pyrimidin-5-yl}acetamide [0249] [0250] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 6 (50 mg, 0.189 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (86 mg, 0.224 mmol) in the presence of NaH (11 mg, 0.250 mmol) in dry DMF (5.0 mL) to give 50 mg of the product as a white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 0.96 (t, J=6.9 Hz, 6H), 2.47-2.53 (m, 4H, overlapped with residual DMSO peak), 3.17 (s, 3H), 3.50 (s, 2H), 3.75 (s, 3H), 5.29 (s, 2H), 7.27 (s, 1H), 7.83-8.02 (m, 4H), 12.76 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 567.00 (M+H) + .",
"Example 41 N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide [0251] [0252] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (80 mg, 0.318 mmol) with 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (84 mg, 0.318 mmol) in the presence of EDCI hydrochloride (74 mg, 0.381 mmol), HOBt (13 mg, 0.096 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (4 mL) to give 52 mg of the product as an off white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.21 (s, 3H), 3.73 (s, 3H), 3.80 (s, 3H), 3.95 (s, 2H), 6.35 (s, 1H), 7.82-8.02 (m, 4H), 12.62 (br s, 1H, exchangeable with D 2 O);",
"APCI-MS (m/z) 496.26 (M+H) + .",
"Example 42 N-[4-(3,5-Difluoro-4-(2,2-dimethylprop oxy)phenyl)-1,3-thiazol-2-yl]-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide [0253] [0254] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (100 mg, 0.398 mmol) with 4-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-amine (118 mg, 0.398 mmol) in the presence of EDCI hydrochloride (91 mg, 0.475 mmol), HOBt (16 mg, 0.118 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (5 mL) to give 40 mg of the product as an off white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 1.01 (s, 9H), 3.21 (s, 3H), 3.73 (s, 3H), 3.80 (s, 5H), 3.93 (s, 2H), 6.35 (s, 1H), 7.64 (d, J=9.6 Hz, 2H), 7.67 (s, 1H), 12.53 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 532.24 (M+H) + .",
"Example 43 N-{4-[2,4-Difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide [0255] [0256] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (100 mg, 0.398 mmol) with 4-[2,4-difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (111 mg, 0.398 mmol) in the presence of EDCI hydrochloride (91 mg, 0.475 mmol), HOBt (16 mg, 0.118 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (5 mL) to give 35 mg of the product as an off white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.21 (s, 3H), 3.73 (s, 3H), 3.81 (s, 3H), 3.95 (s, 2H), 6.35 (s, 1H), 7.51 (d, J=9.9 Hz, 1H), 8.32 (q, J=6.3 Hz, 1H), 12.61 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 514.09 (M+H) + .",
"Example 44 N-{4-[3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(1,3,7-trimethyl-2,4-dioxo-2,3,4,7-tetrahydro-1H-pyrrolo[2,3-d]pyrimidin-5-yl)acetamide [0257] [0258] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 7 (100 mg, 0.398 mmol) with 4-[3,5-difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-amine (123 mg, 0.398 mmol) in the presence of EDCI hydrochloride (91 mg, 0.475 mmol), HOBt (16 mg, 0.118 mmol) and DMAP (4 mg, 0.032 mmol) in 1,2-dichloroethane (5 mL) to give 70 mg of the product as an off white solid;",
"1 H-NMR (δ ppm, DMSO-d 6 , 300 MHz) 3.21 (s, 3H), 3.73 (s, 3H), 3.80 (s, 5H), 3.94 (s, 2H), 4.85 (q, J=8.7 Hz, 2H), 6.35 (s, 1H), 7.69 (d, J=9.3 Hz, 2H), 7.82 (s, 1H), 12.55 (br s, 1H, exchangeable with D 2 O);",
"ESI-MS (m/z) 544.11 (M+H) + .",
"Example 45 N-[4-(4-Isobutylphenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0259] [0260] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-(4-isobutylphenyl)-1,3-thiazol-2-amine (183 mg, 0.793 mmol) in the presence of EDCI hydrochloride (181 mg, 0.952 mmol), HOBt (32 mg, 0.238 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2 dichloroethane (8 ml) to give 32 mg of the product as a white solid;",
"1 H NMR (300 MHz, CDCl 3 ): δ 0.90 (d, J=6.6 Hz, 6H), 2.49 (d, J=5.1 Hz, 2H), 3.46 (s, 3H), 3.50 (s, 3H), 3.99 (s, 3H), 4.16 (s, 2H), 7.08 (s, 1H), 7.18 (d, J=7.8 Hz, 2H), 7.74 (d, J=8.4, 2H), 11.11 (br s, 1H);",
"APCI-MS (m/z): 513.03 (M+H) + .",
"Example 46 N-[4-(4-Chlorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0261] [0262] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(4-chlorophenyl)-1,3-thiazol-2-amine (208 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (8 ml) to give 35 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.16 (s, 3H), 3.36 (s, 3H), 3.84 (s, 3H), 4.39 (s, 2H), 7.50 (d, J=8.4 Hz, 2H), 7.72 (s, 1H), 7.92 (d, J=9.0 Hz, 2H), 12.74 (br s, 1H);",
"APCI-MS (m/z) 445.08 (M+H) + .",
"Example 47 N-{4-[4-(Trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0263] [0264] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-[4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (193 mg, 0.793 mmol) in the presence of EDCI hydrochloride (182 mg, 0.951 mmol), HOBt (32 mg, 0.237 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2-dichloroethane (7.9 ml) to give 13.4 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, CDCl 3 ): δ 3.48 (s, 3H), 3.50 (s, 3H), 4.01 (s, 3H), 4.16 (s, 2H), 7.24 (s, 1H), 7.65 (d, J=7.8, 2H), 7.95 (d, J=7.8, 2H), 11.21 (br s, 1H);",
"APCI-MS (m/z): 479.08 (M+H) + .",
"Example 48 N-{4-[3-(Trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0265] [0266] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (243 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (8 ml) to give 75 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.70 (s, 2H), 7.91 (s, 1H), 8.23-8.29 (m, 2H), 12.80 (br s, 1H);",
"APCI-MS (m/z) 479.09 (M+H) + .",
"Example 49 N-{4-[3-(Trifluoromethoxy)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0267] [0268] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-[3-(trifluoromethoxy)phenyl]-1,3-thiazol-2-amine (206 mg, 0.793 mmol) in the presence of EDCI hydrochloride (181 mg, 0.952 mmol), HOBt (32 mg, 0.238 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2 dichloroethane (8 ml) to give 14 mg of the product as a white solid;",
"1 H NMR (300 MHz, CDCl 3 ): δ 3.48 (s, 3H), 3.50 (s, 3H), 4.00 (s, 3H), 4.16 (s, 2H), 7.18 (s, 2H), 7.42 (t, J=8.1 Hz, 1H), 7.70-7.80 (m, 2H), 11.24 (br s, 1H);",
"ESI-MS (m/z): 495.06 (M+H) + .",
"Example 50 N-[4-(2,4-Difluorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0269] [0270] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(2,4-difluorophenyl)-1,3-thiazol-2-amine (210 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 60 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.23 (t, J=8.4 Hz, 1H), 7.39 (t, J=9.0 Hz, 1H), 7.52 (s, 1H), 8.06 (q, J=8.7 Hz, 1H), 12.76 (br s, 1H);",
"APCI-MS (m/z) 447.08 (M+H) + .",
"Example 51 N-[4-(3,4-Difluorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0271] [0272] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(3,4-difluorophenyl)-1,3-thiazol-2-amine (210 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 26 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.23 (d, J=9.0 Hz, 1H), 7.61 (d, J=7.5 Hz, 2H), 7.91 (s, 1H), 12.79 (br s, 1H);",
"APCI-MS (m/z) 447.00 (M+H) + .",
"Example 52 N-[4-(3,5-Difluorophenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0273] [0274] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(3,5-difluorophenyl)-1,3-thiazol-2-amine (210 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 36 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.23 (d, J=9.0 Hz, 1H), 7.61 (d, J=7.5 Hz, 2H), 7.91 (s, 1H), 12.79 (br s, 1H);",
"APCI-MS (m/z) 447.00 (M+H) + .",
"Example 53 N-{4-[4-Fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0275] [0276] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 45 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.62 (t, J=9.0 Hz, 1H), 7.88 (s, 1H), 8.24-8.30 (m, 2H), 12.80 (br s, 1H);",
"APCI-MS (m/z) 497.05 (M+H) + .",
"Example 54 N-[4-(3-Fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0277] [0278] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-(3-fluoro-4-trifluoromethylphenyl)-1,3-thiazol-2-amine (259 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2-dichloroethane (9.9 ml) to give 80 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.86-8.05 (m, 4H), 12.84 (br s, 1H);",
"ESI-MS (m/z): 497.09 (M+H) + .",
"Example 55 N-{4-[2-Fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0279] [0280] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2-fluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 35 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.41 (s, 2H), 7.54 (t, J=7.8 Hz, 1H), 7.72 (s, 1H), 7.78 (t, J=6.9 Hz, 1H), 8.33 (t, J=7.5 Hz, 1H), 12.83 (br s, 1H);",
"APCI-MS (m/z) 497.00 (M+H) + .",
"Example 56 N-{4-[2-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0281] [0282] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2-Fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2-dichloroethane (9.9 ml) to give 32 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.35 (s, 3H), 3.85 (s, 3H), 4.41 (s, 2H), 7.70-7.86 (m, 3H), 7.26 (t, J=7.8 Hz, 1H), 12.85 (br s, 1H);",
"APCI-MS (m/z) 497.09 (M+H) + .",
"Example 57 N-{4-[2-Fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0283] [0284] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2-fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (260 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 80 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.56-7.65 (m, 1H), 7.72 (s, 1H), 7.76-7.82 (m, 1H), 8.38-8.44 (m, 1H), 12.84 (br s, 1H);",
"APCI-MS (m/z) 497.10 (M+H) + .",
"Example 58 N-{4-[3-Fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0285] [0286] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[3-fluoro-5-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (275 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.19 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2 dichloroethane (8 ml) to give 12 mg of the product as a white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.61 (t, J=9.9 Hz, 1H), 7.82 (s, 1H), 8.00-8.06 (m, 2H), 12.78 (br s, 1H);",
"APCI-MS (m/z) 513.11 (M+H) + .",
"Example 59 N-{4-[3-Fluoro-4-(trifluoromethoxy)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0287] [0288] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (200 mg, 0.793 mmol) with 4-[3-fluoro-4-(trifluoromethoxy)phenyl]-1,3-thiazol-2-amine (220 mg, 0.793 mmol) in the presence of EDCI hydrochloride (181 mg, 0.952 mmol), HOBt (32 mg, 0.238 mmol) and DMAP (9.6 mg, 0.079 mmol) in 1,2 dichloroethane (8 ml) to give 16 mg of the product as a white solid;",
"1 H NMR (300 MHz, CDCl 3 ): δ 3.49, 3.50 (2s, 6H), 4.01 (s, 3H), 4.15 (s, 2H), 7.15 (s, 1H), 7.27-7.35 (m, 1H), 7.61 (d, J=8.1 Hz, 1H), 7.67-7.73 (m, 1H), 11.18 (br s, 1H);",
"ESI-MS (m/z): 495.06 (M+H) + .",
"Example 60 N-{4-[4-Fluoro-3-(trifluoromethoxy)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0289] [0290] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-fluoro-3-(trifluoromethoxy)phenyl]-1,3-thiazol-2-amine (275 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 90 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.61 (t, J=8.7 Hz, 1H), 7.82 (s, 1H), 8.00-8.07 (m, 2H), 12.78 (br s, 1H);",
"APCI-MS (m/z) 513.11 (M+H) + .",
"Example 61 N-{4-[4-(Difluoromethoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0291] [0292] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-(difluoromethoxy)-3-fluorophenyl]-1,3-thiazol-2-amine (258 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 40 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.85 (s, 3H), 4.39 (s, 2H), 7.29 (t, J=72.9 Hz, 1H), 7.45 (t, J=8.4 Hz, 1H), 7.78 (s, 2H), 7.86-7.92 (m, 1H), 12.77 (br s, 1H);",
"ESI-MS (m/z) 495.08 (M+H) + .",
"Example 62 N-{4-[2,3-difluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0293] [0294] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2,3-difluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (277 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 53 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.33 (s, 3H), 3.85 (s, 3H), 4.41 (s, 2H), 7.72-7.79 (m, 1H), 7.84 (s, 1H), 7.99-8.05 (m, 1H), 12.87 (br s, 1H);",
"ESI-MS (m/z) 515.10 (M+H) Example 63 N-{4-[2,4-Difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0295] [0296] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[2,4-difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-amine (279 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (9.69 mg, 0.099 mmol) in 1,2-dichloroethane (8 ml) to give 122 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMF-d 7 ): δ 3.22 (s, 3H), 3.42 (s, 3H), 3.97 (s, 3H), 4.58 (s, 2H), 7.52 (t, J=8.4 Hz, 1H), 7.71 (s, 1H), 8.43 (q, J=9.0 Hz, 1H), 12.80 (br s, 1H);",
"APCI-MS (m/z) 515.07 (M+H) + .",
"Example 64 N-{4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0297] [0298] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-amine (273 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12 mg, 0.099 mmol) in 1,2-dichloroethane (9.9 ml) to give 40 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 3.17 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.40 (s, 2H), 7.28 (t, J=72.3 Hz, 1H), 7.80 (d, J=9.0 Hz, 2H), 7.91 (s, 1H), 12.80 (br s, 1H);",
"APCI-MS (m/z) 513.00 (M+H) + .",
"Example 65 N-[5-(4-Bromophenyl)isoxazol-3-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0299] [0300] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 5-(4-bromophenyl)isoxazol-3-amine (237 mg, 0.992 mmol) in the presence of EDCI hydrochloride (228 mg, 1.190 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 30 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.18 (s, 3H), 3.34 (s, 3H), 3.84 (s, 3H), 4.33 (s, 2H), 7.35 (s, 1H), 7.73 (d, J=8.1 Hz, 2H), 7.83 (d, J=8.7 Hz, 2H), 11.58 (br s, 1H);",
"APCI-MS (m/z) 473.05 (M+H) + .",
"Example 66 N-[5-(Trifluoromethoxy)-1,3-benzothiazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0301] [0302] The title compound was prepared according to the general procedure (Method B) by coupling Intermediate 8 (250 mg, 0.992 mmol) with 5-(trifluoromethoxy)-1,3-benzothiazol-2-amine (234 mg, 0.992 mmol) in the presence of EDCI hydrochloride (458 mg, 2.389 mmol), HOBt (40 mg, 0.297 mmol) and DMAP (12.12 mg, 0.099 mmol) in 1,2-dichloroethane (10 ml) to give 200 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.17 (s, 3H), 3.37 (s, 3H), 3.86 (s, 3H), 4.45 (s, 2H), 7.44 (d, J=8.7 Hz, 1H), 7.86 (d, J=8.7 Hz, 1H), 8.13 (s, 1H), 12.94 (br s, 1H);",
"APCI-MS (m/z) 469.10 (M+H) + .",
"Example 67 N-[4-(4-Chlorophenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0303] [0304] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (150 mg, 0.823 mmol) with 2-bromo-N-[4-(4-chlorophenyl)-1,3-thiazol-2-yl]acetamide (328 mg, 0.988 mmol) in the presence of NaH (50 mg, 1.235 mmol) in dry DMF (3.0 mL) to give 30 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.22 (s, 3H), 3.44 (s, 3H), 5.50 (s, 2H), 7.51 (d, J=8.1 Hz, 2H), 7.73 (s, 1H), 7.89 (s, 1H), 7.93 (d, J=8.4 Hz, 2H), 12.77 (br s, 1H);",
"APCI-MS (m/z): 431.09 (M+H) + .",
"Example 68 2-(4,6-Dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide [0305] [0306] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (62 mg, 0.344 mmol) with 2-bromo-N-{4-[3-fluoro-4-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (110 mg, 0.287 mmol) in the presence of NaH (17 mg, 0.430 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 3.21 (s, 3H), 3.43 (s, 3H), 5.51 (s, 2H), 7.84-8.02 (m, 5H), 12.85 (br s, 1H);",
"APCI-MS (m/z) 481.22 (M−H) − .",
"Example 69 N-{4-[4-(2,2-Dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0307] [0308] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-[4-(2,2-dimethylpropoxy)-3-fluorophenyl]-1,3-thiazol-2-yl}acetamide (107 mg, 0.277 mmol) in the presence of NaH (17 mg, 0.415 mmol) in dry DMF (5.0 mL) to give 50 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.02 (s, 9H), 3.22 (s, 3H), 3.44 (s, 3H), 3.75 (s, 2H), 5.49 (s, 2H), 7.22 (t, J=8.4 Hz, 1H), 7.61 (s, 1H), 7.65-7.75 (m, 2H), 7.89 (s, 1H), 12.72 (br s, 1H);",
"APCI-MS (m/z) 501.45 (M+H) + .",
"Example 70 N-{4-[3-Chloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0309] [0310] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (167 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.04 (s, 9H), 3.22 (s, 3H), 3.43 (s, 3H), 3.76 (s, 2H), 5.49 (s, 2H), 7.19 (d, J=8.7 Hz, 1H), 7.63 (s, 1H), 7.81 (d, J=8.7 Hz, 1H), 7.88 (s, 1H), 7.95 (s, 1H), 12.72 (br s, 1H);",
"APCI-MS (m/z) 517.17 (M+H) + .",
"Example 71 N-{4-[2,4-Difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0311] [0312] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (100 mg, 0.600 mmol) with 2-bromo-N-{4-[2,4-difluoro-3-(trifluoromethyl)phenyl]-1,3-thiazol-2-yl}acetamide (289 mg, 0.720 mmol) in the presence of NaH (36 mg, 0.900 mmol) in dry DMF (3.0 mL) to give 38 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.22 (s, 3H), 3.44 (s, 3H), 5.51 (s, 2H), 7.53 (t, J=9.9 Hz, 1H), 7.69 (s, 1H), 7.89 (s, 1H), 8.30-8.38 (m, 1H), 12.84 (br s, 1H);",
"APCI-MS (m/z): 501.24 (M+H) + .",
"Example 72 N-{4-[4-(Difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0313] [0314] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.331 mmol) with 2-bromo-N-{4-[4-(difluoromethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (110 mg, 0.276 mmol) in the presence of NaH (17 mg, 0.414 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 3.22 (s, 3H), 3.43 (s, 3H), 5.50 (s, 2H), 7.28 (t, J=72.3 Hz, 1H), 7.80 (d, J=9.3 Hz, 1H), 7.89 (s, 1H), 7.92 (s, 1H), 12.82 (br s, 1H);",
"APCI-MS (m/z) 499.20 (M+H) + .",
"Example 73 N-{4-[3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0315] [0316] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (130 mg, 0.700 mmol) with 2-bromo-N-[4-(3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl]acetamide (302 mg, 0.700 mmol) in the presence of NaH (42 mg, 1.050 mmol) in dry DMF (3.0 mL) to give 73 mg of the product as a white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.21 (s, 3H), 3.43 (s, 3H), 4.86 (q, J=9.0 Hz, 2H), 5.50 (s, 2H), 7.71 (d, J=9.9 Hz, 2H), 7.85 (s, 1H), 7.89 (s, 1H), 12.80 (br s, 1H);",
"APCI-MS (m/z): 531.11 (M+H) + .",
"[0317] Further eluting gave 30 mg of N-[4-(3,5-Difluoro-4-(2,2,2-trifluoroethoxy)phenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[4,3-d]pyrimidin-2-yl)acetamide;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.26 (s, 3H), 3.36 (s, 3H), 4.86 (q, J=9.0 Hz, 2H), 5.38 (s, 2H), 7.70 (d, J=8.7 Hz, 2H), 7.88 (s, 1H), 8.08 (s, 1H), 12.85 (br s, 1H);",
"APCI-MS (m/z) 529.10 (M−H) − .",
"Example 74 N-[4-(3,5-Difluoro-4-isobutoxyphenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0318] [0319] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-(3,5-difluoro-4-isobutoxyphenyl)-1,3-thiazol-2-yl}acetamide (162 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 25 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 0.98 (d, J=6.9 Hz, 6H), 1.98-2.04 (m, 1H), 3.22 (s, 3H), 3.43 (s, 3H), 3.91 (d, J=6.6 Hz, 2H), 5.50 (s, 2H), 7.62-7.68 (m, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.77 (br s, 1H);",
"APCI-MS (m/z) 505.13 (M+H) + .",
"Example 75 N-[4-(3,5-Dichloro-4-isobutoxyphenyl)-1,3-thiazol-2-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0320] [0321] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-{4-(3,5-dichloro-4-isobutoxyphenyl)-1,3-thiazol-2-yl}acetamide (175 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 45 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.05 (d, J=6.6 Hz, 6H), 2.05-2.15 (m, 1H), 3.25 (s, 3H), 3.35 (s, 3H), 3.79 (d, J=6.0 Hz, 2H), 5.37 (s, 2H), 7.90 (s, 1H), 8.00 (s, 2H), 8.08 (s, 1H), 12.84 (br s, 1H);",
"APCI-MS (m/z) 505.13 (M+H) + .",
"Example 76 N-{4-[3,5-Difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0322] [0323] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (50 mg, 0.286 mmol) with 2-bromo-N-{4-[3,5-difluoro-4-(3-methylbutoxy)phenyl]-1,3-thiazol-2-yl}acetamide (100 mg, 0.238 mmol) in the presence of NaH (14 mg, 0.357 mmol) in dry DMF (5.0 mL) to give 35 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 0.92 (d, J=6.9 Hz, 6H), 1.55-1.62 (m, 2H), 1.76-1.86 (m, 1H), 3.22 (s, 3H), 3.43 (s, 3H), 4.15 (t, J=6.6 Hz, 2H), 5.50 (s, 2H), 7.62-7.68 (m, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.77 (br s, 1H);",
"APCI-MS (m/z) 519.18 (M+H) + .",
"Example 77 N-{4-[3,5-Dichloro-4-isobutoxyphenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0324] [0325] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-[4-(3,5-difluoro-4-isobutoxyphenyl)-1,3-thiazol-2-yl]acetamide (180 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 45 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 0.96 (d, J=6.9 Hz, 6H), 1.64-1.73 (m, 2H), 1.83-1.92 (m, 1H), 3.25 (s, 3H), 3.36 (s, 3H), 4.04 (t, J=6.6 Hz, 2H), 5.37 (s, 2H), 7.90 (s, 1H), 8.01 (s, 2H), 8.07 (s, 1H), 12.84 (br s, 1H);",
"APCI-MS (m/z) 551.24 (M+H) + .",
"Example 78 N-{4-[4-(2,2-Dimethylpropoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0326] [0327] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (150 mg, 0.800 mmol) with 2-bromo-N-[4-(2,2-dimethylpropoxy)-3,5-difluorophenyl)-1,3-thiazol-2-yl]acetamide (400 mg, 0.96 mmol) in the presence of NaH (48 mg, 1.20 mmol) in dry DMF (3.0 mL) to give 52 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.22 (s, 3H), 3.43 (s, 3H), 3.80 (s, 2H), 5.50 (s, 2H), 7.65 (d, J=9.3 Hz, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.78 (br s, 1H);",
"APCI-MS (m/z): 519.14 (M+H) + .",
"Example 79 N-{4-[3,5-Dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0328] [0329] The title compound was prepared according to the general procedure (Method A) by coupling with Intermediate 9 (80 mg, 0.444 mmol) with 2-bromo-N-{4-[3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl]-1,3-thiazol-2-yl}acetamide (219 mg, 0.488 mmol) in the presence of NaH (27 mg, 0.666 mmol) in dry DMF (5.0 mL) to give 65 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.08 (s, 9H), 3.22 (s, 3H), 3.43 (s, 3H), 3.67 (s, 2H), 5.50 (s, 2H), 7.85-7.91 (m, 2H), 8.00 (s, 2H), 12.77 (br s, 1H);",
"APCI-MS (m/z) 551.16 (M+H) + .",
"Example 80 N-{4-[3-Chloro-4-(2,2-dimethylprop oxy)-5-fluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0330] [0331] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (70 mg, 0.389 mmol) with 2-bromo-N-{4-[3-chloro-4-(2,2-dimethylpropoxy)-5-fluorophenyl]-1,3-thiazol-2-yl}acetamide (203 mg, 0.466 mmol) in the presence of NaH (23 mg, 0.586 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.04 (s, 9H), 3.21 (s, 3H), 3.43 (s, 3H), 3.78 (s, 2H), 5.49 (s, 2H), 7.75-7.91 (m, 4H), 12.77 (br s, 1H);",
"APCI-MS (m/z) 535.23 (M+H) + .",
"Example 81 N-{4-[4-(Cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0332] [0333] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (100 mg, 0.555 mmol) with 2-bromo-N-{4-[4-(cyclobutylmethoxy)-3,5-difluorophenyl]-1,3-thiazol-2-yl}acetamide (278 mg, 0.666 mmol) in the presence of NaH (33 mg, 0.832 mmol) in dry DMF (5.0 mL) to give 55 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.78-1.92 (m, 4H), 2.00-2.06 (m, 2H), 2.65-2.72 (m, 1H), 3.22 (s, 3H), 3.43 (s, 3H), 4.10 (d, J=6.9 Hz, 2H), 5.50 (s, 2H), 7.62-7.68 (m, 2H), 7.79 (s, 1H), 7.89 (s, 1H), 12.77 (br s, 1H);",
"APCI-MS (m/z) 517.15 (M+H) + .",
"Example 82 N-[4-(3,5-Difluoro-4-(2,2-dimethylprop oxy)phenyl)-1,3-thiazol-2-yl]-2-(3,4,6-trimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0334] [0335] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 10 (50 mg, 0.257 mmol) with 2-bromo-N-[4-(3,5-difluoro-4-(2,2-dimethylpropoxy)phenyl)]-1,3-thiazol-2-yl}acetamide (118 mg, 0.283 mmol) in the presence of NaH (12 mg, 0.308 mmol) in dry DMF (5.0 mL) to give 19 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.01 (s, 9H), 2.50 (s, 3H), 3.21 (s, 3H), 3.58 (s, 3H), 3.80 (s, 2H), 5.41 (s, 2H), 7.64 (d, J=9.3 Hz, 2H), 7.87 (s, 1H), 12.74 (br s, 1H);",
"APCI-MS (m/z) 533.16 (M+H) + .",
"Example 83 N-[4-(3,5-Dichloro-4-(2,2-dimethylpropoxy)phenyl)-1,3-thiazol-2-yl]-2-(3,4,6-trimethyl-5,7-dioxo-4,5,6,7-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0336] [0337] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 10 (50 mg, 0.257 mmol) with 2-bromo-N-[4-(3,5-dichloro-4-(2,2-dimethylpropoxy)phenyl)]-1,3-thiazol-2-yl}acetamide (127 mg, 0.283 mmol) in the presence of NaH (15 mg, 0.385 mmol) in dry DMF (5.0 mL) to give 25 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 1.07 (s, 9H), 2.50 (s, 3H), 3.21 (s, 3H), 3.58 (s, 3H), 3.67 (s, 2H), 5.42 (s, 2H), 7.87 (s, 1H), 8.00 (s, 2H), 12.74 (br s, 1H);",
"APCI-MS (m/z) 565.32 (M+H) + .",
"Example 84 N-[5-(4-Bromophenyl)isoxazol-3-yl]-2-(4,6-dimethyl-5,7-dioxo-4,5,6,7,-tetrahydro-1H-pyrazolo[4,3-d]pyrimidin-1-yl)acetamide [0338] [0339] The title compound was prepared according to the general procedure (Method A) by coupling Intermediate 9 (60 mg, 0.333 mmol) with 2-bromo-N-[5-(4-bromophenyl)isoxazol-3-yl]acetamide (144 mg, 0.399 mmol) in the presence of NaH (20 mg, 0.499 mmol) in dry DMF (5.0 mL) to give 40 mg of the product as an off-white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ) δ 3.22 (s, 3H), 3.43 (s, 3H), 5.42 (s, 2H), 7.33 (s, 1H), 7.72 (d, J=8.7 Hz, 2H), 7.85 (d, J=8.1 Hz, 2H), 8.88 (s, 1H), 11.60 (br s, 1H);",
"APCI-MS (m/z) 459.08 (M+H) + .",
"Example 85 N-{4-[3-Fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-yl]-2-(2,5,7-trimethyl-4,6-dioxo-4,5,6,7-tetrahydro-2H-pyrazolo[3,4-d]pyrimidin-3-yl)acetamide [0340] [0341] To a stirred solution of 4-[3-fluoro-4-(trifluoromethyl)phenyl]-1H-imidazol-2-amine (Intermediate 11) (104 mg, 0.428 mmol) in dry toluene (4 ml), sodium hydride (60% dispersion in mineral oil, (12 mg, 1.401 mmol) was added and reaction mixture was stirred for 30 min at room temperature.",
"Step 6 of Intermediate 8 (100 mg, 0.356 mmol) was added to the above reaction mixture and heated to reflux for 48 h. The reaction mixture quenched into water and extracted with ethyl acetate and the combined organic layers were washed with brine, dried over Na 2 SO 4 .",
"Solvent was evaporated and residue obtained was purified by SiO 2 column chromatography using 2% methanol in chloroform to give 23 mg of the product as off white solid;",
"1 H NMR (300 MHz, DMSO-d 6 ): δ 3.18 (s, 3H), 3.36 (s, 3H), 3.85 (s, 3H), 4.30 (s, 2H), 7.62 (s, 1H), 7.70-7.81 (m, 3H), 11.76 (br s, 1H), 11.94 (br s, 1H);",
"APCI-MS (m/z): 480.17 (M+H) + .",
"Pharmacological Activity [0342] The illustrative examples of the present invention are screened for TRPA1 activity according to a modified procedure described in (a) Tóth, A. et al.",
", Life Sciences, 2003, 73, 487-498.",
"(b) McNamara C, R. et al.",
", Proc.",
"Natl.",
"Acad.",
"Sci.",
"U.S.A., 2007, 104, 13525-13530.",
"The screening of the compounds can be carried out by other methods and procedures known to persons skilled in the art.",
"Screening for TRPA1 Antagonist Using the 45 Calcium Uptake Assay [0343] The inhibition of TRPA1 receptor activation was measured as inhibition of allyl isothiocyanate (AITC) induced cellular uptake of radioactive calcium.",
"Test compounds were dissolved in DMSO to prepare 10 mM stock solution and then diluted using plain medium with 0.1% BSA and 1.8 mM CaCl 2 to get desired concentration.",
"Final concentration of DMSO in the reaction was 0.5% (v/v).",
"Human TRPA1 expressing CHO cells were grown in F-12 DMEM medium with 10% FBS, 1% penicillin-streptomycin solution, 400 pg/ml of G-418.",
"Cells were seeded 24 h prior to the assay in 96 well plates so as to get ˜50,000 cells per well on the day of experiment.",
"Cells were treated with test compounds for 10 min followed by addition of AITC at a final concentration of 30 μM and 5 μCi/ml 45 Ca +2 for 3 min.",
"Cells were washed and lysed using buffer containing 1% Triton X-100, 0.1% deoxycholate and 0.1% SDS.",
"Radioactivity in the lysate was measured in Packard Top count after addition of liquid scintillant.",
"Concentration response curves were plotted as a % of maximal response obtained in the absence of test antagonist.",
"IC 50 value was calculated from concentration response curve by nonlinear regression analysis using GraphPad PRISM software.",
"[0344] The compounds prepared were tested using the above assay procedure and the results obtained are given in Table 3.",
"Percentage inhibition at concentrations of 1.0 μM and 10.0 μM are given in the table along with IC 50 (nM) details for selected examples.",
"The IC 50 (nM) values of the compounds are set forth in Table 3 wherein “A”",
"refers to an IC 50 value of less than 50 nM, “B”",
"refers to IC 50 value in range of 50.01 to 100.0 nM and “C”",
"refers to an IC 50 values above 100.0 nM.",
"[0000] TABLE 3 In-vitro screening results of compounds of invention Percentage inhibition Human Examples at 1.0 μM at 10.0 μM IC 50 value (range) 1 23.05 21.39 — 2 35.44 79.51 — 3 94.43 98.77 A 4 34.39 89.77 — 5 55.26 82.29 — 6 42.37 52.84 — 7 35.52 37.28 — 8 91.92 100.00 A 9 60.70 91.28 — 10 91.00 95.30 B 11 96.26 98.07 A 12 97.37 95.97 A 13 86.45 98.82 B 14 92.52 92.54 A 15 76.50 92.50 B 16 94.96 97.14 A 17 33.54 49.94 — 18 38.44 38.71 — 19 72.12 76.86 — 20 22.59 67.70 — 21 11.16 16.23 — 22 81.41 99.41 A 23 87.43 92.21 B 24 93.92 99.43 A 25 68.31 94.76 — 26 95.26 98.27 A 27 87.58 99.15 A 28 99.51 99.68 A 29 95.58 97.08 A 30 93.56 100.00 A 31 87.44 95.35 B 32 92.81 96.32 A 33 0.00 28.30 — 34 88.81 97.01 C 35 64.74 96.79 — 36 35.59 70.11 — 37 52.90 95.44 — 38 57.01 97.80 — 39 4.89 21.09 — 40 48.49 86.22 — 41 37.99 86.55 — 42 41.10 63.14 — 43 30.13 41.58 — 44 27.08 77.03 — 45 93.46 98.87 B 46 89.26 96.58 C 47 98.98 99.45 A 48 92.84 97.51 B 49 52.26 88.46 — 50 0.00 19.84 — 51 57.54 79.68 — 52 37.75 64.81 — 53 97.25 98.63 A 54 97.73 99.61 A 55 92.23 99.15 B 56 96.20 98.16 A 57 43.04 49.81 — 58 94.63 99.25 A 59 97.57 99.33 A 60 93.42 97.19 A 61 86.05 98.33 B 62 90.31 95.76 A 63 95.07 99.74 A 64 97.78 98.29 A 65 12.49 24.64 — 66 45.05 71.55 — 67 57.60 98.43 — 68 91.34 99.43 C 69 97.27 99.75 A 70 91.47 98.76 A 71 78.25 99.28 B 72 85.88 97.67 C 73 99.06 99.91 A 74 92.10 98.78 A 75 99.34 100 A 76 84.32 95.60 C 77 89.48 99.58 B 78 100 99.65 A 79 100 99.99 A 80 99.99 100 A 81 93.95 99.97 A 82 92.85 98.95 B 83 75.59 95.02 A 84 17.24 83.90 — 85 44.10 78.19 —"
] |
TECHNICAL FIELD
[0001] The invention relates the field of server load balancing.
BACKGROUND
[0002] A server load balancer (SLB) is device (hardware and/or software) for balancing session traffic across a set of applications (e.g., server applications), each of which runs on a processing unit (e.g., a server computer, a blade server, etc.). In many environments it is desired to have in-place a stand-by SLB in case the primary SLB fails. It is known that the stand-by SLB can either be a “hot” stand-by or a “cold” stand-by. When using a hot stand-by SLB it is required that connection data (e.g., a connection table) that is used by the primary SLB in balancing traffic across the server applications be replicated to the hot stand-by SLB prior to the failure of the primary SLB. Typically, this replication is accomplished by updating connection data accessible to the hot stand-by SLB each time the connection data maintained by the primary SLB is updated. An advantage of using a hot stand-by SLB is that, in case a failure of the primary SLB (or “active” SLB) occurs, a switchover to the stand-by SLB occurs and this stand-by SLB would have connection data that is identical to the connection data that was maintained by the primary SLB, thereby enabling the stand-by SLB to takeover as primary SLB and continue balance traffic for the already established sessions as well as new session.
[0003] A problem with using the hot stand-by method is that if the hot stand-by fails, then the connection data will be lost. Moreover, the hot stand-by method requires that the hot stand-by SLB work in tandem with the primary SLB so that the primary SLB's connection data can be replicated. Another problem with the hot stand-by method occurs when some event (e.g., power failure, operating system crash, hardware fault) causes the primary SLB and a target processing unit (e.g., a processing unit on which a server application runs) to fail at more less the same time. When such a situation arises, the replicated connection data that is used by the stand-by SLB may include invalid information (e.g., information mapping a session to the failed target processing unit). This could cause the hot stand-by SLB to forward traffic to the failed target processing unit, which is undesirable because the traffic will not get processed due to the failure of the target processing unit.
[0004] A problem with using a cold stand-by SLB is that there is no replication of the primary SLB's connection data, and this means that the cold stand-by SLB can not route traffic corresponding to a session that was established before the primary SLB failed.
[0005] What is desired, therefore, are improved systems and methods for recovering from the failure of an SLB.
SUMMARY
[0006] In one aspect, the invention provides an SLB recovery method that replicates the primary SLB's connection data after the primary SLB experiences a failure, as opposed to before it experiences a failure as is currently done in the known hot stand-by recovery method. In some embodiments, this is made possible by (1) employing a replication agent on each target processing unit (e.g., each processing unit on which a server application runs) and (2) transmitting, from the primary SLB, connection data information (i.e., information comprising a session identifier) to the replication agent running on the target processing unit to which the session is mapped, which replication agent will store the connection data information until it is required to transmit the data to a cold stand-by SLB.
[0007] By having the primary SLB transmit connection data information to the replication agent, the replication agent can provide the connection data information to the cold stand-by SLB in the event the primary SLB experiences a failure. This provides the advantage of enabling a system design solution that can capitalize on the flexibility of cold stand-by methods yet is still able to protect established sessions because the cold stand-by SLB can receive from one or more replication agents connection data information that maps an established session to a particular target processing unit. This is particularly useful in server farms and clustered system designs.
[0008] Moreover, the above described embodiment provides protection against multiple SLB failures because, in the event of a primary SLB failure and a cold stand-by failure, a second cold stand-by SLB can easily replicate the necessary connection data by merely receiving the necessary information from the replication agents.
[0009] Additionally, some embodiments of the invention solve the above described problem that occurs when an event (e.g., power failure, operating system crash, hardware fault, etc) causes the primary SLB and a target processing unit to fail at more less the same time. As described above, in such a situation, the conventional stand-by SLB will have connection data (e.g., a connection table) that includes invalid connection data information (e.g., a records that maps a session to the failed target processing unit). However, if such a situation occurs in a system according to some embodiment of the invention, the replicated connection data used by the stand-by SLB will not contain any such invalid connection data information. This is so because, in some embodiments, the stand-by SLB receives its connection data information from the target processing unit themselves after the primary SLB fails. Thus, if a target has failed at more or less the same time as the primary SLB, then the stand-by SLB will not receive any connection data information from the failed target. Hence, the stand-by SLB will not have connection data that includes connection data information that maps a session to the failed target.
[0010] One aspect of the invention provides a method, performed by a stand-by SLB. In some embodiments, this method includes: replicating, by the stand-by SLB, at least a portion of connection data maintained by the primary SLB such that the replicated connection data is accessible to the stand-by SLB, characterized in that the replicating step occurs in response to a detection of the failure of the primary SLB. After the replicating step, the stand-by SLB may: (a) receive traffic corresponding to a session; (b) access the replicated connection data to determine a target processing unit to which the session is mapped; and (c) forward the traffic to the determined target processing unit (i.e., the stand-by SLB become the primary SLB).
[0011] After the replicating step, the stand-by SLB (which is now a primary SLB) may further: receive traffic corresponding to a second session and access the replicated connection data to determine whether the accessed data comprises information mapping the second session to any of a plurality of target processing units. In response to determining that the accessed data does not comprise information mapping the second session to any of the plurality of target processing units, the stand-by SLB is configured to: (a) select a particular target processing unit; (b) update the replicated connection data so that the replicated connection data will comprise information mapping the second session with the selected target processing unit; and (c) transmit to a replication agent running on the selected target processing unit a connection data update message comprising a session identifier identifying the second session.
[0012] In some embodiments, the step of replicating the connection data comprises: receiving, at the stand-by SLB, a replication message transmitted from a target processing unit, wherein the replication message contains a session identifier identifying a session; and in response to receiving the replication message, storing information that maps the session with the target processing unit. In some embodiments, the replication message may contain a plurality of session identifiers, each identifying a different session, and, in response to receiving the replication message, the stand-by SLB stores information mapping each of the plurality of session identifiers with the target processing unit.
[0013] In some embodiments, the method further includes: transmitting, in response to the failure of the primary SLB, a connection data synchronization message to each of a first and a second target processing unit, wherein each of the first and second target processing units is configured to transmit one or more replication messages to the stand-by SLB in response to receiving the connection data synchronization message.
[0014] In some embodiments, the connection data maintained by the primary SLB comprises first information mapping a first session to the first target processing unit and second information mapping a second session to the second target processing unit, wherein the first information consists of a first record comprising a first field storing a session identifier identifying the first session and a second field storing a target processing unit identifier identifying the first target processing unit, and the second information consists of a second record comprising a second field storing a session identifier identifying the second session and a second field storing a target processing unit identifier identifying the second target processing unit.
[0015] In some embodiments, the step of receiving, at the stand-by SLB, traffic corresponding to a session consists of receiving, at the stand-by SLB, a network packet comprising information identifying the session, wherein the network packet is an Internet Protocol (IP) packet that contains an IP header and a payload, wherein the payload contains a transport layer segment having a transport layer header and payload, and data from the IP header and transport layer header identifies the network packet as corresponding to the session.
[0016] In some embodiments, the primary SLB may execute on one of the target processing units. In this case, the replicated connection data may not contain information that maps any session to the target processing unit on which the primary SLB was running when it failed. This, as described above, is advantageous because it is undesirable for the stand-by SLB to attempt to forward traffic to a failed target, which could happen if the connection table used by the stand-by SLB contains a record that maps a session to a failed target processing unit.
[0017] In another aspect, the invention provides an improved stand-by server load balancer (SLB). The improved stand-by SLB is configured to recover from the failure of a primary SLB, which is operable to use stored connection data to balance traffic across a plurality of target processing units using. The stored connection data comprises information mapping sessions with target processing units. Advantageously, in one embodiment, the stand-by SLB is configured such that, in response to a detection of the failure of the primary SLB, the stand-by SLB replicates the connection data (or most of the connection data) to create replicated connection data. The replicated connection data is accessible to the stand-by SLB so that the stand-by SLB can use the replicated connection data to balance traffic across the plurality of target processing units.
[0018] In some embodiments, the stand-by SLB is configured to replicate the connection data by receiving one or more replication messages from one or more of the target processing units, each of the one or more replication message comprising a session identifier and a target processing unit identifier. In some embodiments, the stand-by SLB is further configured such that, in response to the failure of the primary SLB, the stand-by SLB transmits a connection data synchronization message to at least one of the plurality of target processing units.
[0019] In some embodiments, the connection data comprises a record comprising a first field storing a session identifier identifying a session and a second field storing a target processing unit identifier identifying a target processing unit, and the replicated connection data comprises a record comprising a first field storing the session identifier identifying the session and a second field storing the target processing unit identifier identifying the target processing unit.
[0020] The stand-by SLB may be further operable to: receive a network packet corresponding to a session; use the replicated connection data to determine the target processing unit to which the session is mapped; and forward the network packet to the determined target processing unit. The network packet may be an Internet Protocol (IP) packet that contains an IP header and a payload, wherein the payload contains a transport layer segment having a transport layer header and payload, and data from the IP header and transport layer header identifies the network packet as corresponding to the session.
[0021] In another aspect, the invention provides an improved primary server load balance (SLB) for balancing traffic across a plurality of target processing units. The primary SLB is operable to receive traffic corresponding to a session and access connection data to determine whether the connection data comprises information mapping the session to any of the plurality of target processing units. Advantageously, in response to determining that the connection data does not comprise information mapping the session to any of the plurality of target processing units, the primary SLB selects a particular target processing unit from the plurality of target processing units, updates the connection data so that the connection data will comprise information mapping the session with the selected target processing unit, and transmits to a replication agent running on the selected target processing unit a connection data update message comprising a session identifier identifying the session. The connection update message may comprise a target processing unit identifier for identifying the selected target processing unit.
[0022] In another aspect, the invention provides a computer program product comprising a computer usable medium having a computer readable program code embodied therein, said computer readable program code adapted to be executed to implement a method comprising: accessing connection data, in response to receiving traffic corresponding to a session, to determine whether the connection data comprises information mapping the session to any of the plurality of target processing units; and in response to determining that the connection data does not comprise information mapping the session to any of the plurality of target processing units: (a) selecting a particular target processing unit from the plurality of target processing units and (b) updating the connection data so that the connection data will comprise information mapping the session with the selected target processing unit. Characterized in that the method further comprises, in further response to determining that the connection data does not comprise information mapping the session to any of the plurality of target processing units, transmitting to a replication agent running on the selected target processing unit a connection data update message comprising a session identifier identifying the session.
[0023] In another aspect, the invention provides a computer program product comprising a computer usable medium having a computer readable program code embodied therein, said computer readable program code adapted to be executed to implement a method comprising: replicating connection data used by a primary server load balancer (SLB) immediately in response to a detection that the primary SLB has failed; and using the replicated connection data to balance traffic across a plurality of target processing units.
[0024] In another aspect, the invention provides, a target processing unit, wherein the target processing includes a replication agent. Advantageously, the replication agent is operable to: receive from a primary server load balancer (SLB) a connection data update message comprising a session identifier identifying a session; and store the session identifier in response to receiving the connection data update message, characterized in that: the replication agent is configured to transmit the session identifier to a stand-by SLB in response to receiving a synchronization message.
[0025] The replication agent, in some embodiments, is further operable to: receive from the primary SLB a second connection data update message comprising a second session identifier identifying a second session; and store the second session identifier in response to receiving the second connection data update message, characterized in that: the replication agent is configured such that, in response to receiving the synchronization message, the replication agent transmits to the stand-by SLB a replication message containing the first and second session identifiers. The replication message may further contain an identifier identifying the target processing unit.
[0026] The above and other aspects and embodiments are described below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements.
[0028] FIG. 1 illustrates a system according to an embodiment of the invention.
[0029] FIG. 2 is a flow chart illustrating a processes according an embodiment of the invention.
[0030] FIG. 3 is a flow chart illustrating a processes according an embodiment of the invention.
[0031] FIG. 4 is a functional block diagram of an SLB apparatus according to some embodiments.
DETAILED DESCRIPTION
[0032] Referring now to FIG. 1 , FIG. 1 illustrates a system 100 according to an embodiment of the invention. System 100 includes a primary SLB 114 that is operable to balance session traffic across, among other things, a set of server applications 104 , each of which runs on a processing unit 102 . Also running on each processing unit 102 a to 102 n , is a replication agent 106 .
[0033] FIG. 2 is a flow chart illustrating a process 200 , according to some embodiments, that is performed by primary SLB 114 . Process 200 may begin in step 202 , where primary SLB 114 receives session traffic (e.g., a packet), via network 120 , transmitted from some device (not shown) connected to network 120 , which may be an Internet Protocol (IP) network, such as the Internet, other network. Thus, in some embodiments, the received traffic is an IP packet, which, as is well known in the art, includes a header and payload. For the sake of simplicity, we shall assume that in step 202 SLB 114 received an IP packet.
[0034] In step 204 , SLB 114 extracts data from the received packet to generate a session identifier (e.g., a data structure, such as a string of bits or other structure, containing data from certain fields of the packet that together identify a session). For example, in step 204 , assuming the IP packet encapsulates a Transmission Control Protocol (TCP) packet or a User Datagram Protocol (UDP) packet, SLB 114 may form a data structure containing: (a) the following items from the IP header of the packet: source address, destination address, version (e.g. IPv4 or IPv6), and protocol (e.g., TCP or UDP) and (b) the following items from the TCP/UDP header: source port and destination port.
[0035] In step 206 , SLB 114 determines whether the packet corresponds to a new session. In the case where the packet is a TCP/IP packet, in some embodiments, SLB 114 determines whether the packet corresponds to a new session by determining if the packet contains a TCP packet that indicates that the TCP packet is a TCP connection request (i.e., the SYN bit of the TCP packet is set).
[0036] In the case where the packet is a UDP/IP packet, in some embodiments, SLB 114 determines whether the packet corresponds to a new session by determining whether the generated session identifier matches a session identifier stored in a connection table 117 stored in storage unit 115 , which may be a volatile (e.g., RAM) or non-volatile storage unit. In some embodiments, connection table 117 stores connection data that includes information mapping sessions to target processing units 102 . For example, the connection data may include a plurality of records, where each record comprises a first field for storing a session identifier identifying a session and a second field for storing a processing unit identifier (e.g., an IP address) associated with a target processing unit 102 . In some embodiments, the records may include additional fields.
[0037] If the traffic corresponds to a new session, then the process proceeds to step 212 , otherwise it proceeds to step 222 .
[0038] In step 212 , SLB 114 selects a target processing unit. For example, a table 121 of targeting processing unit identifiers may be stored in storage unit 115 , and SLB 114 selects a target processing unit in step 212 by, for example, randomly selecting from the table 121 an identifier that identifies a target processing unit.
[0039] In step 214 , SLB 114 forwards the packet received in step 202 to the selected target processing unit 102 . The packet is then received and processed by protocol stack 108 and, if the packet contains application data, then the application data contained in the packet is provided to server application 104 .
[0040] In step 216 , SLB 114 updates connection table 117 . For example, in step 216 , SLB 114 may add a record to table 117 , which record contains in one field the session identifier generated in step 204 and in another field a target processing unit identifier that identifies the target processing unit selected in step 212 .
[0041] Advantageously, in some embodiments, in step 218 , SLB 114 sends to the selected target processing unit a connection data update message that includes the generated session identifier. This message is received by a protocol stack 108 running on the target processing unit 102 and the message is then provided to the replication agent 106 running on the target processing unit 102 . Replication agent 106 , in response to receiving the message, stores in storage unit 109 the session identifier included in the connection update message (step 220 ). Accordingly, a portion of connection table 117 is duplicated in storage unit 109 . This provides the distinct advantage of enabling replication agent 106 to inform stand-by SLB 116 of the active sessions that were handled by primary SLB 114 , as well as the target processing units associated with those active sessions, in the event primary SLB 114 experiences a failure. This information regarding the active sessions enables the cold stand-by SLB 114 to take over the handling of these active sessions.
[0042] While replication agent 106 is shown as being separate and apart from protocol stack 108 (i.e., replication agent 106 is a user application), this was done solely for the sake of illustration. In some other embodiments, replication agent 106 may be part of protocol stack 108 or some other part of the operating system. In the case where, replication agent 108 is a part of protocol stack 108 , step 218 may be unnecessary because (a) the replication agent 106 may obtain from the protocol stack 108 a copy of the packet (or a copy of some portion of the packet) that was forwarded in step 214 and (b) replication agent 106 can be configured to use this information to generate the session identifier in the same manner that SLB 114 generates the session identifier as described above. After replication agent 106 generates the session identifier, agent 106 can store it in storage unit 109 .
[0043] In step 222 , SLB 114 determines the target processing unit that is associated with the generated session identifier. SLB 114 , in some embodiments, makes this determination by selecting the record in connection table 117 that includes a session identifier that matches the session identifier generated in step 204 . This selected record will contain a target processing unit identifier that identifies the target processing unit associated with the generated session identifier.
[0044] In step 224 , SLB 114 forwards the packet received in step 202 to the determined target processing unit 102 . In step 226 , SLB 114 determines whether the packet indicates the end of the session. For example, in the case where the packet is a TCP/IP packet, SLB 114 determines that the packet indicates the end of the session when the FIN bit of the TCP packet is set. If the packet does not indicate the end of the session, the process may proceed back to step 202 , where SLB 114 receives a new packet. If the packet indicates the end of the session, then SLB 114 updates its connection table by removing the record in the table that contains a session identifier that matches the session identifier generated in step 204 (step 228 ). In step 230 , SLB 114 sends to the replication agent on the determined target processing unit a connection data update message that includes the generated session identifier (the message may also include an end-of-session indication). In response to receiving this message, the replication agent 106 removes from storage unit 109 the session identifier that matches the session identifier included in the message (step 232 ).
[0045] Referring now to FIG. 3 , FIG. 3 is a flow chart illustrating a process 300 that shows steps that are preformed in the event primary SLB 114 experiences a failure. Process 300 may begin in step 302 , where SLB monitor 112 determines whether SLB 114 has experienced a failure. If SLB 114 has not experienced a failure, SLB monitor 112 continues monitoring SLB 114 . In the event of a failure, process 300 proceeds to step 304 .
[0046] In step 304 , a control message (a.k.a., a connection data synchronization message) is transmitted to each target processing unit 102 a to 102 n (or each target processing unit identified in table 121 ). Each control message may be addressed to the replication agent 106 running on the target processing unit to which the control message was sent, thus, the control message is provided to the replication agent. The control message may be sent by SLB monitor 112 in response to it determining that SLB 114 has failed. While SLB monitor 112 is shown as being separate and apart from stand-by SLB 116 , this is not a requirement as monitor 112 may be a module of SLB 116 .
[0047] In response to receiving the control message, the replication agent 106 transmits to stand-by SLB 116 each of the session identifiers it stored in storage unit 109 if it hasn't earlier removed the session identifier from the storage unit (step 306 ). For example, replication agent 106 may transmit to SLB 116 a replication message comprising the set of session identifiers. Replication agent 106 may obtain the network address of stand-by SLB 116 from a configuration file stored in storage unit 109 or it may be included in the control message.
[0048] In step 308 , stand-by SLB 116 uses the session identifiers it receives from each replication agent to form connection table 123 , which, at least in part, is a replication of connection table 117 . Thus, connection table 123 is replicated connection data. For example, for each session identifier that SLB 116 receives from a particular replication agent 106 , SLB 116 may add to table 123 a record comprising a first field that stores the session identifier and a second field that stores a target processing unit identifier that identifies the target processing unit on which the replication agent is running, thereby storing information that maps the session identified by the session identifier with the target processing unit identified by the target processing unit identifier. This target processing unit identifier may be included in the replication message sent by the replication agent in step 306 .
[0049] In step 310 , SLB 116 receives session traffic (e.g., a packet), via network 120 , transmitted from some device (not shown) connected to network 120 , and uses the information mapping sessions to target processing units (e.g., connection table 123 ) to forward the packet to the appropriate target processing unit as described above in connection with FIG. 2 .
[0050] Referring back to FIG. 1 , while primary SLB 114 is shown as being separate and apart from the target processing units 102 , this is not a requirement. SLB 114 , in fact, may run on one of the target processing units. In this embodiment, when such a target processing unit fails, SLB 114 will fail along with the replication agent 106 running on the failed target processing unit. Accordingly, stand-by SLB 116 will not receive any replication message from the failed replication agent 106 . Thus, connection table 123 will not be an exact duplicate of connection table 117 . However, as long as the other replication agents have not failed, then connection table 123 will contain all of the records from connection table 117 that map a session to a target processing unit other than the failed target processing unit, which means that stand-by SLB will be able to route all of the active sessions that were not mapped to the failed target processing unit 102 .
[0051] Referring now to FIG. 4 , FIG. 4 illustrates a block diagram of an SLB apparatus 400 , according to some embodiments, configured to perform SLB functions described above. As shown in FIG. 4 , SLB 400 may include: a data processor 402 , which may include one or more microprocessors and/or one or more circuits, such as an application specific integrated circuit (ASIC), Field-programmable gate arrays (FPGAs), etc; a network interface 404 for interfacing with network 110 ; a network interface 405 for interfacing with network 120 ; a storage system 406 , which may include one or more non-volatile storage devices and/or one or more volatile storage devices (e.g., random access memory (RAM)). In embodiments where data processor 402 includes a microprocessor, computer instructions 408 (i.e., software) may be stored in storage system 406 . For example, the computer instructions 408 may be embodied in a computer program stored using a computer readable means, such as, but not limited, to magnetic media (e.g., a hard disk), optical media (e.g., a DVD), memory devices (e.g., random access memory), etc. In some embodiments, computer instructions 408 is configured such that when computer instructions 408 are executed, SLB 400 is operable to perform steps described above (e.g., steps describe above with reference to the flow charts shown in FIGS. 2 and 3 ). In other embodiments, SLB 400 is configured to perform steps described above without the need for software 408 . That is, for example, data processor 402 may consist merely of one or more ASICs. Hence, the features of the present invention described above may be implemented in hardware and/or software.
[0052] 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 limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
[0053] Additionally, while the processes described above and illustrated in the drawings are shown as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, and some steps may be performed in parallel. | The invention provides, in one aspect, a server load balancer (SLB) recovery method that replicates a primary SLB's connection data after the primary SLB experiences a failure, as opposed to before it experiences a failure as is currently done in the known hot stand-by recovery method. In some embodiments, this is made possible by (1) employing a replication agent on each target processing unit (e.g., each processing unit on which a server application runs) and (2) transmitting, from the primary SLB, connection data information (i.e., information comprising a session identifier) to the replication agent running on the target processing unit to which the session is mapped, which replication agent will store the data until it is required to transmit the data to a cold stand-by SLB. | Briefly outline the background technology and the problem the invention aims to solve. | [
"TECHNICAL FIELD [0001] The invention relates the field of server load balancing.",
"BACKGROUND [0002] A server load balancer (SLB) is device (hardware and/or software) for balancing session traffic across a set of applications (e.g., server applications), each of which runs on a processing unit (e.g., a server computer, a blade server, etc.).",
"In many environments it is desired to have in-place a stand-by SLB in case the primary SLB fails.",
"It is known that the stand-by SLB can either be a “hot”",
"stand-by or a “cold”",
"stand-by.",
"When using a hot stand-by SLB it is required that connection data (e.g., a connection table) that is used by the primary SLB in balancing traffic across the server applications be replicated to the hot stand-by SLB prior to the failure of the primary SLB.",
"Typically, this replication is accomplished by updating connection data accessible to the hot stand-by SLB each time the connection data maintained by the primary SLB is updated.",
"An advantage of using a hot stand-by SLB is that, in case a failure of the primary SLB (or “active”",
"SLB) occurs, a switchover to the stand-by SLB occurs and this stand-by SLB would have connection data that is identical to the connection data that was maintained by the primary SLB, thereby enabling the stand-by SLB to takeover as primary SLB and continue balance traffic for the already established sessions as well as new session.",
"[0003] A problem with using the hot stand-by method is that if the hot stand-by fails, then the connection data will be lost.",
"Moreover, the hot stand-by method requires that the hot stand-by SLB work in tandem with the primary SLB so that the primary SLB's connection data can be replicated.",
"Another problem with the hot stand-by method occurs when some event (e.g., power failure, operating system crash, hardware fault) causes the primary SLB and a target processing unit (e.g., a processing unit on which a server application runs) to fail at more less the same time.",
"When such a situation arises, the replicated connection data that is used by the stand-by SLB may include invalid information (e.g., information mapping a session to the failed target processing unit).",
"This could cause the hot stand-by SLB to forward traffic to the failed target processing unit, which is undesirable because the traffic will not get processed due to the failure of the target processing unit.",
"[0004] A problem with using a cold stand-by SLB is that there is no replication of the primary SLB's connection data, and this means that the cold stand-by SLB can not route traffic corresponding to a session that was established before the primary SLB failed.",
"[0005] What is desired, therefore, are improved systems and methods for recovering from the failure of an SLB.",
"SUMMARY [0006] In one aspect, the invention provides an SLB recovery method that replicates the primary SLB's connection data after the primary SLB experiences a failure, as opposed to before it experiences a failure as is currently done in the known hot stand-by recovery method.",
"In some embodiments, this is made possible by (1) employing a replication agent on each target processing unit (e.g., each processing unit on which a server application runs) and (2) transmitting, from the primary SLB, connection data information (i.e., information comprising a session identifier) to the replication agent running on the target processing unit to which the session is mapped, which replication agent will store the connection data information until it is required to transmit the data to a cold stand-by SLB.",
"[0007] By having the primary SLB transmit connection data information to the replication agent, the replication agent can provide the connection data information to the cold stand-by SLB in the event the primary SLB experiences a failure.",
"This provides the advantage of enabling a system design solution that can capitalize on the flexibility of cold stand-by methods yet is still able to protect established sessions because the cold stand-by SLB can receive from one or more replication agents connection data information that maps an established session to a particular target processing unit.",
"This is particularly useful in server farms and clustered system designs.",
"[0008] Moreover, the above described embodiment provides protection against multiple SLB failures because, in the event of a primary SLB failure and a cold stand-by failure, a second cold stand-by SLB can easily replicate the necessary connection data by merely receiving the necessary information from the replication agents.",
"[0009] Additionally, some embodiments of the invention solve the above described problem that occurs when an event (e.g., power failure, operating system crash, hardware fault, etc) causes the primary SLB and a target processing unit to fail at more less the same time.",
"As described above, in such a situation, the conventional stand-by SLB will have connection data (e.g., a connection table) that includes invalid connection data information (e.g., a records that maps a session to the failed target processing unit).",
"However, if such a situation occurs in a system according to some embodiment of the invention, the replicated connection data used by the stand-by SLB will not contain any such invalid connection data information.",
"This is so because, in some embodiments, the stand-by SLB receives its connection data information from the target processing unit themselves after the primary SLB fails.",
"Thus, if a target has failed at more or less the same time as the primary SLB, then the stand-by SLB will not receive any connection data information from the failed target.",
"Hence, the stand-by SLB will not have connection data that includes connection data information that maps a session to the failed target.",
"[0010] One aspect of the invention provides a method, performed by a stand-by SLB.",
"In some embodiments, this method includes: replicating, by the stand-by SLB, at least a portion of connection data maintained by the primary SLB such that the replicated connection data is accessible to the stand-by SLB, characterized in that the replicating step occurs in response to a detection of the failure of the primary SLB.",
"After the replicating step, the stand-by SLB may: (a) receive traffic corresponding to a session;",
"(b) access the replicated connection data to determine a target processing unit to which the session is mapped;",
"and (c) forward the traffic to the determined target processing unit (i.e., the stand-by SLB become the primary SLB).",
"[0011] After the replicating step, the stand-by SLB (which is now a primary SLB) may further: receive traffic corresponding to a second session and access the replicated connection data to determine whether the accessed data comprises information mapping the second session to any of a plurality of target processing units.",
"In response to determining that the accessed data does not comprise information mapping the second session to any of the plurality of target processing units, the stand-by SLB is configured to: (a) select a particular target processing unit;",
"(b) update the replicated connection data so that the replicated connection data will comprise information mapping the second session with the selected target processing unit;",
"and (c) transmit to a replication agent running on the selected target processing unit a connection data update message comprising a session identifier identifying the second session.",
"[0012] In some embodiments, the step of replicating the connection data comprises: receiving, at the stand-by SLB, a replication message transmitted from a target processing unit, wherein the replication message contains a session identifier identifying a session;",
"and in response to receiving the replication message, storing information that maps the session with the target processing unit.",
"In some embodiments, the replication message may contain a plurality of session identifiers, each identifying a different session, and, in response to receiving the replication message, the stand-by SLB stores information mapping each of the plurality of session identifiers with the target processing unit.",
"[0013] In some embodiments, the method further includes: transmitting, in response to the failure of the primary SLB, a connection data synchronization message to each of a first and a second target processing unit, wherein each of the first and second target processing units is configured to transmit one or more replication messages to the stand-by SLB in response to receiving the connection data synchronization message.",
"[0014] In some embodiments, the connection data maintained by the primary SLB comprises first information mapping a first session to the first target processing unit and second information mapping a second session to the second target processing unit, wherein the first information consists of a first record comprising a first field storing a session identifier identifying the first session and a second field storing a target processing unit identifier identifying the first target processing unit, and the second information consists of a second record comprising a second field storing a session identifier identifying the second session and a second field storing a target processing unit identifier identifying the second target processing unit.",
"[0015] In some embodiments, the step of receiving, at the stand-by SLB, traffic corresponding to a session consists of receiving, at the stand-by SLB, a network packet comprising information identifying the session, wherein the network packet is an Internet Protocol (IP) packet that contains an IP header and a payload, wherein the payload contains a transport layer segment having a transport layer header and payload, and data from the IP header and transport layer header identifies the network packet as corresponding to the session.",
"[0016] In some embodiments, the primary SLB may execute on one of the target processing units.",
"In this case, the replicated connection data may not contain information that maps any session to the target processing unit on which the primary SLB was running when it failed.",
"This, as described above, is advantageous because it is undesirable for the stand-by SLB to attempt to forward traffic to a failed target, which could happen if the connection table used by the stand-by SLB contains a record that maps a session to a failed target processing unit.",
"[0017] In another aspect, the invention provides an improved stand-by server load balancer (SLB).",
"The improved stand-by SLB is configured to recover from the failure of a primary SLB, which is operable to use stored connection data to balance traffic across a plurality of target processing units using.",
"The stored connection data comprises information mapping sessions with target processing units.",
"Advantageously, in one embodiment, the stand-by SLB is configured such that, in response to a detection of the failure of the primary SLB, the stand-by SLB replicates the connection data (or most of the connection data) to create replicated connection data.",
"The replicated connection data is accessible to the stand-by SLB so that the stand-by SLB can use the replicated connection data to balance traffic across the plurality of target processing units.",
"[0018] In some embodiments, the stand-by SLB is configured to replicate the connection data by receiving one or more replication messages from one or more of the target processing units, each of the one or more replication message comprising a session identifier and a target processing unit identifier.",
"In some embodiments, the stand-by SLB is further configured such that, in response to the failure of the primary SLB, the stand-by SLB transmits a connection data synchronization message to at least one of the plurality of target processing units.",
"[0019] In some embodiments, the connection data comprises a record comprising a first field storing a session identifier identifying a session and a second field storing a target processing unit identifier identifying a target processing unit, and the replicated connection data comprises a record comprising a first field storing the session identifier identifying the session and a second field storing the target processing unit identifier identifying the target processing unit.",
"[0020] The stand-by SLB may be further operable to: receive a network packet corresponding to a session;",
"use the replicated connection data to determine the target processing unit to which the session is mapped;",
"and forward the network packet to the determined target processing unit.",
"The network packet may be an Internet Protocol (IP) packet that contains an IP header and a payload, wherein the payload contains a transport layer segment having a transport layer header and payload, and data from the IP header and transport layer header identifies the network packet as corresponding to the session.",
"[0021] In another aspect, the invention provides an improved primary server load balance (SLB) for balancing traffic across a plurality of target processing units.",
"The primary SLB is operable to receive traffic corresponding to a session and access connection data to determine whether the connection data comprises information mapping the session to any of the plurality of target processing units.",
"Advantageously, in response to determining that the connection data does not comprise information mapping the session to any of the plurality of target processing units, the primary SLB selects a particular target processing unit from the plurality of target processing units, updates the connection data so that the connection data will comprise information mapping the session with the selected target processing unit, and transmits to a replication agent running on the selected target processing unit a connection data update message comprising a session identifier identifying the session.",
"The connection update message may comprise a target processing unit identifier for identifying the selected target processing unit.",
"[0022] In another aspect, the invention provides a computer program product comprising a computer usable medium having a computer readable program code embodied therein, said computer readable program code adapted to be executed to implement a method comprising: accessing connection data, in response to receiving traffic corresponding to a session, to determine whether the connection data comprises information mapping the session to any of the plurality of target processing units;",
"and in response to determining that the connection data does not comprise information mapping the session to any of the plurality of target processing units: (a) selecting a particular target processing unit from the plurality of target processing units and (b) updating the connection data so that the connection data will comprise information mapping the session with the selected target processing unit.",
"Characterized in that the method further comprises, in further response to determining that the connection data does not comprise information mapping the session to any of the plurality of target processing units, transmitting to a replication agent running on the selected target processing unit a connection data update message comprising a session identifier identifying the session.",
"[0023] In another aspect, the invention provides a computer program product comprising a computer usable medium having a computer readable program code embodied therein, said computer readable program code adapted to be executed to implement a method comprising: replicating connection data used by a primary server load balancer (SLB) immediately in response to a detection that the primary SLB has failed;",
"and using the replicated connection data to balance traffic across a plurality of target processing units.",
"[0024] In another aspect, the invention provides, a target processing unit, wherein the target processing includes a replication agent.",
"Advantageously, the replication agent is operable to: receive from a primary server load balancer (SLB) a connection data update message comprising a session identifier identifying a session;",
"and store the session identifier in response to receiving the connection data update message, characterized in that: the replication agent is configured to transmit the session identifier to a stand-by SLB in response to receiving a synchronization message.",
"[0025] The replication agent, in some embodiments, is further operable to: receive from the primary SLB a second connection data update message comprising a second session identifier identifying a second session;",
"and store the second session identifier in response to receiving the second connection data update message, characterized in that: the replication agent is configured such that, in response to receiving the synchronization message, the replication agent transmits to the stand-by SLB a replication message containing the first and second session identifiers.",
"The replication message may further contain an identifier identifying the target processing unit.",
"[0026] The above and other aspects and embodiments are described below with reference to the accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0027] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.",
"In the drawings, like reference numbers indicate identical or functionally similar elements.",
"[0028] FIG. 1 illustrates a system according to an embodiment of the invention.",
"[0029] FIG. 2 is a flow chart illustrating a processes according an embodiment of the invention.",
"[0030] FIG. 3 is a flow chart illustrating a processes according an embodiment of the invention.",
"[0031] FIG. 4 is a functional block diagram of an SLB apparatus according to some embodiments.",
"DETAILED DESCRIPTION [0032] Referring now to FIG. 1 , FIG. 1 illustrates a system 100 according to an embodiment of the invention.",
"System 100 includes a primary SLB 114 that is operable to balance session traffic across, among other things, a set of server applications 104 , each of which runs on a processing unit 102 .",
"Also running on each processing unit 102 a to 102 n , is a replication agent 106 .",
"[0033] FIG. 2 is a flow chart illustrating a process 200 , according to some embodiments, that is performed by primary SLB 114 .",
"Process 200 may begin in step 202 , where primary SLB 114 receives session traffic (e.g., a packet), via network 120 , transmitted from some device (not shown) connected to network 120 , which may be an Internet Protocol (IP) network, such as the Internet, other network.",
"Thus, in some embodiments, the received traffic is an IP packet, which, as is well known in the art, includes a header and payload.",
"For the sake of simplicity, we shall assume that in step 202 SLB 114 received an IP packet.",
"[0034] In step 204 , SLB 114 extracts data from the received packet to generate a session identifier (e.g., a data structure, such as a string of bits or other structure, containing data from certain fields of the packet that together identify a session).",
"For example, in step 204 , assuming the IP packet encapsulates a Transmission Control Protocol (TCP) packet or a User Datagram Protocol (UDP) packet, SLB 114 may form a data structure containing: (a) the following items from the IP header of the packet: source address, destination address, version (e.g. IPv4 or IPv6), and protocol (e.g., TCP or UDP) and (b) the following items from the TCP/UDP header: source port and destination port.",
"[0035] In step 206 , SLB 114 determines whether the packet corresponds to a new session.",
"In the case where the packet is a TCP/IP packet, in some embodiments, SLB 114 determines whether the packet corresponds to a new session by determining if the packet contains a TCP packet that indicates that the TCP packet is a TCP connection request (i.e., the SYN bit of the TCP packet is set).",
"[0036] In the case where the packet is a UDP/IP packet, in some embodiments, SLB 114 determines whether the packet corresponds to a new session by determining whether the generated session identifier matches a session identifier stored in a connection table 117 stored in storage unit 115 , which may be a volatile (e.g., RAM) or non-volatile storage unit.",
"In some embodiments, connection table 117 stores connection data that includes information mapping sessions to target processing units 102 .",
"For example, the connection data may include a plurality of records, where each record comprises a first field for storing a session identifier identifying a session and a second field for storing a processing unit identifier (e.g., an IP address) associated with a target processing unit 102 .",
"In some embodiments, the records may include additional fields.",
"[0037] If the traffic corresponds to a new session, then the process proceeds to step 212 , otherwise it proceeds to step 222 .",
"[0038] In step 212 , SLB 114 selects a target processing unit.",
"For example, a table 121 of targeting processing unit identifiers may be stored in storage unit 115 , and SLB 114 selects a target processing unit in step 212 by, for example, randomly selecting from the table 121 an identifier that identifies a target processing unit.",
"[0039] In step 214 , SLB 114 forwards the packet received in step 202 to the selected target processing unit 102 .",
"The packet is then received and processed by protocol stack 108 and, if the packet contains application data, then the application data contained in the packet is provided to server application 104 .",
"[0040] In step 216 , SLB 114 updates connection table 117 .",
"For example, in step 216 , SLB 114 may add a record to table 117 , which record contains in one field the session identifier generated in step 204 and in another field a target processing unit identifier that identifies the target processing unit selected in step 212 .",
"[0041] Advantageously, in some embodiments, in step 218 , SLB 114 sends to the selected target processing unit a connection data update message that includes the generated session identifier.",
"This message is received by a protocol stack 108 running on the target processing unit 102 and the message is then provided to the replication agent 106 running on the target processing unit 102 .",
"Replication agent 106 , in response to receiving the message, stores in storage unit 109 the session identifier included in the connection update message (step 220 ).",
"Accordingly, a portion of connection table 117 is duplicated in storage unit 109 .",
"This provides the distinct advantage of enabling replication agent 106 to inform stand-by SLB 116 of the active sessions that were handled by primary SLB 114 , as well as the target processing units associated with those active sessions, in the event primary SLB 114 experiences a failure.",
"This information regarding the active sessions enables the cold stand-by SLB 114 to take over the handling of these active sessions.",
"[0042] While replication agent 106 is shown as being separate and apart from protocol stack 108 (i.e., replication agent 106 is a user application), this was done solely for the sake of illustration.",
"In some other embodiments, replication agent 106 may be part of protocol stack 108 or some other part of the operating system.",
"In the case where, replication agent 108 is a part of protocol stack 108 , step 218 may be unnecessary because (a) the replication agent 106 may obtain from the protocol stack 108 a copy of the packet (or a copy of some portion of the packet) that was forwarded in step 214 and (b) replication agent 106 can be configured to use this information to generate the session identifier in the same manner that SLB 114 generates the session identifier as described above.",
"After replication agent 106 generates the session identifier, agent 106 can store it in storage unit 109 .",
"[0043] In step 222 , SLB 114 determines the target processing unit that is associated with the generated session identifier.",
"SLB 114 , in some embodiments, makes this determination by selecting the record in connection table 117 that includes a session identifier that matches the session identifier generated in step 204 .",
"This selected record will contain a target processing unit identifier that identifies the target processing unit associated with the generated session identifier.",
"[0044] In step 224 , SLB 114 forwards the packet received in step 202 to the determined target processing unit 102 .",
"In step 226 , SLB 114 determines whether the packet indicates the end of the session.",
"For example, in the case where the packet is a TCP/IP packet, SLB 114 determines that the packet indicates the end of the session when the FIN bit of the TCP packet is set.",
"If the packet does not indicate the end of the session, the process may proceed back to step 202 , where SLB 114 receives a new packet.",
"If the packet indicates the end of the session, then SLB 114 updates its connection table by removing the record in the table that contains a session identifier that matches the session identifier generated in step 204 (step 228 ).",
"In step 230 , SLB 114 sends to the replication agent on the determined target processing unit a connection data update message that includes the generated session identifier (the message may also include an end-of-session indication).",
"In response to receiving this message, the replication agent 106 removes from storage unit 109 the session identifier that matches the session identifier included in the message (step 232 ).",
"[0045] Referring now to FIG. 3 , FIG. 3 is a flow chart illustrating a process 300 that shows steps that are preformed in the event primary SLB 114 experiences a failure.",
"Process 300 may begin in step 302 , where SLB monitor 112 determines whether SLB 114 has experienced a failure.",
"If SLB 114 has not experienced a failure, SLB monitor 112 continues monitoring SLB 114 .",
"In the event of a failure, process 300 proceeds to step 304 .",
"[0046] In step 304 , a control message (a.k.a., a connection data synchronization message) is transmitted to each target processing unit 102 a to 102 n (or each target processing unit identified in table 121 ).",
"Each control message may be addressed to the replication agent 106 running on the target processing unit to which the control message was sent, thus, the control message is provided to the replication agent.",
"The control message may be sent by SLB monitor 112 in response to it determining that SLB 114 has failed.",
"While SLB monitor 112 is shown as being separate and apart from stand-by SLB 116 , this is not a requirement as monitor 112 may be a module of SLB 116 .",
"[0047] In response to receiving the control message, the replication agent 106 transmits to stand-by SLB 116 each of the session identifiers it stored in storage unit 109 if it hasn't earlier removed the session identifier from the storage unit (step 306 ).",
"For example, replication agent 106 may transmit to SLB 116 a replication message comprising the set of session identifiers.",
"Replication agent 106 may obtain the network address of stand-by SLB 116 from a configuration file stored in storage unit 109 or it may be included in the control message.",
"[0048] In step 308 , stand-by SLB 116 uses the session identifiers it receives from each replication agent to form connection table 123 , which, at least in part, is a replication of connection table 117 .",
"Thus, connection table 123 is replicated connection data.",
"For example, for each session identifier that SLB 116 receives from a particular replication agent 106 , SLB 116 may add to table 123 a record comprising a first field that stores the session identifier and a second field that stores a target processing unit identifier that identifies the target processing unit on which the replication agent is running, thereby storing information that maps the session identified by the session identifier with the target processing unit identified by the target processing unit identifier.",
"This target processing unit identifier may be included in the replication message sent by the replication agent in step 306 .",
"[0049] In step 310 , SLB 116 receives session traffic (e.g., a packet), via network 120 , transmitted from some device (not shown) connected to network 120 , and uses the information mapping sessions to target processing units (e.g., connection table 123 ) to forward the packet to the appropriate target processing unit as described above in connection with FIG. 2 .",
"[0050] Referring back to FIG. 1 , while primary SLB 114 is shown as being separate and apart from the target processing units 102 , this is not a requirement.",
"SLB 114 , in fact, may run on one of the target processing units.",
"In this embodiment, when such a target processing unit fails, SLB 114 will fail along with the replication agent 106 running on the failed target processing unit.",
"Accordingly, stand-by SLB 116 will not receive any replication message from the failed replication agent 106 .",
"Thus, connection table 123 will not be an exact duplicate of connection table 117 .",
"However, as long as the other replication agents have not failed, then connection table 123 will contain all of the records from connection table 117 that map a session to a target processing unit other than the failed target processing unit, which means that stand-by SLB will be able to route all of the active sessions that were not mapped to the failed target processing unit 102 .",
"[0051] Referring now to FIG. 4 , FIG. 4 illustrates a block diagram of an SLB apparatus 400 , according to some embodiments, configured to perform SLB functions described above.",
"As shown in FIG. 4 , SLB 400 may include: a data processor 402 , which may include one or more microprocessors and/or one or more circuits, such as an application specific integrated circuit (ASIC), Field-programmable gate arrays (FPGAs), etc;",
"a network interface 404 for interfacing with network 110 ;",
"a network interface 405 for interfacing with network 120 ;",
"a storage system 406 , which may include one or more non-volatile storage devices and/or one or more volatile storage devices (e.g., random access memory (RAM)).",
"In embodiments where data processor 402 includes a microprocessor, computer instructions 408 (i.e., software) may be stored in storage system 406 .",
"For example, the computer instructions 408 may be embodied in a computer program stored using a computer readable means, such as, but not limited, to magnetic media (e.g., a hard disk), optical media (e.g., a DVD), memory devices (e.g., random access memory), etc.",
"In some embodiments, computer instructions 408 is configured such that when computer instructions 408 are executed, SLB 400 is operable to perform steps described above (e.g., steps describe above with reference to the flow charts shown in FIGS. 2 and 3 ).",
"In other embodiments, SLB 400 is configured to perform steps described above without the need for software 408 .",
"That is, for example, data processor 402 may consist merely of one or more ASICs.",
"Hence, the features of the present invention described above may be implemented in hardware and/or software.",
"[0052] 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 limitation.",
"Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.",
"Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.",
"[0053] Additionally, while the processes described above and illustrated in the drawings are shown as a sequence of steps, this was done solely for the sake of illustration.",
"Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, and some steps may be performed in parallel."
] |
This is a continuation of international patent application PCT/EP2007/054529, filed May 10, 2007, which claims priority of German patent application S.N. 10 2006 023 641.6 filed May 18, 2006.
FIELD OF THE INVENTION
The invention relates in general to mobile communication networks, and in particular it relates to mobile communication networks operating according to GSM- and/or UMTS-standards for the communication of mobile stations.
BACKGROUND OF THE INVENTION
A mobile network generally comprises base stations which are arranged in an approximately hexagonal pattern. The pattern results from radio cells. The special extension of each radio cell is formed by the covered range of the base stations which are in contact with a mobile station. For this purpose each base station supplies three radio cells by means of three antennas having a relative angle of 120.degree. Each of the three antennas of a base station thereby emits a “sending lobe” of about 120.degree. Such an arrangement of the radio cells of a mobile network system is called “clover model”. For the wireless data transmission various resources are available for the operator of a mobile network, such as, for example, frequency bands which are divided into several physical transmission channels. Different transmission resources, for example, frequency bands, in two adjacent radio cells of a mobile network are attributed to the mobile stations. The transmission resources are adjusted in such a way that there is no superposition at all at the borders.
In order to simultaneously support as many connections as possible transmission channels are divided by frequency slots within a frequency bands, time slots within the transmission frame, codes with UMTS. In a GSM-mobile network (=Global System for Mobile communication), for example, a physical channel is formed by a frequency slot and a time slot within the transmission frame of eight subsequent time slots.
The operator of a network must, therefore, re-use the transmission resources as often as possible within the network. Generally, this is achieved when the entire amount of transmission resources is divided into orthogonal subgroups which are then attributed to the respective radio cells. A careful planning of the resources is required for this purpose. Only resources from the subgroup attributed to one particular radio cell are used for the communication in this particular radio cell. Thereby, the distance between radio cells is increase which use the same resources and which are exposed to mobile network signals interfering with each other. A measure for the influence of a transmission by interference is the ratio of a wanted signal intensity and the interference intensity, abbreviated by SIR (Signal to Interference Ratio). Only from a certain SIR-value an acceptable communication can be achieved. This threshold depends on additional thermal noise in the components and the requirements of the individual application, i.e. of quality parameters QoS (Quality of Service).
A further important measure with the planning of the resources, such as, for example, the planning of the frequencies, is the reuse factor. This reuse factor of the individual resource describes, for example, the frequency reuse factor, i.e. the amount of orthogonal subgroups. A reuse factor of one corresponds to the case where each radio cell uses the same resources because there is one group only. A high reuse factor reduces the interference intensity in a mobile network considerably, but limits the spectral efficiency of the network, because in each radio cell only a small amount of the entire resources of the operator of the mobile network is used.
Very often reuse factors “3” and “7” are used in mobile networks. In order to achieve a SIR-value required for a certain service in the entire cell area the system is designed based on the worst case. Therefore, the edge areas of a radio cell where higher interferences occur due to users in adjacent radio cells sending nearby determine the reuse factor of the planned resource. Thereby regions are generated which have an unnecessarily high SIR-value in the central region around the base station thereby reducing the spectral efficiency of the mobile network system.
In order to achieve a special distribution of the SIR in a radio cell which is as homogenous as possible overlay concept systems are described in the literature which have overlapping resource planning. For example the resource can be attributed with a low reuse factor in the inner region of the radio cell and with a high reuse factor in the edge regions. It is a disadvantage of this solution that further reduction of the interfering intensity due to interference suppressing methods is not possible because there are no strong and thereby detectable interferences occur due to the resource planning.
SUMMARY OF THE INVENTION
It is an object of the invention to avoid the disadvantages of the prior art and in particular to increase the efficiency of the mobile network and to increase the capacity thereof.
According to the invention this object is achieved in that with a mobile network, especially operating according to GSM- and/or UMTS-standards for the communication of mobile stations, wherein the transmission resources of the far range of two adjacent radio cells are coincident. The network comprises at least two base stations with antennas for sending and/or receiving communication signals, wherein the covered area of a base station forms a radio cell which is divided into a close-up range and a far range, wherein different transmission sources are provided for the radio traffic.
Furthermore this object is achieved with a method for attributing transmission sources in a mobile network, especially according to GSM- and/or UMTS-standard, for mobile stations for communication, comprising the steps of:
a) forming of at least two radio cells, each resulting from the covered area of a base station with antennas for sending and/or receiving, b) dividing the radio cells into a close-up range and a far range, and c) attributing different transmission sources to the close-up range and the far range of the radio cells, so that coincident transmission sources can be attributed to the mobile stations for the communication in the far range of two adjacent radio cells.
Contrary to the prior art the mobile network and method of the invention do not principally try to minimize the interfering intensity caused by interference from adjacent radio cells. Strong interferences are intentionally admitted. The mobile station of a user must adapt to such known interferences and eliminate if necessary. In such a way users of adjacent radio cells can use the same transmission resource, such as a frequency slot, a time slot or a multi user code.
This can be achieved by using a low resource reuse factor at the edge of the cell, i.e. at the border between adjacent radio cells, because then the probability of a user with the same transmission resource in an adjacent radio cell, i.e. in the immediate proximity of the considered user is increased. Such few interferences with high intensity can be removed from the signal of the user using signal processing methods which suppress interferences and thereby a transmission is enabled. By using a low reuse factor the spectral efficiency of the mobile network is increased.
In cell regions where the occurrence of strong and significant interferences is less likely, as it is the case in the center of a radio cell where there is no immediate border of an adjacent radio cell the use of interference suppressing methods makes little sense due to the bad detectability of the weak interferences. In the present invention the interference is reduced by using a high reuse factor.
Thereby, an inverse superposition is achieved. In the prior art a coincident attribution of transmission resources is effected only in the close-up range but not along the cell edges, the far range. Contrary to the above inverse attribution is used with the present invention. Coincident transmission resources are used in the far range and different transmission resources in the close-up range, i.e. just the other way round compared to the prior art.
As to another aspect of the invention, the mobile stations of the mobile network are provided with filter means for removing interfering signals having a higher, the same or slightly smaller intensity than the wanted signal. A slightly smaller intensity corresponds in a preferred embodiment of the invention to a distance of 10 dB between the interference signal and the wanted signal. In an alternative embodiment the distance can be 3 dB or 6 dB. By this measure it is achieved that the interfering signals which are caused in particular by the interference from adjacent radio cells are directly filtered from the wanted signal in the mobile end station of the user and taken off after its detection. It is, therefore, also subject matter of the present invention a mobile station with filter means which are provided for the removing of interfering signals in such a mobile network.
Further advantages result from the subject matter of other claims and the drawings with the accompanying description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows an embodiment of a mobile network with a reuse factor “3” where the use of a certain frequency range is effected in all three radio cells;
FIG. 2 schematically shows an embodiment of a mobile network with a reuse factor “7” where the use of a certain frequency range is effected in all three radio cells;
FIG. 3 shows an embodiment of a mobile network with sending lobes with the reuse factor “1” in the center of the cell and the reuse factor “3” at the edge of the cell;
FIG. 4 shows an embodiment of a mobile network as sending lobes with the reuse factor “3” in the center of the cell and the reuse factor “1” at the edge of the cell; and
FIG. 5 shows an embodiment of a mobile network with mobile stations for the suppression of interfering signals.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a schematic drawing of a mobile network 10 is shown. The mobile network 10 generally comprises base stations 12 which are arranged in an approximately hexagonal structure 14 . The hexagonal structure 14 results from radio cells 16 . The base stations 12 are represented by black dots. Each base station 12 supplies three of the radio cells 16 with three antennas which have a horizontal angle of 120 degree with respect to each other. Each of the three antennas of a base station 12 , therefore, emits a sending lobe 18 , 20 , 22 having about 120.degree. an example of which is shown at the base station 12 a. Such an arrangement of radio cells 16 of a mobile network 10 is called “clover model” and serves in this description for illustration purposes only. The described method may also be used for any other cellular mobile network 10 . Frequency bands are used as an example for transmission resource which must be divided between the cells.
Each of the sending lobes 18 , 20 , 22 of each base station 12 emits in a different frequency band. The different frequency bands are denoted by A, B, C. An important measure for the planning of frequencies is the reuse factor of the respective resource describing the amount of orthogonal subgroups. A reuse factor of “1” corresponds to the case where each radio cell 16 uses the same frequency band A as there is only one group. A high reuse factor reduces the interference intensity in the mobile network 10 but limits the spectral efficiency of the mobile network 10 as only a small portion of the entire resources is used in each radio cell 16 . FIG. 1 shows a mobile network 10 with the reuse factor 3.
FIG. 2 shows a corresponding mobile network 10 with the reuse factor “7”. The frequency bands are denoted A, B, C, D, E, F and G.
FIG. 3 shows a mobile network 10 according to the current prior art. Instead of the hexagonal structure 14 shown above only sending lobes 18 , 20 , 22 , 24 are shown. A close-up range 26 and a far range 28 are attributed to each base station 12 . The close-up range 26 is in the immediate neighborhood of each base station 12 . The far range 28 extends to the edge of the radio cell 16 . Reuse factor “1” is provided for the close-up range 26 . All sending lobes 24 in the close-up range 26 are provided with the same frequency band A. In the far range 28 of each base station 12 the reuse factor “3” is provided. All sending lobes 18 , 20 , 22 are provided with different frequency bands B, C, D.
FIG. 4 shows a mobile network 10 according to the present invention with inverse frequency superposition. A close-up range 26 and a far range 28 are attributed to each base station 12 corresponding to FIG. 3 . The close-up range 26 is in the immediate neighborhood of each base station 12 . The far range 28 extends from there to the edge of the radio cells 16 . The close-up range 26 is supplied by sending lobes 30 , 32 , 34 . The far range 28 is covered by sending lobes 36 . The sending lobes 30 , 32 , 34 have different frequency bands B, C, D. The sending lobes 36 of the far range use a coincident frequency band A. The present mobile network 10 , therefore, is provided with a reuse factor “3” in the close-up range 26 and with a reuse factor “1” in the far range with respect to the frequency bands A, B, C, D. Thereby the same coincident frequency bands A are always used in the far range 28 of two adjacent radio cells.
An embodiment for interference suppressing methods is described in greater detail below. In FIG. 5 four mobile stations 38 are shown which communicate from the edge of a cell 40 with the base station 12 of the respective radio cell 16 . Such connections are represented by arrows 42 . The mobile stations 38 in the mobile network 10 with inverse frequency band superposition use a small frequency band reuse factor. With the reuse factor of 1 used in the present embodiment all mobile stations 38 use the same frequency band A in the far range 28 of the radio cells 16 and, therefore, generate an interfering intensity by interference with each other.
In the uplink from the mobile stations 38 to the base stations 12 each base station 12 , therefore, receives a superposition of signals of a user attributed thereto having signals of users from adjacent radio cells 16 . Adjacent base stations 12 can now connect to an active group 44 in such a way that they transmit their signals received from, for example, landlines or radio relay systems, to a central knot which, for example, can be formed from one of the base stations 46 of the active group 44 , and thereby form a virtual multiple point to point MIMO system. The term MIMO (=Multiple Input Multiple Output) generally denotes systems with several sender—and receiver antennas for the increase of the data rate and the improvement of the transmission quality.
In multiple point to point MIMO systems a common signal processing can be achieved only at the receiver as the transmitters do not cooperate as it is the case in the uplink of a mobile network system. In such a central knot known MIMO detection methods, such as, for example, VBLAST-receivers, decision feedback demodulator, successive or parallel interference suppression or linear demodulation can be used to separate the individual uplink data flows of the active group 44 and to forward them to the mobile network 10 for further transmission or processing. Such a common processing of the received signal is summarized in the literature with the term “joint detection”. The strong interference which would exclude the successful detection at individual base stations 12 is inherently removed by the MIMO detection.
The formation of the active group 44 and the attribution of a central knot can be dynamically effected in the running network operation by measuring the interference situation. For this purpose the measurement of the strength of the transmission channel between a mobile station 38 and adjacent base stations 12 can be used by means of pilot sequences which are present in the handover procedures.
Furthermore the knowledge of the transmission channels with a significant intensity portion between the mobile station 38 and the base station 12 of the active group 44 is necessary for a successful MIMO detection. For this purpose a possibility for the undisturbed channel measurement must be provided which can be carried out by orthogonal pilot sequences or the sending of pilot sequences in time multiplex methods.
In the downlink from the base stations 12 to the mobile stations 38 a point to multiple point MIMO system can be formed by the described cooperation between the base stations 12 where in one central knot a pre-processing of the sending signals of each base station 12 is effected in such a way that the signal received and superimposed by the mobile stations 12 has a high SIR-value. Linear pre-modulation or “Tomlinson-Harashima Precoding (THP) can be used as pre-modulate methods. The knowledge of the transmission channel on the sender side necessary for this method can be obtained in TDD (=Tine Division Duplex) Systems by measuring the transmission channel in the uplink because the transmission channel is reciprocal regarding the uplink and downlink. If this reciprocal channel is not present, such as, for example, in FDD (=frequency division duplex) systems the channel estimates determined in the uplink can be transmitted through a return channel to the sender. | The invention relates to a mobile network, especially according to that of GSM- and/or UMTS-standards for the communication of mobile stations. The network consists of at least two base stations with antennas for sending and/or receiving communication signals, wherein the covered area of the base stations forms a radio cell which is divided into a close-up range and a far range, wherein different transmission sources are provided for the radio traffic. | Summarize the document in concise, focusing on the main idea's functionality and advantages. | [
"This is a continuation of international patent application PCT/EP2007/054529, filed May 10, 2007, which claims priority of German patent application S.N. 10 2006 023 641.6 filed May 18, 2006.",
"FIELD OF THE INVENTION The invention relates in general to mobile communication networks, and in particular it relates to mobile communication networks operating according to GSM- and/or UMTS-standards for the communication of mobile stations.",
"BACKGROUND OF THE INVENTION A mobile network generally comprises base stations which are arranged in an approximately hexagonal pattern.",
"The pattern results from radio cells.",
"The special extension of each radio cell is formed by the covered range of the base stations which are in contact with a mobile station.",
"For this purpose each base station supplies three radio cells by means of three antennas having a relative angle of 120.",
"degree.",
"Each of the three antennas of a base station thereby emits a “sending lobe”",
"of about 120.",
"degree.",
"Such an arrangement of the radio cells of a mobile network system is called “clover model.”",
"For the wireless data transmission various resources are available for the operator of a mobile network, such as, for example, frequency bands which are divided into several physical transmission channels.",
"Different transmission resources, for example, frequency bands, in two adjacent radio cells of a mobile network are attributed to the mobile stations.",
"The transmission resources are adjusted in such a way that there is no superposition at all at the borders.",
"In order to simultaneously support as many connections as possible transmission channels are divided by frequency slots within a frequency bands, time slots within the transmission frame, codes with UMTS.",
"In a GSM-mobile network (=Global System for Mobile communication), for example, a physical channel is formed by a frequency slot and a time slot within the transmission frame of eight subsequent time slots.",
"The operator of a network must, therefore, re-use the transmission resources as often as possible within the network.",
"Generally, this is achieved when the entire amount of transmission resources is divided into orthogonal subgroups which are then attributed to the respective radio cells.",
"A careful planning of the resources is required for this purpose.",
"Only resources from the subgroup attributed to one particular radio cell are used for the communication in this particular radio cell.",
"Thereby, the distance between radio cells is increase which use the same resources and which are exposed to mobile network signals interfering with each other.",
"A measure for the influence of a transmission by interference is the ratio of a wanted signal intensity and the interference intensity, abbreviated by SIR (Signal to Interference Ratio).",
"Only from a certain SIR-value an acceptable communication can be achieved.",
"This threshold depends on additional thermal noise in the components and the requirements of the individual application, i.e. of quality parameters QoS (Quality of Service).",
"A further important measure with the planning of the resources, such as, for example, the planning of the frequencies, is the reuse factor.",
"This reuse factor of the individual resource describes, for example, the frequency reuse factor, i.e. the amount of orthogonal subgroups.",
"A reuse factor of one corresponds to the case where each radio cell uses the same resources because there is one group only.",
"A high reuse factor reduces the interference intensity in a mobile network considerably, but limits the spectral efficiency of the network, because in each radio cell only a small amount of the entire resources of the operator of the mobile network is used.",
"Very often reuse factors “3”",
"and “7”",
"are used in mobile networks.",
"In order to achieve a SIR-value required for a certain service in the entire cell area the system is designed based on the worst case.",
"Therefore, the edge areas of a radio cell where higher interferences occur due to users in adjacent radio cells sending nearby determine the reuse factor of the planned resource.",
"Thereby regions are generated which have an unnecessarily high SIR-value in the central region around the base station thereby reducing the spectral efficiency of the mobile network system.",
"In order to achieve a special distribution of the SIR in a radio cell which is as homogenous as possible overlay concept systems are described in the literature which have overlapping resource planning.",
"For example the resource can be attributed with a low reuse factor in the inner region of the radio cell and with a high reuse factor in the edge regions.",
"It is a disadvantage of this solution that further reduction of the interfering intensity due to interference suppressing methods is not possible because there are no strong and thereby detectable interferences occur due to the resource planning.",
"SUMMARY OF THE INVENTION It is an object of the invention to avoid the disadvantages of the prior art and in particular to increase the efficiency of the mobile network and to increase the capacity thereof.",
"According to the invention this object is achieved in that with a mobile network, especially operating according to GSM- and/or UMTS-standards for the communication of mobile stations, wherein the transmission resources of the far range of two adjacent radio cells are coincident.",
"The network comprises at least two base stations with antennas for sending and/or receiving communication signals, wherein the covered area of a base station forms a radio cell which is divided into a close-up range and a far range, wherein different transmission sources are provided for the radio traffic.",
"Furthermore this object is achieved with a method for attributing transmission sources in a mobile network, especially according to GSM- and/or UMTS-standard, for mobile stations for communication, comprising the steps of: a) forming of at least two radio cells, each resulting from the covered area of a base station with antennas for sending and/or receiving, b) dividing the radio cells into a close-up range and a far range, and c) attributing different transmission sources to the close-up range and the far range of the radio cells, so that coincident transmission sources can be attributed to the mobile stations for the communication in the far range of two adjacent radio cells.",
"Contrary to the prior art the mobile network and method of the invention do not principally try to minimize the interfering intensity caused by interference from adjacent radio cells.",
"Strong interferences are intentionally admitted.",
"The mobile station of a user must adapt to such known interferences and eliminate if necessary.",
"In such a way users of adjacent radio cells can use the same transmission resource, such as a frequency slot, a time slot or a multi user code.",
"This can be achieved by using a low resource reuse factor at the edge of the cell, i.e. at the border between adjacent radio cells, because then the probability of a user with the same transmission resource in an adjacent radio cell, i.e. in the immediate proximity of the considered user is increased.",
"Such few interferences with high intensity can be removed from the signal of the user using signal processing methods which suppress interferences and thereby a transmission is enabled.",
"By using a low reuse factor the spectral efficiency of the mobile network is increased.",
"In cell regions where the occurrence of strong and significant interferences is less likely, as it is the case in the center of a radio cell where there is no immediate border of an adjacent radio cell the use of interference suppressing methods makes little sense due to the bad detectability of the weak interferences.",
"In the present invention the interference is reduced by using a high reuse factor.",
"Thereby, an inverse superposition is achieved.",
"In the prior art a coincident attribution of transmission resources is effected only in the close-up range but not along the cell edges, the far range.",
"Contrary to the above inverse attribution is used with the present invention.",
"Coincident transmission resources are used in the far range and different transmission resources in the close-up range, i.e. just the other way round compared to the prior art.",
"As to another aspect of the invention, the mobile stations of the mobile network are provided with filter means for removing interfering signals having a higher, the same or slightly smaller intensity than the wanted signal.",
"A slightly smaller intensity corresponds in a preferred embodiment of the invention to a distance of 10 dB between the interference signal and the wanted signal.",
"In an alternative embodiment the distance can be 3 dB or 6 dB.",
"By this measure it is achieved that the interfering signals which are caused in particular by the interference from adjacent radio cells are directly filtered from the wanted signal in the mobile end station of the user and taken off after its detection.",
"It is, therefore, also subject matter of the present invention a mobile station with filter means which are provided for the removing of interfering signals in such a mobile network.",
"Further advantages result from the subject matter of other claims and the drawings with the accompanying description.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 schematically shows an embodiment of a mobile network with a reuse factor “3”",
"where the use of a certain frequency range is effected in all three radio cells;",
"FIG. 2 schematically shows an embodiment of a mobile network with a reuse factor “7”",
"where the use of a certain frequency range is effected in all three radio cells;",
"FIG. 3 shows an embodiment of a mobile network with sending lobes with the reuse factor “1”",
"in the center of the cell and the reuse factor “3”",
"at the edge of the cell;",
"FIG. 4 shows an embodiment of a mobile network as sending lobes with the reuse factor “3”",
"in the center of the cell and the reuse factor “1”",
"at the edge of the cell;",
"and FIG. 5 shows an embodiment of a mobile network with mobile stations for the suppression of interfering signals.",
"DETAILED DESCRIPTION OF THE INVENTION In FIG. 1 a schematic drawing of a mobile network 10 is shown.",
"The mobile network 10 generally comprises base stations 12 which are arranged in an approximately hexagonal structure 14 .",
"The hexagonal structure 14 results from radio cells 16 .",
"The base stations 12 are represented by black dots.",
"Each base station 12 supplies three of the radio cells 16 with three antennas which have a horizontal angle of 120 degree with respect to each other.",
"Each of the three antennas of a base station 12 , therefore, emits a sending lobe 18 , 20 , 22 having about 120.",
"degree.",
"an example of which is shown at the base station 12 a. Such an arrangement of radio cells 16 of a mobile network 10 is called “clover model”",
"and serves in this description for illustration purposes only.",
"The described method may also be used for any other cellular mobile network 10 .",
"Frequency bands are used as an example for transmission resource which must be divided between the cells.",
"Each of the sending lobes 18 , 20 , 22 of each base station 12 emits in a different frequency band.",
"The different frequency bands are denoted by A, B, C. An important measure for the planning of frequencies is the reuse factor of the respective resource describing the amount of orthogonal subgroups.",
"A reuse factor of “1”",
"corresponds to the case where each radio cell 16 uses the same frequency band A as there is only one group.",
"A high reuse factor reduces the interference intensity in the mobile network 10 but limits the spectral efficiency of the mobile network 10 as only a small portion of the entire resources is used in each radio cell 16 .",
"FIG. 1 shows a mobile network 10 with the reuse factor 3.",
"FIG. 2 shows a corresponding mobile network 10 with the reuse factor “7.”",
"The frequency bands are denoted A, B, C, D, E, F and G. FIG. 3 shows a mobile network 10 according to the current prior art.",
"Instead of the hexagonal structure 14 shown above only sending lobes 18 , 20 , 22 , 24 are shown.",
"A close-up range 26 and a far range 28 are attributed to each base station 12 .",
"The close-up range 26 is in the immediate neighborhood of each base station 12 .",
"The far range 28 extends to the edge of the radio cell 16 .",
"Reuse factor “1”",
"is provided for the close-up range 26 .",
"All sending lobes 24 in the close-up range 26 are provided with the same frequency band A. In the far range 28 of each base station 12 the reuse factor “3”",
"is provided.",
"All sending lobes 18 , 20 , 22 are provided with different frequency bands B, C, D. FIG. 4 shows a mobile network 10 according to the present invention with inverse frequency superposition.",
"A close-up range 26 and a far range 28 are attributed to each base station 12 corresponding to FIG. 3 .",
"The close-up range 26 is in the immediate neighborhood of each base station 12 .",
"The far range 28 extends from there to the edge of the radio cells 16 .",
"The close-up range 26 is supplied by sending lobes 30 , 32 , 34 .",
"The far range 28 is covered by sending lobes 36 .",
"The sending lobes 30 , 32 , 34 have different frequency bands B, C, D. The sending lobes 36 of the far range use a coincident frequency band A. The present mobile network 10 , therefore, is provided with a reuse factor “3”",
"in the close-up range 26 and with a reuse factor “1”",
"in the far range with respect to the frequency bands A, B, C, D. Thereby the same coincident frequency bands A are always used in the far range 28 of two adjacent radio cells.",
"An embodiment for interference suppressing methods is described in greater detail below.",
"In FIG. 5 four mobile stations 38 are shown which communicate from the edge of a cell 40 with the base station 12 of the respective radio cell 16 .",
"Such connections are represented by arrows 42 .",
"The mobile stations 38 in the mobile network 10 with inverse frequency band superposition use a small frequency band reuse factor.",
"With the reuse factor of 1 used in the present embodiment all mobile stations 38 use the same frequency band A in the far range 28 of the radio cells 16 and, therefore, generate an interfering intensity by interference with each other.",
"In the uplink from the mobile stations 38 to the base stations 12 each base station 12 , therefore, receives a superposition of signals of a user attributed thereto having signals of users from adjacent radio cells 16 .",
"Adjacent base stations 12 can now connect to an active group 44 in such a way that they transmit their signals received from, for example, landlines or radio relay systems, to a central knot which, for example, can be formed from one of the base stations 46 of the active group 44 , and thereby form a virtual multiple point to point MIMO system.",
"The term MIMO (=Multiple Input Multiple Output) generally denotes systems with several sender—and receiver antennas for the increase of the data rate and the improvement of the transmission quality.",
"In multiple point to point MIMO systems a common signal processing can be achieved only at the receiver as the transmitters do not cooperate as it is the case in the uplink of a mobile network system.",
"In such a central knot known MIMO detection methods, such as, for example, VBLAST-receivers, decision feedback demodulator, successive or parallel interference suppression or linear demodulation can be used to separate the individual uplink data flows of the active group 44 and to forward them to the mobile network 10 for further transmission or processing.",
"Such a common processing of the received signal is summarized in the literature with the term “joint detection.”",
"The strong interference which would exclude the successful detection at individual base stations 12 is inherently removed by the MIMO detection.",
"The formation of the active group 44 and the attribution of a central knot can be dynamically effected in the running network operation by measuring the interference situation.",
"For this purpose the measurement of the strength of the transmission channel between a mobile station 38 and adjacent base stations 12 can be used by means of pilot sequences which are present in the handover procedures.",
"Furthermore the knowledge of the transmission channels with a significant intensity portion between the mobile station 38 and the base station 12 of the active group 44 is necessary for a successful MIMO detection.",
"For this purpose a possibility for the undisturbed channel measurement must be provided which can be carried out by orthogonal pilot sequences or the sending of pilot sequences in time multiplex methods.",
"In the downlink from the base stations 12 to the mobile stations 38 a point to multiple point MIMO system can be formed by the described cooperation between the base stations 12 where in one central knot a pre-processing of the sending signals of each base station 12 is effected in such a way that the signal received and superimposed by the mobile stations 12 has a high SIR-value.",
"Linear pre-modulation or “Tomlinson-Harashima Precoding (THP) can be used as pre-modulate methods.",
"The knowledge of the transmission channel on the sender side necessary for this method can be obtained in TDD (=Tine Division Duplex) Systems by measuring the transmission channel in the uplink because the transmission channel is reciprocal regarding the uplink and downlink.",
"If this reciprocal channel is not present, such as, for example, in FDD (=frequency division duplex) systems the channel estimates determined in the uplink can be transmitted through a return channel to the sender."
] |
REFERENCE TO RELATED APPLICATIONS
This application is a division of Ser. No. 11/569,473, filed Oct. 18, 2007, now U.S. Pat. No. 7,615,159, which, in turn, is a 371 of PCT/EP2005/005313 filed May 14, 2005.
The invention relates to a chromatographic process for substance separation in the context of the preparation of chemicals such as, for example, chiral pharmaceuticals, isomers or biomolecules on the small scale and production scale, based on Simulated Moving Bed (SMB=countercurrent chromatography) technology.
SMB is a process which allows continuous substance separations by imitating (simulating) the countercurrent between the adsorbent and mobile phase (liquid, gas or in the supercritical state).
U.S. Pat. No. 3,706,612 of A. J. de Rosset and R. W. Neuzil describes a simulated moving bed (countercurrent chromatography) unit on the pilot scale. Likewise, an operating problem is described there when such units are operated on the large scale and a circulating pump is utilized in order to guarantee the circulation of the liquid in the process. This invention (U.S. Pat. No. 3,706,612) describes the use of a valve at the starting end of each adsorber bed in order to prevent an opposed flow.
U.S. Pat. No. 4,434,051 of M. W. Golem describes an apparatus which allows countercurrent chromatography by utilizing a large number of multiway valves instead of a single rotary valve.
The separation of racemic mixtures on chiral adsorbents is described in an article in the Journal of Chromatography, 590 (1992), pp. 113-117; an alternative arrangement of 8 adsorption chambers and 4 rotary valves is utilized there.
U.S. Pat. No. 3,268,605 describes a control system which controls the flow rate of three of the main streams by flow regulators and the fourth stream by means of a pressure regulator. A similar control concept for chiral substance systems is described in WO 92/16274 of Bayer AG. This reference uses a number of two-way valves in order to simulate the countercurrent of the adsorbent.
In all these known techniques, however, the separating capacity is impaired by the holdup volume of the circulation flow pump, which must be compensated by additional measures, such as, for example, asynchronous timing, alteration of the column lengths or flow adjustment [such as, for example, in EP 0688590 A1, Sepharex (Novasep), “Totvolumenkompensation der Kreislaufpumpe durch Reduktion des Volumens” (Dead volume compensation of the circulating pump by reduction of the volume) (Länge); “asynchronous timing” as in EP 0688589 A1, Sepharex (Novasep); EP 0688588 A1 “Durchsatzänderung der Rezyklieipumpe” (Throughput alteration of the recycling pump)]. In DE 19833502 A1 of Novasep, for this, the SMB base regulation by means of pressure is described by simultaneous variation of at least two throughputs.
Consequently, the asynchronous timing in one zone was further developed to asynchronous timing in a number of or all zones (WO 00/25885 A).
For example, WO 93/04022 A of Daicel in which SMB is employed for resolution with subsequent re-racemization of the unwanted isomer, or WO 91/13046 A of Daicel which likewise describes the use of SMB with a chiral stationary phase for resolution afford examples of the use of SMB technology.
The prior art for the regulation of the internal and external mass flows in simulated countercurrent chromatography is described, for example, in U.S. Pat. Nos. 4,499,115, 5,685,992, 5,762,806, EP 960642 A1 and DE 19833502 A1.
Customarily, for the transport of the fluids 5 pumps are employed there, in each case one pump being located in the corresponding supply and outlet lines—feed, eluent, extract and raffinate lines, and a further pump is arranged within a closed circuit. For the simulation of the solid countercurrent, after a specific time interval, the timing period τ, is retimed, i.e. by means of appropriate valve circuits the addition and removal sites are displaced around a column in the flow direction of the fluid phase. The circulating pump thus “migrates” through the individual zones and transports different volume flows during a cycle.
FIG. 2 shows a customary SMB process. The fluid stream flows on SMB operation in the circulation of a number of fixed bed columns filled with adsorbent. The unit is subdivided into four functional zones by the continuous addition or removal of the feed, desorbent, extract and raffinate streams. Each one of these zones here takes on a special separation or workup function. Also shown is the recycle stream, transported by a recycle pump. Each functional zone, between the positions of the external supply and discharge streams, are in each case situated one to a number of chromatographic columns. The concentration profile established on suitable choice of the operating parameters in the cyclically stationary state within the SMB unit of the main components to be separated is shown schematically in the right section of FIG. 2 relative to the positions of the supply and discharge streams at the point of time of the end of the cycle.
FIGS. 3 and 4 show schematically the apparatus construction of a customary SMB process with the arrangement of individual valves in two successive cycles. In the supply line of each column 2 individual valves for the switching of alternative feed or eluent stream and in the outlet line of each column 3 individual valves for alternative raffinate, extract or recycling stream. On each further cycle, the valve circuits are displaced by one position to the next column.
If the connecting lines between the columns are of different length and contain a dead volume not to be neglected compared to the column volume, this fact must be taken into account, and a worsening of the separating capacity possibly associated therewith must be counteracted. Asynchronous switching of the valves (EP 688589 B1), specific adjustment of the zone volumes (EP 688690 B2) or an adjustment of the output of the circulating pump (EP 688588 B1) provide possible corrective measures.
For continuous operation as intended, the most exact possible adherence to the internal and external mass flows is an indispensable requirement. For this, customarily three of the four supplied and discharged mass flows (Q F , Q D , Q Ex and Q Raf ) are constantly controlled, while the fourth part of the flow is readjusted by means of a specified system pressure such that this system pressure remains constant, by which the overall mass balance is adhered to.
This so far customary mode of operation of SMB chromatography units therefore has the following serious disadvantages:
The pressure regulation must on the one hand compensate all malfunctions in the area of the mass flows as quickly and exactly as possible, on the other hand it is itself in some cases perceptibly disturbed by operation-related pressure variations (e.g. also by the cyclical switching processes). In particular in the case of high purity requirements and/or short cycle times, this can lead to instabilities up to the loss of the separating capacity. The locking of the mass balance by means of pressure regulation requires a permanently closed circulation. Short-term opening of the circulation, e.g. for the discharge of impurities is thereby not possible. The internal circulating pump is confronted with continuously changing mass flows, in addition this type of switching causes variable dead volumes and thus inherent process malfunctions, which must be compensated. As already mentioned, this frequently proves to be difficult, in particular in the case of short cycle times and demanding separation tasks.
In circuit operation as intended, in the SMB process generally 4 internal (Q I , Q II , Q III and Q IV ) and 4 external mass flows (Q F , Q D , Q Ex and Q Raf ) exist, which are linked to one another by means of the following mass balances
Q I =Q D +Q IV
Q II =Q I −Q Ex
Q III =Q II +Q F
Q IV =Q III −Q Raf (1)
For the setting of the working point, 3 external and one internal mass flow and the timing period τ must be specified in such a way that the separating task is achieved and thereby economical optimum operation is obtained with adherence to the specified product purities. The timing period τ here determines the “speed” of the apparent solid countercurrent.
In the entire prior art, for the operation of the SMB, however, circulation pumps are fundamentally employed, which leads to the problems already described due to the holdup volume of the pump.
It has now surprisingly been found that contrary to expectation no circulation flow pump is necessary in order to maintain the fluid circulation in an SMB.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the principle of the SMB chromatography unit according to the invention.
FIG. 2 shows a customary SMB process.
FIGS. 3 and 4 show schematically the apparatus construction of a customary SMB process with the arrangement of individual valves in two successive cycles.
FIG. 5 shows the integration of the multicolumn chromatography process in an overall process for the preparation of chemical and pharmaceutical substances as exemplified by racemic substances.
FIG. 6 shows a four-valve block with master board.
FIG. 7 shows the inventive valve with individual components.
FIG. 8 shows, by way of example, a hexagonal master board or rod.
FIG. 9 shows the preferred concentric seal area.
FIG. 10 shows a particular design of the sealing valve spindle contour.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention therefore relates to an SMB process in which instead of the previously customary 5 pump concept a 4 pump concept is used by pumping the eluent stream with constant flow and extract, raffinate and feed stream. For the two outlet streams, alternatively control valves instead of forced delivery pumps are also possible here.
FIG. 1 shows the principle of the SMB chromatography unit according to the invention. The unit is only shown schematically here, for example the detailed line paths contained, the valve circuits and the other instrumentation are absent. In addition, for a better overview, the blocks shown in each case represent the functional zones and not individual separating columns. The symbol FI represents a continuous flow measurement, FIC and LIC represent continuous flow or level regulations including the measuring and control devices needed for this. Q, provided with different indices, in each case represents a mass flow which occurs in a certain position of the chromatography unit.
The circulation stream, as can be seen in FIG. 1 , is interrupted/separated by an intermediate container. In addition to robust mass flow regulation, this additionally allows a discharge of fractions containing potential impurities in the running operation, which can be determined by suitable online analysis such as, for example, UV, NIR, RI or US (in FIG. 1 marked as QIS). The pump arranged in a fixed manner behind the intermediate container here conveys the eluent stream with constant flow directly to the first separating column of the SMB chromatography unit, mainly independently of whether the eluent is discharged after flowing through the unit or fed back in a closed circulation via the intermediate container.
In order that a circulation flow pump is saved and an eluent pump having constant flow is used, it is not necessary to compensate the separating capacity-disrupting holdup volume of the circulation flow pump by additional measures, such as, for example, asynchronous timing, alteration of the column length or flow adjustment (see prior art above). The further development of the asynchronous timing in one zone to the asynchronous timing of a number of or all zones is thus also superfluous, since the separating capacity in the process according to the invention can also already be achieved directly by the holdup-optimized circuit of the chromatography unit according to the invention.
Likewise, by the described discharge of contaminated eluent fractions in the circulation flow, laborious stoppage or even startup and shutdown of the unit are avoided. In addition to the more robust control, this furthermore increases the economy of the process due to the described invention.
The more robust separating process of multicolumn chromatography in countercurrent operation according to the invention moreover allows a more efficient integration into the preparation process of chemicals and pharmaceuticals. Thus a reactor can be connected upstream and the starting material connected directly as a feed to the multicolumn chromatography unit. Likewise, recovery of nontarget fractions after further rearrangements or reactions, such as, for example, re-racemization by means of pH or temperature shift, are more efficiently possible in the feed mixture or the reactor.
A further point is that both the downstream connected solvent workup and product workup by means of evaporation, drying and/or crystallization steps can be carried out more efficiently, since by means of the described invention the throughput is higher, the product dilution lower and the operating flows more constant; technically a working point can be chosen which is nearer to the theoretical optimum.
In a particularly preferred embodiment, a novel modular valve system (MVS), which itself is also a subject of this invention, additionally replaces the known one-way or multiway fittings and is characterized here by its versatility. The process paths to be switched can be realized by incorporation of the valve heads in a single distributor body. In addition, process parameters (such as, for example, pressure, temperature or concentrations) can also be determined by means of appropriate adaptations. The MVS is distinguished by its compact manner of construction, the modular expandability, cGMP-relevant features (avoidance of dead volumes, good cleanability) high ease of maintenance. The valve seats can be replaced in the most simple manner and adjusted to the needs. The compactness makes possible very short circuit times with very high circuit cycles. By means of these significant improvements, the unit availability on the pilot and production scale can be markedly increased. Moreover, it is possible using this invention to operate units nearer to the theoretical optimum which increases the throughput/the productivity of the entire unit.
From WO 03/052308, a valve is already known which is of modular construction and can be actuated pneumatically. A characteristic of this valve is an extremely small closing stroke of the valve spindle. On account of the construction of this valve, however, only a monodirectional flow of the valve is possible, whereby this valve is unusable for the use according to the invention.
In order to facilitate the simplification of the SMB process to the process according to the invention and to make possible an improved and thus preferred embodiment, it was necessary to develop a valve which has extremely low closing times in the OPEN/CLOSED position, performs a very large number of switching cycles without showing wear phenomena, exhibits very low product-side dead spaces, has small structural dimensions and can be flowed through with product from both sides, so that in addition to the valve function in basic use operational cleaning processes by means of reversed flow directions and CIP (Cleaning in Place) or SIP (Sterilization in Place) can also be accomplished simply. Moreover, high process requirements with respect to pressure and temperature must not restrict the functionality of the valve. In particular in the case of a circuit of a number of valves in a very small space, it is absolutely necessary to produce compact valves having few components in a modular design, which make a very low holdup and thus sharp separating capacities possible in switching processes. In spite of a small switching path, the ideal valve should have a position indicator, by means of which the user can identify the actual valve position at any time. The automatic or mechanical switching of the valve to a specified process-side safety position in the case of control energy outage should in the best case also still be made possible. No valve known from the prior art can cope with these requirements in a completely satisfactory manner.
Surprisingly, however, it is possible to build an MVS which particularly fulfills the above-mentioned requirements. This MVS according to the invention consists of a master board ( 10 ), on which at least one valve according to the invention is installed. The valve according to the invention consists of a valve housing ( 20 ) and a control housing ( 30 ), the control housing having an interior pneumatic space, which is divided into a lower control space ( 33 ) and an upper control space ( 34 ) by a piston ( 31 ) having a seal ( 32 ). The lower control space is separated from the valve housing by a closing plate ( 35 ) and additional seals ( 36 ). On the piston is located an extended valve spindle ( 37 ), which runs through the valve housing up to the seal seat ( 11 ) in the area of the master board. The valve housing and the control housing are fixed to one another using a centering plate ( 21 ) with seals ( 22 ). The valve housing is positioned relative to the master board using a second fixing, the seal seat ( 11 ) using associated seals ( 12 ), such that a channel connection by means of the seal seat in the product space of the valve housing is created by means of a supply channel ( 13 ) having a lateral transverse channel ( 14 ) in the master board. From the product space, in turn, a discharge channel ( 15 ) for product discharge is available, by which with the supply channel together a flow channel is formed. The valve spindle is bilaterally extended to the piston such that on the one hand the valve spindle reaches through the upper control space to outside the control housing and on the other hand the valve spindle is extended through the valve housing into the seal seat, the valve spindle having a sealing contour to the valve seat and completely closing in the closed position the extended transverse channel and preventing the product flow. The seal seat is positioned with its seals half in the master board and half in the valve housing, such that all valve parts are centred and positioned during installation.
In addition, a characterizing feature of the MVS is that a number of valves are arranged in a space-saving manner, such that a common master board having a common central supply channel can admit at least two valve seats having an identical number of transverse channels and forms particularly low dead-space block valves which make possible the necessary sharp substance separation in process chromatography by means of appropriate control.
This type of valve according to the invention is characterized in a further particular embodiment in that the pressurized control space and the pressurized product space are separated by a pressure-less space and as a result leakage monitoring is made possible.
The valve according to the invention has a particular seal contour pairing between the lower, extended valve spindle and the seal seat, characterized in that different contour pairings and material pairings combine in order to form concentric seal contours, which safely prevent product flow in the closed position of the valve, a round to conical contour pairing preferably being used.
Further preferred contours for the valve spindle and seal seat are concave and or convex designs of spherical and conical contours, but combination with straight surfaces is also possible.
In one particular embodiment, the sealing valve spindle is designed such that the sealing ends of the valve spindle are hollowed out in order to employ a complete sphere, to bond both parts, and to obtain an extremely smooth surface contour for the sealing function. In a particularly preferred embodiment of the valve spindle having a sphere, the sphere extends the valve spindle around the sphere radius and very particularly preferably the sphere extends the spindle around the half radius.
Various embodiments of the valves on master boards offer particular advantages for the acceptance of at least two of the valve sets according to the invention, the master board being designed in the form of a square or hexagonal rod and particularly preferably in spatial shape up to a dodecahedron, the number of valves situated on the master board being reduced by one to two based on all surfaces of the master board. By means of the common master board, it is possible to position two, three, four and more valves in a very small space, one to two areas having to remain free on the master board for the central supply and discharge of the product.
The extension of the valve spindle by the control housing makes possible the external application of a position detector, which signals the current valve position.
Likewise, a subject of this application is therefore also block valves which consist of a master board on which at least two valve housings each having a control housing and in each case associated internal components, and a position indicator is attached to each control housing.
The position indicator makes possible to the operator a visual indication of the actual valve position, which position indicator is based on an electrical and or electronic and or mechanical signal generation, such that an inexpensive visual position indicator is producible.
In a preferred embodiment of the valve according to the invention, the valve seat is situated completely in the master board.
The closing stroke of the valve spindle is preferably less than 5 mm, particularly preferably less than 3 mm and very particularly preferably less than 1 mm.
All metallic and nonmetallic materials can be used for the preparation of the valve.
In a further embodiment, the valve spindle contours seals the valve in the seal scat and the diameter course of the concentric seal area of the two contours is greater than the hydraulic diameter of the transverse channel, preferably, the seal range is 1.1 to 1.3 times and particularly preferably the seal area lies on a diameter in the seal seat of 1.4 to 1.6 times the hydraulic diameter of the transverse channel.
The valves according to the invention are particularly suitable for guaranteeing a reciprocal sharply separating product flow in process chromatography units. Block valves of small construction with a central master board are particularly suitable for use in process chromatography units.
In process chromatography units according to the invention which essentially consist of a number of columns connected in series, the columns arbitrarily having to be capable of being cut off mutually or to one another, valves are continuously pressurized by means of the product supply and the product discharge line, in addition the valves are alternatively switched at short time intervals in order, for example in the case of different fractions (product specifications) to make possible a rapid and sharp separation. Since the products are generally expensive, on account of the low closing stroke between the OPEN and CLOSED position the valve according to the invention increases the efficiency of the entire process chromatography unit. The high valve functionality of the valves, which is achieved in the form of a high leak tightness with, at the same time, a high number of switching cycles, is particularly important. Use in batch chromatography units is therefore also possible.
In FIG. 6 , four inventive valves ( 1 , 2 , 3 , 4 ), according to FIG. 7 , installed on a common master board, are shown.
In FIG. 7 , all individual valve parts are shown on a common master board ( 10 ). It can be seen in FIG. 7 that the master board ( 11 ) has a central supply channel ( 11 ) for the product and from the supply channel four transverse channels ( 14 ) branch off to the valves adapted to the master board. At least two further valves can be installed on the master board, in which a further valve housing ( 20 ) and control housing ( 30 ) having appropriate fixing elements (e.g. screws) are detachably connected to the master board. The valve housing is centered on the master board by means of the seal scat ( 11 ) and the centering of the control housing is carried out using a centering plate ( 21 ), which engages in the closing plate ( 35 ). In the control housing is a piston ( 31 ) having a firmly connected bilaterally extended valve spindle ( 37 ), in order to form an upper and lower control space ( 33 , 34 ) in the control housing. The extended valve spindle extends on the one side up to the seal seat and on the other side to outside the control housing, in order, if appropriate, to be able to admit a position detector outside the valve. The inner parts of the valve are provided with elastic seals, such that a product flowing through is specifically conducted by the valve, cannot escape outward, product space and control space are separate from one another and leakage or failure of a seal is recognized. In addition, the seals employed serve to seal individual valve components in their planes. The seal ( 32 ) on the piston separates the upper and lower control space. The two seals ( 36 ) separate the lower control space from the pressureless valve space, the inner seal sealing to the valve spindle and the outer seal sealing to the control housing. The centering plate ( 21 ) likewise has two seal ( 22 ) in in one plane, such that one seals the product space to the valve spindle and the other prevents a bypass flow. The centering plate has a transverse drilling ( 23 ), which is extended outwards through the transverse drilling of the valve housing ( 24 ), such that a pressureless intermediate space is formed between the product space and control space. The transverse drillings signal a leakage or a failure of the product-side seals.
The flowing through of the valve with product takes place by means of the central supply channel, the transverse channel ( 14 ) and the seal seat, such that the end of the valve spindle contour is flowed around and the product can flow through the discharge channel ( 15 ) from the valve. The product flowing through is prevented if, for example, an employed pressure spring ( 38 ) in the upper control space presses the piston with valve spindle into the contour of the seal seat. The valve opens if, for example, in the lower control space the attached compressed air builds up pressure and the compressive force generated is greater than the spring force in the upper control space, such that the piston is raised, the valve spindle separates from the seal seat, and a liquid or gaseous substance can pass.
In FIG. 6 , three further positions of the master board are occupied by valves in order to form a four-block valve.
FIG. 8 shows the cross-section of a hexagonal rod or hexagonal master board ( 10 ), the central supply channel ( 13 ) and the transverse channels ( 14 ) being incorporated in the hexagonal master board, and a receiving drilling of the seal seats being incorporated on each outer surface. FIG. 8 shows clearly that six valves with the valve housing ( 20 ) and control housing ( 30 ) can be positioned in a narrow space and in the case of a hexagonal rod even a multiple of six valves one after the other is handleable in the narrowest space. It is not urgently necessary here, however, to equip each valve position.
In FIG. 9 , the special seal contours of the valve spindle ( 37 ) and of the seal seat ( 11 ) are shown. It can be seen that the preferred seal area (X 2 −X 1 ) is greater than the hydraulic cross-section of the transverse channel. This has the advantage that with a high number of switching cycles at high differential pressures the sealing contours are not deformed.
In FIG. 10 , a special form of the sealing valve spindle contour ( 37 ) is shown. Here, the production of a very smooth sealing surface is carried out, by way of example, by the application of a sphere ( 37 ′). The sphere projects here partially into the cross-section of the valve spindle and a part of the sphere is available elevated as a sealing contour.
An embodiment of the process according to the invention is likewise preferred in which a certain mass flow control is employed, which surprisingly leads to a further performance increase and is likewise a subject of the present invention.
In the SMB unit according to the invention, the operating point is specified by means of the external streams feed Q F , extract Q Ex and raffinate Q Raf , and the internal eluent stream Q I and timing period τ.
A mass flow control has now surprisingly been found (see FIG. 1 ), in which the mass flows Q F , Q Ex , Q Raf and Q I are continuously measured and directly regulated by means of the speed of rotation of the corresponding pumps (4-pump procedure). Alternatively, the adjustment of the product streams Q Ex and Q Raf by means of suitable regulating valves instead of discharge pumps is possible (2-pump procedure). The adherence of the total mass balance, and thus the correct adjustment of the desorbent stream Q D as the remaining external stream, is also achieved by the filling level regulation in the eluent receiver. This filling level regulation compensates the deviations from the nominal mass balance inevitably caused by disturbances and/or measuring errors and determines, together with the switching on of the nominal desorbent amount resulting from the balances,
Q D 0 =Q Ex +Q Raf −Q F +Q Dest (2)
the flow of freshly added desorbent (eluent):
Q D =Q D 0 +ΔQ D LLC . (3)
This value is then adjusted by means of the flow regulation of the desorbent amount and monitored by means of continuous flow measurement.
In a very particularly preferred embodiment, a continuous online analysis measurement QIS is introduced into the recycle line after zone IV ( FIG. 1 ). In the case of contamination of the solvent stream fed back (e.g. breakthrough of product from zone IV), this triggers a corresponding valve circuit, such that the contaminated solvent stream is discharged and is not fed back into the eluent receiver.
The additional flow measurement in the recycle stream serves, in the case of quality-related discharge of the recycle stream, for the determination Of Q Dest , in operation as intended, by the utilization of the redundancy achieved with the measurement of the flow Q Dest in the mass flow measurements and balances, a measurement data validation (data reconciliation) is performed for all mass flows and thus the accuracy of the mass flow regulation is additionally increased.
The mass flow regulation according to the invention makes possible—in particular by dispensing with a pressure regulation for the conclusion of the mass balance—a more accurate and more robust adjustment of the mass flows for the confirmation of the separating capacity of the unit.
The very particularly preferred embodiment according to the invention of a combination of the unit and regulation concept makes possible both operation with a closed and with an open circulation. In the case of open circulation, by means of the online analysis measurement in the recycle line, a possible impurity can be directly discharged. In the conventional circulation operation, discharge of impurities is only possible by means of the product streams and thus associated with a loss of yield.
The redundancy in the mass flow measurements provided according to the invention and the measuring error balance for the flow measurements based thereon additionally increases the accuracy of the mass flow regulation and thus confirms the fulfillment of the separation task.
Using the unit and regulation concept according to the invention, variable dead volumes and the process disruptions associated therewith are avoided. Special countermeasures such as, for example, the asynchronous switching of the valves are thus no longer necessary.
The following examples are intended to illustrate the present invention without, however, restricting it:
FIG. 5 shows the integration of the multicolumn chromatography process in an overall process for the preparation of chemical and pharmaceutical substances as exemplified by racemic substances. There is the possibility directly, without intermediate storage after the reaction, leading the reaction mixture continuously into the chromatography unit. Furthermore, the direct workup and the recycling of the solvent from the product streams extract and raffinate into the eluent receiver is possible. The quality of the eluent must be measured and adjusted before use again in the chromatography unit. For this, depending on the eluent composition required, a number of offline methods (such as, for example, GC and HPLC) and online methods (such as, for example, ultrasound, capacitative, NIR) are available. From a feed container, in a further container the feed mixture of solid or fluid consistency is introduced in the specified eluent composition. Extract and raffinate are supplied from the chromatography unit to evaporators and the evaporated solvent is recycled into the eluent container. Fresh solvent is metered in from various eluent receiver containers, depending on the number of solvents involved in the eluent mixture, until the required eluent specification is achieved in the eluent supply to the chromatography unit. The concentrated product after evaporating is stored in containers and generally crystallized, filtered and dried in the further product workup. The byproduct—in the example case the “wrong” enantiomer—is usually re-racemized for economic reasons (often, for example, by pH or temperature change) and after quality control added to the feed mixture derived from the original reaction stage.
Figures
Reference Symbols for the FIGS.
1 , 2 , 3 , 4 valves
10 master board
11 seal seat
12 seals of the seal scat
13 supply channel
14 transverse channel
15 discharge channel
16
20 valve housing
21 centering plate
22 seals of the centering plate
23 transverse drilling of centering plate
24 transverse drilling of valve housing
30 control housing
31 piston
32 seals
33 lower control space
34 upper control space
35 closing plate
36 seals of the closing plate
37 valve spindle
37 ′ sphere
38 pressure spring | The invention relates to a chromatographic process for substance separation in the context of the preparation of chemicals such as, for example, chiral pharmaceuticals, isomers or biomolecules on the small-scale and production scale, based on Simulated Moving Bed (SMB=countercurrent chromatography) technology. | Condense the core contents of the given document. | [
"REFERENCE TO RELATED APPLICATIONS This application is a division of Ser.",
"No. 11/569,473, filed Oct. 18, 2007, now U.S. Pat. No. 7,615,159, which, in turn, is a 371 of PCT/EP2005/005313 filed May 14, 2005.",
"The invention relates to a chromatographic process for substance separation in the context of the preparation of chemicals such as, for example, chiral pharmaceuticals, isomers or biomolecules on the small scale and production scale, based on Simulated Moving Bed (SMB=countercurrent chromatography) technology.",
"SMB is a process which allows continuous substance separations by imitating (simulating) the countercurrent between the adsorbent and mobile phase (liquid, gas or in the supercritical state).",
"U.S. Pat. No. 3,706,612 of A. J. de Rosset and R. W. Neuzil describes a simulated moving bed (countercurrent chromatography) unit on the pilot scale.",
"Likewise, an operating problem is described there when such units are operated on the large scale and a circulating pump is utilized in order to guarantee the circulation of the liquid in the process.",
"This invention (U.S. Pat. No. 3,706,612) describes the use of a valve at the starting end of each adsorber bed in order to prevent an opposed flow.",
"U.S. Pat. No. 4,434,051 of M. W. Golem describes an apparatus which allows countercurrent chromatography by utilizing a large number of multiway valves instead of a single rotary valve.",
"The separation of racemic mixtures on chiral adsorbents is described in an article in the Journal of Chromatography, 590 (1992), pp. 113-117;",
"an alternative arrangement of 8 adsorption chambers and 4 rotary valves is utilized there.",
"U.S. Pat. No. 3,268,605 describes a control system which controls the flow rate of three of the main streams by flow regulators and the fourth stream by means of a pressure regulator.",
"A similar control concept for chiral substance systems is described in WO 92/16274 of Bayer AG.",
"This reference uses a number of two-way valves in order to simulate the countercurrent of the adsorbent.",
"In all these known techniques, however, the separating capacity is impaired by the holdup volume of the circulation flow pump, which must be compensated by additional measures, such as, for example, asynchronous timing, alteration of the column lengths or flow adjustment [such as, for example, in EP 0688590 A1, Sepharex (Novasep), “Totvolumenkompensation der Kreislaufpumpe durch Reduktion des Volumens”",
"(Dead volume compensation of the circulating pump by reduction of the volume) (Länge);",
"“asynchronous timing”",
"as in EP 0688589 A1, Sepharex (Novasep);",
"EP 0688588 A1 “Durchsatzänderung der Rezyklieipumpe”",
"(Throughput alteration of the recycling pump)].",
"In DE 19833502 A1 of Novasep, for this, the SMB base regulation by means of pressure is described by simultaneous variation of at least two throughputs.",
"Consequently, the asynchronous timing in one zone was further developed to asynchronous timing in a number of or all zones (WO 00/25885 A).",
"For example, WO 93/04022 A of Daicel in which SMB is employed for resolution with subsequent re-racemization of the unwanted isomer, or WO 91/13046 A of Daicel which likewise describes the use of SMB with a chiral stationary phase for resolution afford examples of the use of SMB technology.",
"The prior art for the regulation of the internal and external mass flows in simulated countercurrent chromatography is described, for example, in U.S. Pat. Nos. 4,499,115, 5,685,992, 5,762,806, EP 960642 A1 and DE 19833502 A1.",
"Customarily, for the transport of the fluids 5 pumps are employed there, in each case one pump being located in the corresponding supply and outlet lines—feed, eluent, extract and raffinate lines, and a further pump is arranged within a closed circuit.",
"For the simulation of the solid countercurrent, after a specific time interval, the timing period τ, is retimed, i.e. by means of appropriate valve circuits the addition and removal sites are displaced around a column in the flow direction of the fluid phase.",
"The circulating pump thus “migrates”",
"through the individual zones and transports different volume flows during a cycle.",
"FIG. 2 shows a customary SMB process.",
"The fluid stream flows on SMB operation in the circulation of a number of fixed bed columns filled with adsorbent.",
"The unit is subdivided into four functional zones by the continuous addition or removal of the feed, desorbent, extract and raffinate streams.",
"Each one of these zones here takes on a special separation or workup function.",
"Also shown is the recycle stream, transported by a recycle pump.",
"Each functional zone, between the positions of the external supply and discharge streams, are in each case situated one to a number of chromatographic columns.",
"The concentration profile established on suitable choice of the operating parameters in the cyclically stationary state within the SMB unit of the main components to be separated is shown schematically in the right section of FIG. 2 relative to the positions of the supply and discharge streams at the point of time of the end of the cycle.",
"FIGS. 3 and 4 show schematically the apparatus construction of a customary SMB process with the arrangement of individual valves in two successive cycles.",
"In the supply line of each column 2 individual valves for the switching of alternative feed or eluent stream and in the outlet line of each column 3 individual valves for alternative raffinate, extract or recycling stream.",
"On each further cycle, the valve circuits are displaced by one position to the next column.",
"If the connecting lines between the columns are of different length and contain a dead volume not to be neglected compared to the column volume, this fact must be taken into account, and a worsening of the separating capacity possibly associated therewith must be counteracted.",
"Asynchronous switching of the valves (EP 688589 B1), specific adjustment of the zone volumes (EP 688690 B2) or an adjustment of the output of the circulating pump (EP 688588 B1) provide possible corrective measures.",
"For continuous operation as intended, the most exact possible adherence to the internal and external mass flows is an indispensable requirement.",
"For this, customarily three of the four supplied and discharged mass flows (Q F , Q D , Q Ex and Q Raf ) are constantly controlled, while the fourth part of the flow is readjusted by means of a specified system pressure such that this system pressure remains constant, by which the overall mass balance is adhered to.",
"This so far customary mode of operation of SMB chromatography units therefore has the following serious disadvantages: The pressure regulation must on the one hand compensate all malfunctions in the area of the mass flows as quickly and exactly as possible, on the other hand it is itself in some cases perceptibly disturbed by operation-related pressure variations (e.g. also by the cyclical switching processes).",
"In particular in the case of high purity requirements and/or short cycle times, this can lead to instabilities up to the loss of the separating capacity.",
"The locking of the mass balance by means of pressure regulation requires a permanently closed circulation.",
"Short-term opening of the circulation, e.g. for the discharge of impurities is thereby not possible.",
"The internal circulating pump is confronted with continuously changing mass flows, in addition this type of switching causes variable dead volumes and thus inherent process malfunctions, which must be compensated.",
"As already mentioned, this frequently proves to be difficult, in particular in the case of short cycle times and demanding separation tasks.",
"In circuit operation as intended, in the SMB process generally 4 internal (Q I , Q II , Q III and Q IV ) and 4 external mass flows (Q F , Q D , Q Ex and Q Raf ) exist, which are linked to one another by means of the following mass balances Q I =Q D +Q IV Q II =Q I −Q Ex Q III =Q II +Q F Q IV =Q III −Q Raf (1) For the setting of the working point, 3 external and one internal mass flow and the timing period τ must be specified in such a way that the separating task is achieved and thereby economical optimum operation is obtained with adherence to the specified product purities.",
"The timing period τ here determines the “speed”",
"of the apparent solid countercurrent.",
"In the entire prior art, for the operation of the SMB, however, circulation pumps are fundamentally employed, which leads to the problems already described due to the holdup volume of the pump.",
"It has now surprisingly been found that contrary to expectation no circulation flow pump is necessary in order to maintain the fluid circulation in an SMB.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows the principle of the SMB chromatography unit according to the invention.",
"FIG. 2 shows a customary SMB process.",
"FIGS. 3 and 4 show schematically the apparatus construction of a customary SMB process with the arrangement of individual valves in two successive cycles.",
"FIG. 5 shows the integration of the multicolumn chromatography process in an overall process for the preparation of chemical and pharmaceutical substances as exemplified by racemic substances.",
"FIG. 6 shows a four-valve block with master board.",
"FIG. 7 shows the inventive valve with individual components.",
"FIG. 8 shows, by way of example, a hexagonal master board or rod.",
"FIG. 9 shows the preferred concentric seal area.",
"FIG. 10 shows a particular design of the sealing valve spindle contour.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention therefore relates to an SMB process in which instead of the previously customary 5 pump concept a 4 pump concept is used by pumping the eluent stream with constant flow and extract, raffinate and feed stream.",
"For the two outlet streams, alternatively control valves instead of forced delivery pumps are also possible here.",
"FIG. 1 shows the principle of the SMB chromatography unit according to the invention.",
"The unit is only shown schematically here, for example the detailed line paths contained, the valve circuits and the other instrumentation are absent.",
"In addition, for a better overview, the blocks shown in each case represent the functional zones and not individual separating columns.",
"The symbol FI represents a continuous flow measurement, FIC and LIC represent continuous flow or level regulations including the measuring and control devices needed for this.",
"Q, provided with different indices, in each case represents a mass flow which occurs in a certain position of the chromatography unit.",
"The circulation stream, as can be seen in FIG. 1 , is interrupted/separated by an intermediate container.",
"In addition to robust mass flow regulation, this additionally allows a discharge of fractions containing potential impurities in the running operation, which can be determined by suitable online analysis such as, for example, UV, NIR, RI or US (in FIG. 1 marked as QIS).",
"The pump arranged in a fixed manner behind the intermediate container here conveys the eluent stream with constant flow directly to the first separating column of the SMB chromatography unit, mainly independently of whether the eluent is discharged after flowing through the unit or fed back in a closed circulation via the intermediate container.",
"In order that a circulation flow pump is saved and an eluent pump having constant flow is used, it is not necessary to compensate the separating capacity-disrupting holdup volume of the circulation flow pump by additional measures, such as, for example, asynchronous timing, alteration of the column length or flow adjustment (see prior art above).",
"The further development of the asynchronous timing in one zone to the asynchronous timing of a number of or all zones is thus also superfluous, since the separating capacity in the process according to the invention can also already be achieved directly by the holdup-optimized circuit of the chromatography unit according to the invention.",
"Likewise, by the described discharge of contaminated eluent fractions in the circulation flow, laborious stoppage or even startup and shutdown of the unit are avoided.",
"In addition to the more robust control, this furthermore increases the economy of the process due to the described invention.",
"The more robust separating process of multicolumn chromatography in countercurrent operation according to the invention moreover allows a more efficient integration into the preparation process of chemicals and pharmaceuticals.",
"Thus a reactor can be connected upstream and the starting material connected directly as a feed to the multicolumn chromatography unit.",
"Likewise, recovery of nontarget fractions after further rearrangements or reactions, such as, for example, re-racemization by means of pH or temperature shift, are more efficiently possible in the feed mixture or the reactor.",
"A further point is that both the downstream connected solvent workup and product workup by means of evaporation, drying and/or crystallization steps can be carried out more efficiently, since by means of the described invention the throughput is higher, the product dilution lower and the operating flows more constant;",
"technically a working point can be chosen which is nearer to the theoretical optimum.",
"In a particularly preferred embodiment, a novel modular valve system (MVS), which itself is also a subject of this invention, additionally replaces the known one-way or multiway fittings and is characterized here by its versatility.",
"The process paths to be switched can be realized by incorporation of the valve heads in a single distributor body.",
"In addition, process parameters (such as, for example, pressure, temperature or concentrations) can also be determined by means of appropriate adaptations.",
"The MVS is distinguished by its compact manner of construction, the modular expandability, cGMP-relevant features (avoidance of dead volumes, good cleanability) high ease of maintenance.",
"The valve seats can be replaced in the most simple manner and adjusted to the needs.",
"The compactness makes possible very short circuit times with very high circuit cycles.",
"By means of these significant improvements, the unit availability on the pilot and production scale can be markedly increased.",
"Moreover, it is possible using this invention to operate units nearer to the theoretical optimum which increases the throughput/the productivity of the entire unit.",
"From WO 03/052308, a valve is already known which is of modular construction and can be actuated pneumatically.",
"A characteristic of this valve is an extremely small closing stroke of the valve spindle.",
"On account of the construction of this valve, however, only a monodirectional flow of the valve is possible, whereby this valve is unusable for the use according to the invention.",
"In order to facilitate the simplification of the SMB process to the process according to the invention and to make possible an improved and thus preferred embodiment, it was necessary to develop a valve which has extremely low closing times in the OPEN/CLOSED position, performs a very large number of switching cycles without showing wear phenomena, exhibits very low product-side dead spaces, has small structural dimensions and can be flowed through with product from both sides, so that in addition to the valve function in basic use operational cleaning processes by means of reversed flow directions and CIP (Cleaning in Place) or SIP (Sterilization in Place) can also be accomplished simply.",
"Moreover, high process requirements with respect to pressure and temperature must not restrict the functionality of the valve.",
"In particular in the case of a circuit of a number of valves in a very small space, it is absolutely necessary to produce compact valves having few components in a modular design, which make a very low holdup and thus sharp separating capacities possible in switching processes.",
"In spite of a small switching path, the ideal valve should have a position indicator, by means of which the user can identify the actual valve position at any time.",
"The automatic or mechanical switching of the valve to a specified process-side safety position in the case of control energy outage should in the best case also still be made possible.",
"No valve known from the prior art can cope with these requirements in a completely satisfactory manner.",
"Surprisingly, however, it is possible to build an MVS which particularly fulfills the above-mentioned requirements.",
"This MVS according to the invention consists of a master board ( 10 ), on which at least one valve according to the invention is installed.",
"The valve according to the invention consists of a valve housing ( 20 ) and a control housing ( 30 ), the control housing having an interior pneumatic space, which is divided into a lower control space ( 33 ) and an upper control space ( 34 ) by a piston ( 31 ) having a seal ( 32 ).",
"The lower control space is separated from the valve housing by a closing plate ( 35 ) and additional seals ( 36 ).",
"On the piston is located an extended valve spindle ( 37 ), which runs through the valve housing up to the seal seat ( 11 ) in the area of the master board.",
"The valve housing and the control housing are fixed to one another using a centering plate ( 21 ) with seals ( 22 ).",
"The valve housing is positioned relative to the master board using a second fixing, the seal seat ( 11 ) using associated seals ( 12 ), such that a channel connection by means of the seal seat in the product space of the valve housing is created by means of a supply channel ( 13 ) having a lateral transverse channel ( 14 ) in the master board.",
"From the product space, in turn, a discharge channel ( 15 ) for product discharge is available, by which with the supply channel together a flow channel is formed.",
"The valve spindle is bilaterally extended to the piston such that on the one hand the valve spindle reaches through the upper control space to outside the control housing and on the other hand the valve spindle is extended through the valve housing into the seal seat, the valve spindle having a sealing contour to the valve seat and completely closing in the closed position the extended transverse channel and preventing the product flow.",
"The seal seat is positioned with its seals half in the master board and half in the valve housing, such that all valve parts are centred and positioned during installation.",
"In addition, a characterizing feature of the MVS is that a number of valves are arranged in a space-saving manner, such that a common master board having a common central supply channel can admit at least two valve seats having an identical number of transverse channels and forms particularly low dead-space block valves which make possible the necessary sharp substance separation in process chromatography by means of appropriate control.",
"This type of valve according to the invention is characterized in a further particular embodiment in that the pressurized control space and the pressurized product space are separated by a pressure-less space and as a result leakage monitoring is made possible.",
"The valve according to the invention has a particular seal contour pairing between the lower, extended valve spindle and the seal seat, characterized in that different contour pairings and material pairings combine in order to form concentric seal contours, which safely prevent product flow in the closed position of the valve, a round to conical contour pairing preferably being used.",
"Further preferred contours for the valve spindle and seal seat are concave and or convex designs of spherical and conical contours, but combination with straight surfaces is also possible.",
"In one particular embodiment, the sealing valve spindle is designed such that the sealing ends of the valve spindle are hollowed out in order to employ a complete sphere, to bond both parts, and to obtain an extremely smooth surface contour for the sealing function.",
"In a particularly preferred embodiment of the valve spindle having a sphere, the sphere extends the valve spindle around the sphere radius and very particularly preferably the sphere extends the spindle around the half radius.",
"Various embodiments of the valves on master boards offer particular advantages for the acceptance of at least two of the valve sets according to the invention, the master board being designed in the form of a square or hexagonal rod and particularly preferably in spatial shape up to a dodecahedron, the number of valves situated on the master board being reduced by one to two based on all surfaces of the master board.",
"By means of the common master board, it is possible to position two, three, four and more valves in a very small space, one to two areas having to remain free on the master board for the central supply and discharge of the product.",
"The extension of the valve spindle by the control housing makes possible the external application of a position detector, which signals the current valve position.",
"Likewise, a subject of this application is therefore also block valves which consist of a master board on which at least two valve housings each having a control housing and in each case associated internal components, and a position indicator is attached to each control housing.",
"The position indicator makes possible to the operator a visual indication of the actual valve position, which position indicator is based on an electrical and or electronic and or mechanical signal generation, such that an inexpensive visual position indicator is producible.",
"In a preferred embodiment of the valve according to the invention, the valve seat is situated completely in the master board.",
"The closing stroke of the valve spindle is preferably less than 5 mm, particularly preferably less than 3 mm and very particularly preferably less than 1 mm.",
"All metallic and nonmetallic materials can be used for the preparation of the valve.",
"In a further embodiment, the valve spindle contours seals the valve in the seal scat and the diameter course of the concentric seal area of the two contours is greater than the hydraulic diameter of the transverse channel, preferably, the seal range is 1.1 to 1.3 times and particularly preferably the seal area lies on a diameter in the seal seat of 1.4 to 1.6 times the hydraulic diameter of the transverse channel.",
"The valves according to the invention are particularly suitable for guaranteeing a reciprocal sharply separating product flow in process chromatography units.",
"Block valves of small construction with a central master board are particularly suitable for use in process chromatography units.",
"In process chromatography units according to the invention which essentially consist of a number of columns connected in series, the columns arbitrarily having to be capable of being cut off mutually or to one another, valves are continuously pressurized by means of the product supply and the product discharge line, in addition the valves are alternatively switched at short time intervals in order, for example in the case of different fractions (product specifications) to make possible a rapid and sharp separation.",
"Since the products are generally expensive, on account of the low closing stroke between the OPEN and CLOSED position the valve according to the invention increases the efficiency of the entire process chromatography unit.",
"The high valve functionality of the valves, which is achieved in the form of a high leak tightness with, at the same time, a high number of switching cycles, is particularly important.",
"Use in batch chromatography units is therefore also possible.",
"In FIG. 6 , four inventive valves ( 1 , 2 , 3 , 4 ), according to FIG. 7 , installed on a common master board, are shown.",
"In FIG. 7 , all individual valve parts are shown on a common master board ( 10 ).",
"It can be seen in FIG. 7 that the master board ( 11 ) has a central supply channel ( 11 ) for the product and from the supply channel four transverse channels ( 14 ) branch off to the valves adapted to the master board.",
"At least two further valves can be installed on the master board, in which a further valve housing ( 20 ) and control housing ( 30 ) having appropriate fixing elements (e.g. screws) are detachably connected to the master board.",
"The valve housing is centered on the master board by means of the seal scat ( 11 ) and the centering of the control housing is carried out using a centering plate ( 21 ), which engages in the closing plate ( 35 ).",
"In the control housing is a piston ( 31 ) having a firmly connected bilaterally extended valve spindle ( 37 ), in order to form an upper and lower control space ( 33 , 34 ) in the control housing.",
"The extended valve spindle extends on the one side up to the seal seat and on the other side to outside the control housing, in order, if appropriate, to be able to admit a position detector outside the valve.",
"The inner parts of the valve are provided with elastic seals, such that a product flowing through is specifically conducted by the valve, cannot escape outward, product space and control space are separate from one another and leakage or failure of a seal is recognized.",
"In addition, the seals employed serve to seal individual valve components in their planes.",
"The seal ( 32 ) on the piston separates the upper and lower control space.",
"The two seals ( 36 ) separate the lower control space from the pressureless valve space, the inner seal sealing to the valve spindle and the outer seal sealing to the control housing.",
"The centering plate ( 21 ) likewise has two seal ( 22 ) in in one plane, such that one seals the product space to the valve spindle and the other prevents a bypass flow.",
"The centering plate has a transverse drilling ( 23 ), which is extended outwards through the transverse drilling of the valve housing ( 24 ), such that a pressureless intermediate space is formed between the product space and control space.",
"The transverse drillings signal a leakage or a failure of the product-side seals.",
"The flowing through of the valve with product takes place by means of the central supply channel, the transverse channel ( 14 ) and the seal seat, such that the end of the valve spindle contour is flowed around and the product can flow through the discharge channel ( 15 ) from the valve.",
"The product flowing through is prevented if, for example, an employed pressure spring ( 38 ) in the upper control space presses the piston with valve spindle into the contour of the seal seat.",
"The valve opens if, for example, in the lower control space the attached compressed air builds up pressure and the compressive force generated is greater than the spring force in the upper control space, such that the piston is raised, the valve spindle separates from the seal seat, and a liquid or gaseous substance can pass.",
"In FIG. 6 , three further positions of the master board are occupied by valves in order to form a four-block valve.",
"FIG. 8 shows the cross-section of a hexagonal rod or hexagonal master board ( 10 ), the central supply channel ( 13 ) and the transverse channels ( 14 ) being incorporated in the hexagonal master board, and a receiving drilling of the seal seats being incorporated on each outer surface.",
"FIG. 8 shows clearly that six valves with the valve housing ( 20 ) and control housing ( 30 ) can be positioned in a narrow space and in the case of a hexagonal rod even a multiple of six valves one after the other is handleable in the narrowest space.",
"It is not urgently necessary here, however, to equip each valve position.",
"In FIG. 9 , the special seal contours of the valve spindle ( 37 ) and of the seal seat ( 11 ) are shown.",
"It can be seen that the preferred seal area (X 2 −X 1 ) is greater than the hydraulic cross-section of the transverse channel.",
"This has the advantage that with a high number of switching cycles at high differential pressures the sealing contours are not deformed.",
"In FIG. 10 , a special form of the sealing valve spindle contour ( 37 ) is shown.",
"Here, the production of a very smooth sealing surface is carried out, by way of example, by the application of a sphere ( 37 ′).",
"The sphere projects here partially into the cross-section of the valve spindle and a part of the sphere is available elevated as a sealing contour.",
"An embodiment of the process according to the invention is likewise preferred in which a certain mass flow control is employed, which surprisingly leads to a further performance increase and is likewise a subject of the present invention.",
"In the SMB unit according to the invention, the operating point is specified by means of the external streams feed Q F , extract Q Ex and raffinate Q Raf , and the internal eluent stream Q I and timing period τ.",
"A mass flow control has now surprisingly been found (see FIG. 1 ), in which the mass flows Q F , Q Ex , Q Raf and Q I are continuously measured and directly regulated by means of the speed of rotation of the corresponding pumps (4-pump procedure).",
"Alternatively, the adjustment of the product streams Q Ex and Q Raf by means of suitable regulating valves instead of discharge pumps is possible (2-pump procedure).",
"The adherence of the total mass balance, and thus the correct adjustment of the desorbent stream Q D as the remaining external stream, is also achieved by the filling level regulation in the eluent receiver.",
"This filling level regulation compensates the deviations from the nominal mass balance inevitably caused by disturbances and/or measuring errors and determines, together with the switching on of the nominal desorbent amount resulting from the balances, Q D 0 =Q Ex +Q Raf −Q F +Q Dest (2) the flow of freshly added desorbent (eluent): Q D =Q D 0 +ΔQ D LLC .",
"(3) This value is then adjusted by means of the flow regulation of the desorbent amount and monitored by means of continuous flow measurement.",
"In a very particularly preferred embodiment, a continuous online analysis measurement QIS is introduced into the recycle line after zone IV ( FIG. 1 ).",
"In the case of contamination of the solvent stream fed back (e.g. breakthrough of product from zone IV), this triggers a corresponding valve circuit, such that the contaminated solvent stream is discharged and is not fed back into the eluent receiver.",
"The additional flow measurement in the recycle stream serves, in the case of quality-related discharge of the recycle stream, for the determination Of Q Dest , in operation as intended, by the utilization of the redundancy achieved with the measurement of the flow Q Dest in the mass flow measurements and balances, a measurement data validation (data reconciliation) is performed for all mass flows and thus the accuracy of the mass flow regulation is additionally increased.",
"The mass flow regulation according to the invention makes possible—in particular by dispensing with a pressure regulation for the conclusion of the mass balance—a more accurate and more robust adjustment of the mass flows for the confirmation of the separating capacity of the unit.",
"The very particularly preferred embodiment according to the invention of a combination of the unit and regulation concept makes possible both operation with a closed and with an open circulation.",
"In the case of open circulation, by means of the online analysis measurement in the recycle line, a possible impurity can be directly discharged.",
"In the conventional circulation operation, discharge of impurities is only possible by means of the product streams and thus associated with a loss of yield.",
"The redundancy in the mass flow measurements provided according to the invention and the measuring error balance for the flow measurements based thereon additionally increases the accuracy of the mass flow regulation and thus confirms the fulfillment of the separation task.",
"Using the unit and regulation concept according to the invention, variable dead volumes and the process disruptions associated therewith are avoided.",
"Special countermeasures such as, for example, the asynchronous switching of the valves are thus no longer necessary.",
"The following examples are intended to illustrate the present invention without, however, restricting it: FIG. 5 shows the integration of the multicolumn chromatography process in an overall process for the preparation of chemical and pharmaceutical substances as exemplified by racemic substances.",
"There is the possibility directly, without intermediate storage after the reaction, leading the reaction mixture continuously into the chromatography unit.",
"Furthermore, the direct workup and the recycling of the solvent from the product streams extract and raffinate into the eluent receiver is possible.",
"The quality of the eluent must be measured and adjusted before use again in the chromatography unit.",
"For this, depending on the eluent composition required, a number of offline methods (such as, for example, GC and HPLC) and online methods (such as, for example, ultrasound, capacitative, NIR) are available.",
"From a feed container, in a further container the feed mixture of solid or fluid consistency is introduced in the specified eluent composition.",
"Extract and raffinate are supplied from the chromatography unit to evaporators and the evaporated solvent is recycled into the eluent container.",
"Fresh solvent is metered in from various eluent receiver containers, depending on the number of solvents involved in the eluent mixture, until the required eluent specification is achieved in the eluent supply to the chromatography unit.",
"The concentrated product after evaporating is stored in containers and generally crystallized, filtered and dried in the further product workup.",
"The byproduct—in the example case the “wrong”",
"enantiomer—is usually re-racemized for economic reasons (often, for example, by pH or temperature change) and after quality control added to the feed mixture derived from the original reaction stage.",
"Figures Reference Symbols for the FIGS. 1 , 2 , 3 , 4 valves 10 master board 11 seal seat 12 seals of the seal scat 13 supply channel 14 transverse channel 15 discharge channel 16 20 valve housing 21 centering plate 22 seals of the centering plate 23 transverse drilling of centering plate 24 transverse drilling of valve housing 30 control housing 31 piston 32 seals 33 lower control space 34 upper control space 35 closing plate 36 seals of the closing plate 37 valve spindle 37 ′ sphere 38 pressure spring"
] |
FIELD OF THE INVENTION
The present invention relates to an improved amphibious craft or vehicle and, in particular, but not exclusively, to a craft or vehicle that may be used for commercial and rescue tasks in a great variety of weather conditions. An amphibious craft or vehicle for the purposes of the present invention is one that is designed for operation on or from both water and land.
BACKGROUND TO THE INVENTION
Planing boats are widely operated in a variety of water and weather conditions. A planing hull is a hull designed to climb toward the surface of the water as power is supplied, thus reducing the friction or drag and therefore increasing hull speed. In other words a planing hull can rise bodily in the water and ride over the wave created by its progress through the water. The weight of a planing hull is supported by hydrodynamic lift and it does not displace an equal weight of water.
Planing boats with rigid “deep V” hulls and inflatable collars provide a robust and potentially fast craft. A “deep V” hull is able to plane at speed, while slicing through waves, minimising slamming at the bow. However, a slipway or hard surface is required for launching such a craft. Also, it is very difficult and potentially dangerous to launch such a craft in high waves or strong winds. Such craft are unable to cross exposed sand or mud banks, may be impeded in fouled water, or may strike submerged objects in flood water. In addition, conventional marine engines rely on water cooling. The water intakes of such conventional marine engines commonly become blocked in fouled or flood water, reducing engine reliability and compromising speed of response and safety of the craft to which they are fitted.
Known small hovercraft can be fully amphibious and are be able to cross-exposed sand or mud banks. They are immune to the problems in fouled water, -or flood water noted above. Conventional hovercraft engines rely on air cooling (for example, engines may be direct air cooled, or liquid-cooled with an air radiator) and are not compromised in fouled or flood water. Small hovercraft have hulls designed to ride over a surface on an air cushion. However, if the height of waves or obstructions is similar or greater than the height of the air cushion, such hovercraft cease to operate correctly and instead become displacement craft. A displacement craft is one having a hull that plows through the water displacing a weight of water equal to its own weight even when more power is added. As a displacement craft moves through water, the water is parted at the bow and closes in again at the stern.
The hull shapes of known hovercraft are not suited for use by a displacement craft. While such hull shapes do work, the hovercraft bounce and slam dangerously in waves. Similarly, thrust from air expelled at the back of the craft is not suited for use as a means for propelling a displacement craft. Again, such thrust works but provides poor acceleration and/or control. This means that such hovercraft can only operate in good weather conditions. Also, small hovercraft are also vulnerable to strong winds, or gusts, because they have very little friction with the surface, and so may be blown off course quite readily. Craft that do not alter the direction that the thrust air is expelled can have poor maneuverability, because controls in the air stream provide a turning moment on the body of the craft, but the course of the craft alters only as the craft loses momentum in an original direction through friction with the surface.
Moreover, hovercraft that are small enough to be transported by road without dismantling either have small rigid hulls, which limit their load-carrying capacity, or have a “loop and segment” skirt system which extends the lift cushion to a greater width around the hull. However, conventional “loop and segment” skirt systems have a large bag (loop) that collapses when lift air is turned off. The collapsed bag then impedes rapid loading on to a trailer. Some hovercraft have thrust reversers which provide a braking force. However, it can be extremely difficult to steer the craft while operating the reverse thrust.
It has previously been proposed (U.S. Pat. No. 3,389,672) to provide a displacement hulled vessel capable of operating as a gaseous cushion borne craft. However, such a vehicle would suffer in use from the slamming at the bow noted above or from limited speed associated with the displacement hull.
U.S. Pat. No. 4,535,712 shows a vessel having a variable geometry hull capable also of operating on the air cushion principle. This presents the problem that the geometry of the hull must be altered before the vehicle can change its mode of operation.
It is an advantage of the present invention that it eliminates or at least substantially reduces the problems noted above, while maintaining the benefits of the different craft considered.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the present invention, an amphibious vehicle comprises a fixed geometry planing hull and a skirt system.
This has as an advantage that the fixed geometry planing hull allows the craft or vehicle to operate in high waves, strong winds or other adverse conditions too severe for known hovercraft of a similar size, while the skirt system contains a cushion of air providing the craft or vehicle with a full amphibious capability so that the craft can operate as a conventional hovercraft in good conditions or enter and leave water in any conditions. A full amphibious capability should be understood to mean that the craft or vehicle is able to support all of its weight by cushion pressure in order to travel as far as is required in this manner.
Additionally no manual conversion is required as between the modes of operation to alter the mode of operation of the vehicle. This should be understood to distinguish the present invention from those craft where the sides are physically assembled and bolted on after being transported in separate pieces.
Preferably, the skirt system is retractable.
Preferably, the skirt system comprises a plurality of side wings each pivotally connected at a first end to the hull of the craft, at least one collar connected to a second end of each of the side wings, a plurality of skirt segments supported from the at least one collar and a lift duct.
More preferably, the lift duct comprises a flexible membrane extending between the at least one collar and the hull.
Preferably, the at least one collar is inflatable.
Preferably, the vehicle comprises at least one fan duct adapted to contain a rudder or thrust reverser. Alternatively, the vehicle comprises at least one rudder adapted to operate as a thrust reverser.
Preferably, the or each fan duct comprises a propelling nozzle at an outlet and further comprises a plurality of apertures in side walls of the or each fan duct and vertical turning vanes associated with the plurality of apertures.
More preferably, the or each rudder comprises a plurality of vertical control surfaces located between fan means and the or an outlet of a fan duct.
More preferably, the or each rudder is arranged to direct air into or to block the apertures and associated vanes.
This has as an advantage that the or each rudder may be used to block the apertures and associated vanes to provide steering at the same time as reverse thrust.
Preferably, a single throttle lever controls a or the thrust reverser, an engine throttle and a gear box.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example only, with reference to and as illustrated in the accompanying drawings, in which:
FIG. 1 illustrates in side section a side view of a craft in accordance with the present invention in which the wings are illustrated in both an extended and retracted position;
FIG. 2 illustrates a plan view of the air propulsion system;
FIG. 3 illustrates in part section the hull and associated skirt system; and
FIG. 4 illustrates in a plan view the craft of FIG. 1 showing to one side a side wing extended and to the other the side wing retracted.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 , an amphibious craft in accordance with the present invention is provided with a fixed geometry planing hull 2 and a skirt system 4 . The fixed geometry planing hull 2 allows the craft to operate in high waves, strong winds, or other conditions too severe for a conventional hovercraft of a similar size. The skirt system 4 contains a cushion of air, providing the craft with a full amphibious capability, so that the craft can operate as a conventional hovercraft in good conditions, or to enter and leave the water in any conditions. No manual conversion is required for the craft to alter its mode of operation.
Thrust may be provided by any air or water propulsion system, or systems. These include air propellers, fans, air jets, water propellers and water jets. In the illustrated embodiment, thrust is provided by one or more fan ducts 5 each having at an exit a nozzle 6 formed by a reduction in cross-sectional area (to accelerate the expelled air), the nozzle 6 being fed with air by one or more air fans 8 . Thrust may additionally be supplied by one or more water propellers or water jets 10 .
Only one fan duct 5 is shown in FIG. 4 for clarity. In practice, the craft has a pair of fan ducts arranged side by side at the rear of the craft.
Lift may be provided by any means of supplying air or another gas to a containment device. In the illustrated embodiment, lift is provided by drawing a proportion of the air flow from ducted fans into a lift duct 12 , from where the air flow is fed through the hull 2 to the skirt system 4 . Splitter plates 14 are controlled to provide adequate lift air and may close to divert all of the air through the fan duct 5 to the thrust nozzle 6 , while the craft is supported by the fixed geometry planing hull 2 . The skirt system 4 may be rigid or flexible. In the illustrated embodiment, the skirt system consists of skirt segments 21 comprising open-ended flexible bags with a pocket sewn into each bag ( FIG. 3 ). The skirt segments 21 may be formed from any suitable material. The skirt segments 21 are represented by the dashed lines in the lower part of FIG. 4 .
The planing hull 2 may be a “deep V” design. In the illustrated embodiment, the hull 2 is a “deep V” design, with a bow 16 designed to slice through waves and push floating debris or ice to each side. The hull geometry is suitable to support the lower edges of the skirt segments 21 and at least one inflatable collar 18 , so that the upper edges of the skirt segments 21 are supported from the inflatable collar(s) 18 . A “tunnel” 20 in the hull bottom is formed behind the bow 16 . A water propeller 10 is shown housed in the tunnel 20 , so that the propeller 10 is above the bottom of the keel, or keels. In the illustrated embodiment, the bow 16 deflects floating debris or ice, so that clear water is fed to the propeller 10 in the tunnel 20 , while the tunnel 20 protects the propeller 10 from damage when the craft dries out or is used over solid surfaces or submerged debris or obstructions.
The hull width is suitable for transport on a road trailer, or in a shipping container. Adequate width for the cushion of air is provided by side “wings” 22 . The side skirt segments 21 are attached to the inflatable collar(s) 18 on the side wings 22 ( FIG. 3 ). The inflatable collar(s) 18 may be separate or a single entity. In the illustrated embodiment, separate inflatable collars 18 are attached to the wings 22 and to the rigid part of the hull 2 around the bow 16 , joined by envelopes 24 having sufficient flexibility for the side wings 22 to move through their full travel (the vertical component of this movement being shown in FIG. 1 , and the horizontal component in FIG. 4 ). In FIG. 3 a wing 22 may be seen in a folded up position A and also a folded down position B. The connection between the wing 22 and the hull 2 is articulated at point 23 ( FIG. 3 ). The wings 22 may be folded down to give maximum width for the cushion. The wings 22 may be folded up to give minimum width for transport out of the water. The skirt segments 21 may be pulled up out of the water by the action of the folding wings 22 . In this way, hydrodynamic drag from the skirt segments 21 dragging in the water may be reduced, by lifting the skirt segments 21 clear of the water while the craft operates in its planing mode. Folding the wings 22 up also raises the inflatable collars 18 at the sides of the craft to their maximum height, which increases the freeboard and improves safety in poor weather conditions. In the illustrated embodiment, operation of the folding wings 22 is by an automatic control, allowing a rapid transition from planing to cushion operation without manual conversion. This allows the craft to enter high waves from a beach, mud flat or any other surface and then enter the planing mode of operation to proceed away safely. Similarly, the craft may leave disturbed water or high waves by driving at speed on to a beach, mud flat or any other surface and then enter the cushion mode of operation to proceed away safely.
The lift ducts 12 at the side of the craft may be collapsible, so that they occupy minimum space when the side wings 22 are folded up (shown in ghost in FIG. 3 ). In the illustrated embodiment, the lift ducts 12 are formed between the wings 22 and the sides of the hull 2 , with a flexible membrane 26 to contain the air. When the wings 22 are in the folded up position, the membrane 26 is contained and does not impede rapid loading on to a trailer. Rapid deployment from a trailer is possible by folding down the wings 22 and using the air cushion to drive the craft directly off the trailer. In the illustrated embodiment, the skirt segments 21 have slits 29 (illustrated by the gaps in the dashed lines in FIG. 4 ) in their side walls 28 . The slits 29 allow the segments 21 to be pulled clear of the water without tearing as the wings 22 fold up. When lift air flows into the skirt segments 21 , the side walls 28 of the skirt segments 21 seal against each other to prevent loss of air. There is no difference in air pressure between adjacent skirt segments 21 , so there is no flow of air out of the slits 29 in the side walls 28 . In the illustrated embodiment, the top of each segment 21 is attached to the hull 2 or the inflatable collar 18 by a lip provided with a hook and loop fastening system. This allows damaged segments to be changed rapidly.
A set of drag flaps 38 at the stern of the craft are long enough to drag underneath the aft skirt segments ( FIG. 1 ). The drag flaps 38 are bouyant, so that when the craft is floating or planing the drag flaps 38 lift the aft skirt segments clear of the water, to provide minimum drag.
The craft may conveniently be provided with one or more thrust reversers. The thrust reversers may be formed integral with the air rudders or separately. In the illustrated embodiment, a thrust reverser comprises a compound air rudder mounted in between the air fan 8 and the nozzle 6 of the fan duct 5 . The compound rudder consists of two vertical control surfaces 30 mounted on a jockey bar. The control surfaces 30 are normally fixed parallel to each other and the jockey bar is rotated about a vertical axis to provide a turning moment at the rear of the craft. A separate control moves the control surfaces 30 relative to each other about vertical axes from the jockey bar, until their leading edges meet on a vertical line, so that the control surfaces 30 form a V in plan view ( FIG. 2 ). This blocks the fan duct 5 and deflects the air flow from the fan 8 outwards towards side walls 35 of the fan duct 5 . An aperture 32 in each side wall 35 has a number of vertical turning vanes 34 , which deflect the air flow forwards. The reaction from the deflected air provides reverse thrust.
With the craft's steering in a neutral (straight-ahead) position, the reverse airflow is equal on both sides of the fan duct 5 and there is no turning moment on the rear of the craft. Moving the steering away from the neutral position rotates the rudder jockey bar, whether the control surfaces 30 have been locked parallel ( FIG. 4 ) or moved to form a thrust reverser ( FIG. 2 ). If the control surfaces 30 have been moved to form a thrust reverser, the outer edges of the V move across the side apertures 32 , so that the open (un-blocked) area on one side is increased, while the open area on the other is decreased. The turning vanes 34 are at different angles, so that air emerging towards the back of the aperture exits at a greater angle to the craft axis than air emerging towards the front of the aperture. Thus, more air flow emerges on one side of the fan duct 5 than the other and the side with the greater flow also has more air directed sideways, so that the lateral reaction forces are unbalanced. This provides a turning moment at the rear of the craft, so that the craft can be steered while reverse thrust is operating.
Reverse thrust may be used to slow and stop the craft, or to reverse it. Effective steering while reversing allows the craft to be maneuvered easily. There is nothing to block the reverse flow apertures 32 or vanes 34 , either when the control surfaces 30 are locked parallel, or in a V. When the control surfaces 30 are locked parallel and steering is neutral, little or no air escapes out of the apertures 32 because the air has sufficient momentum to get past the apertures 32 . At forward speed, air from outside the fan duct 5 provides an additional sealing pressure. When the steering is moved away from neutral, some air is deflected by a vertical control surface 30 and out of one side of the fan duct 5 . The reaction to this flow provides a powerful turning moment at the rear of the craft which, added to the reaction on the compound rudder, improves the maneuverability while the craft is stationary or traveling forwards, compared with a conventional craft.
The craft is also fitted with a pair of water rudders 36 , which operate in a conventional manner.
Conventional boats may have a throttle box with a foward/reverse movement. Forward engages the gearbox forward gear before advancing the throttle cable. Reverse engages the gearbox reverse gear before advancing the throttle cable and the propeller turns in the opposite direction to pull the boat back or slow it down. This makes maneuvering the boat simple and quick.
Conventional hovercraft may have separate controls for throttle and thrust reverser(s), vectored thrust, elevons or skirt shifting mechanisms. These are effective but require a trained operator.
The amphibious craft of the present invention may have a single throttle lever that controls the thrust reverser, engine throttle and a gearbox. As the lever is moved forward from its neutral position, the vertical control surfaces 30 may be rotated until they are parallel to one another, forming a rudder assembly. The same movement of the lever advances the engine throttle once the vertical control surfaces 30 have moved. As the lever is moved backwards from its neutral position, the vertical control surfaces 30 may be rotated until they form a thrust reverser. The same movement of the lever advances the engine throttle once the control surfaces 30 have moved. The effect is that the craft can be moved forward, backward or slowed using the same control movement as a conventional boat throttle box. Operators of craft constructed in accordance with this aspect of the present invention will accordingly require little further training to use the system.
The amphibious craft of the present invention may have a water thrust system. This may be engaged or disengaged using the same control box. The box may have a separate lever, button or other control to do this, or it may have a separate movement of the single control lever. The control box may allow the lever to move in an H pattern in plan view. From the neutral position, the lever can be moved sideways to change from one side of the H to the other. The sideways movement may engage or disengage the water thrust system, so that forward/reverse movement on one side of the H has the water system engaged and on the other has the water system disengaged. The stops on the travel of the lever may be at different positions around the H, allowing the maximum engine power to be limited for different configurations. This system allows the operator to control the craft rapidly and easily, without using different controls for the various systems on the craft.
The steering system controls the compound air rudders and the water rudders simultaneously, so that steering is provided by a single control however the craft is operating. | The present invention relates to an improved amphibious craft or vehicle and, in particular, but not exclusively, to a craft or vehicle that may be used for commercial and rescue tasks in a great variety of weather conditions. To achieve this, an amphibious vehicle comprises a fixed geometry planing hull ( 2 ) and a skirt system ( 4 ). This has as an advantage that the fixed geometry planing hull ( 2 ) allows the craft or vehicle to operate in high waves, strong winds or other adverse conditions too severe for known hovercraft of a similar size, while the skirt system ( 4 ) contains a cushion of air providing the craft or vehicle with a full amphibious capability so that the craft can operate as a conventional hovercraft in good conditions or enter and leave water in any conditions. | Summarize the patent information, clearly outlining the technical challenges and proposed solutions. | [
"FIELD OF THE INVENTION The present invention relates to an improved amphibious craft or vehicle and, in particular, but not exclusively, to a craft or vehicle that may be used for commercial and rescue tasks in a great variety of weather conditions.",
"An amphibious craft or vehicle for the purposes of the present invention is one that is designed for operation on or from both water and land.",
"BACKGROUND TO THE INVENTION Planing boats are widely operated in a variety of water and weather conditions.",
"A planing hull is a hull designed to climb toward the surface of the water as power is supplied, thus reducing the friction or drag and therefore increasing hull speed.",
"In other words a planing hull can rise bodily in the water and ride over the wave created by its progress through the water.",
"The weight of a planing hull is supported by hydrodynamic lift and it does not displace an equal weight of water.",
"Planing boats with rigid “deep V”",
"hulls and inflatable collars provide a robust and potentially fast craft.",
"A “deep V”",
"hull is able to plane at speed, while slicing through waves, minimising slamming at the bow.",
"However, a slipway or hard surface is required for launching such a craft.",
"Also, it is very difficult and potentially dangerous to launch such a craft in high waves or strong winds.",
"Such craft are unable to cross exposed sand or mud banks, may be impeded in fouled water, or may strike submerged objects in flood water.",
"In addition, conventional marine engines rely on water cooling.",
"The water intakes of such conventional marine engines commonly become blocked in fouled or flood water, reducing engine reliability and compromising speed of response and safety of the craft to which they are fitted.",
"Known small hovercraft can be fully amphibious and are be able to cross-exposed sand or mud banks.",
"They are immune to the problems in fouled water, -or flood water noted above.",
"Conventional hovercraft engines rely on air cooling (for example, engines may be direct air cooled, or liquid-cooled with an air radiator) and are not compromised in fouled or flood water.",
"Small hovercraft have hulls designed to ride over a surface on an air cushion.",
"However, if the height of waves or obstructions is similar or greater than the height of the air cushion, such hovercraft cease to operate correctly and instead become displacement craft.",
"A displacement craft is one having a hull that plows through the water displacing a weight of water equal to its own weight even when more power is added.",
"As a displacement craft moves through water, the water is parted at the bow and closes in again at the stern.",
"The hull shapes of known hovercraft are not suited for use by a displacement craft.",
"While such hull shapes do work, the hovercraft bounce and slam dangerously in waves.",
"Similarly, thrust from air expelled at the back of the craft is not suited for use as a means for propelling a displacement craft.",
"Again, such thrust works but provides poor acceleration and/or control.",
"This means that such hovercraft can only operate in good weather conditions.",
"Also, small hovercraft are also vulnerable to strong winds, or gusts, because they have very little friction with the surface, and so may be blown off course quite readily.",
"Craft that do not alter the direction that the thrust air is expelled can have poor maneuverability, because controls in the air stream provide a turning moment on the body of the craft, but the course of the craft alters only as the craft loses momentum in an original direction through friction with the surface.",
"Moreover, hovercraft that are small enough to be transported by road without dismantling either have small rigid hulls, which limit their load-carrying capacity, or have a “loop and segment”",
"skirt system which extends the lift cushion to a greater width around the hull.",
"However, conventional “loop and segment”",
"skirt systems have a large bag (loop) that collapses when lift air is turned off.",
"The collapsed bag then impedes rapid loading on to a trailer.",
"Some hovercraft have thrust reversers which provide a braking force.",
"However, it can be extremely difficult to steer the craft while operating the reverse thrust.",
"It has previously been proposed (U.S. Pat. No. 3,389,672) to provide a displacement hulled vessel capable of operating as a gaseous cushion borne craft.",
"However, such a vehicle would suffer in use from the slamming at the bow noted above or from limited speed associated with the displacement hull.",
"U.S. Pat. No. 4,535,712 shows a vessel having a variable geometry hull capable also of operating on the air cushion principle.",
"This presents the problem that the geometry of the hull must be altered before the vehicle can change its mode of operation.",
"It is an advantage of the present invention that it eliminates or at least substantially reduces the problems noted above, while maintaining the benefits of the different craft considered.",
"BRIEF SUMMARY OF THE INVENTION According to a first aspect of the present invention, an amphibious vehicle comprises a fixed geometry planing hull and a skirt system.",
"This has as an advantage that the fixed geometry planing hull allows the craft or vehicle to operate in high waves, strong winds or other adverse conditions too severe for known hovercraft of a similar size, while the skirt system contains a cushion of air providing the craft or vehicle with a full amphibious capability so that the craft can operate as a conventional hovercraft in good conditions or enter and leave water in any conditions.",
"A full amphibious capability should be understood to mean that the craft or vehicle is able to support all of its weight by cushion pressure in order to travel as far as is required in this manner.",
"Additionally no manual conversion is required as between the modes of operation to alter the mode of operation of the vehicle.",
"This should be understood to distinguish the present invention from those craft where the sides are physically assembled and bolted on after being transported in separate pieces.",
"Preferably, the skirt system is retractable.",
"Preferably, the skirt system comprises a plurality of side wings each pivotally connected at a first end to the hull of the craft, at least one collar connected to a second end of each of the side wings, a plurality of skirt segments supported from the at least one collar and a lift duct.",
"More preferably, the lift duct comprises a flexible membrane extending between the at least one collar and the hull.",
"Preferably, the at least one collar is inflatable.",
"Preferably, the vehicle comprises at least one fan duct adapted to contain a rudder or thrust reverser.",
"Alternatively, the vehicle comprises at least one rudder adapted to operate as a thrust reverser.",
"Preferably, the or each fan duct comprises a propelling nozzle at an outlet and further comprises a plurality of apertures in side walls of the or each fan duct and vertical turning vanes associated with the plurality of apertures.",
"More preferably, the or each rudder comprises a plurality of vertical control surfaces located between fan means and the or an outlet of a fan duct.",
"More preferably, the or each rudder is arranged to direct air into or to block the apertures and associated vanes.",
"This has as an advantage that the or each rudder may be used to block the apertures and associated vanes to provide steering at the same time as reverse thrust.",
"Preferably, a single throttle lever controls a or the thrust reverser, an engine throttle and a gear box.",
"BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described, by way of example only, with reference to and as illustrated in the accompanying drawings, in which: FIG. 1 illustrates in side section a side view of a craft in accordance with the present invention in which the wings are illustrated in both an extended and retracted position;",
"FIG. 2 illustrates a plan view of the air propulsion system;",
"FIG. 3 illustrates in part section the hull and associated skirt system;",
"and FIG. 4 illustrates in a plan view the craft of FIG. 1 showing to one side a side wing extended and to the other the side wing retracted.",
"DETAILED DESCRIPTION OF THE INVENTION Referring first to FIG. 1 , an amphibious craft in accordance with the present invention is provided with a fixed geometry planing hull 2 and a skirt system 4 .",
"The fixed geometry planing hull 2 allows the craft to operate in high waves, strong winds, or other conditions too severe for a conventional hovercraft of a similar size.",
"The skirt system 4 contains a cushion of air, providing the craft with a full amphibious capability, so that the craft can operate as a conventional hovercraft in good conditions, or to enter and leave the water in any conditions.",
"No manual conversion is required for the craft to alter its mode of operation.",
"Thrust may be provided by any air or water propulsion system, or systems.",
"These include air propellers, fans, air jets, water propellers and water jets.",
"In the illustrated embodiment, thrust is provided by one or more fan ducts 5 each having at an exit a nozzle 6 formed by a reduction in cross-sectional area (to accelerate the expelled air), the nozzle 6 being fed with air by one or more air fans 8 .",
"Thrust may additionally be supplied by one or more water propellers or water jets 10 .",
"Only one fan duct 5 is shown in FIG. 4 for clarity.",
"In practice, the craft has a pair of fan ducts arranged side by side at the rear of the craft.",
"Lift may be provided by any means of supplying air or another gas to a containment device.",
"In the illustrated embodiment, lift is provided by drawing a proportion of the air flow from ducted fans into a lift duct 12 , from where the air flow is fed through the hull 2 to the skirt system 4 .",
"Splitter plates 14 are controlled to provide adequate lift air and may close to divert all of the air through the fan duct 5 to the thrust nozzle 6 , while the craft is supported by the fixed geometry planing hull 2 .",
"The skirt system 4 may be rigid or flexible.",
"In the illustrated embodiment, the skirt system consists of skirt segments 21 comprising open-ended flexible bags with a pocket sewn into each bag ( FIG. 3 ).",
"The skirt segments 21 may be formed from any suitable material.",
"The skirt segments 21 are represented by the dashed lines in the lower part of FIG. 4 .",
"The planing hull 2 may be a “deep V”",
"design.",
"In the illustrated embodiment, the hull 2 is a “deep V”",
"design, with a bow 16 designed to slice through waves and push floating debris or ice to each side.",
"The hull geometry is suitable to support the lower edges of the skirt segments 21 and at least one inflatable collar 18 , so that the upper edges of the skirt segments 21 are supported from the inflatable collar(s) 18 .",
"A “tunnel”",
"20 in the hull bottom is formed behind the bow 16 .",
"A water propeller 10 is shown housed in the tunnel 20 , so that the propeller 10 is above the bottom of the keel, or keels.",
"In the illustrated embodiment, the bow 16 deflects floating debris or ice, so that clear water is fed to the propeller 10 in the tunnel 20 , while the tunnel 20 protects the propeller 10 from damage when the craft dries out or is used over solid surfaces or submerged debris or obstructions.",
"The hull width is suitable for transport on a road trailer, or in a shipping container.",
"Adequate width for the cushion of air is provided by side “wings”",
"22 .",
"The side skirt segments 21 are attached to the inflatable collar(s) 18 on the side wings 22 ( FIG. 3 ).",
"The inflatable collar(s) 18 may be separate or a single entity.",
"In the illustrated embodiment, separate inflatable collars 18 are attached to the wings 22 and to the rigid part of the hull 2 around the bow 16 , joined by envelopes 24 having sufficient flexibility for the side wings 22 to move through their full travel (the vertical component of this movement being shown in FIG. 1 , and the horizontal component in FIG. 4 ).",
"In FIG. 3 a wing 22 may be seen in a folded up position A and also a folded down position B. The connection between the wing 22 and the hull 2 is articulated at point 23 ( FIG. 3 ).",
"The wings 22 may be folded down to give maximum width for the cushion.",
"The wings 22 may be folded up to give minimum width for transport out of the water.",
"The skirt segments 21 may be pulled up out of the water by the action of the folding wings 22 .",
"In this way, hydrodynamic drag from the skirt segments 21 dragging in the water may be reduced, by lifting the skirt segments 21 clear of the water while the craft operates in its planing mode.",
"Folding the wings 22 up also raises the inflatable collars 18 at the sides of the craft to their maximum height, which increases the freeboard and improves safety in poor weather conditions.",
"In the illustrated embodiment, operation of the folding wings 22 is by an automatic control, allowing a rapid transition from planing to cushion operation without manual conversion.",
"This allows the craft to enter high waves from a beach, mud flat or any other surface and then enter the planing mode of operation to proceed away safely.",
"Similarly, the craft may leave disturbed water or high waves by driving at speed on to a beach, mud flat or any other surface and then enter the cushion mode of operation to proceed away safely.",
"The lift ducts 12 at the side of the craft may be collapsible, so that they occupy minimum space when the side wings 22 are folded up (shown in ghost in FIG. 3 ).",
"In the illustrated embodiment, the lift ducts 12 are formed between the wings 22 and the sides of the hull 2 , with a flexible membrane 26 to contain the air.",
"When the wings 22 are in the folded up position, the membrane 26 is contained and does not impede rapid loading on to a trailer.",
"Rapid deployment from a trailer is possible by folding down the wings 22 and using the air cushion to drive the craft directly off the trailer.",
"In the illustrated embodiment, the skirt segments 21 have slits 29 (illustrated by the gaps in the dashed lines in FIG. 4 ) in their side walls 28 .",
"The slits 29 allow the segments 21 to be pulled clear of the water without tearing as the wings 22 fold up.",
"When lift air flows into the skirt segments 21 , the side walls 28 of the skirt segments 21 seal against each other to prevent loss of air.",
"There is no difference in air pressure between adjacent skirt segments 21 , so there is no flow of air out of the slits 29 in the side walls 28 .",
"In the illustrated embodiment, the top of each segment 21 is attached to the hull 2 or the inflatable collar 18 by a lip provided with a hook and loop fastening system.",
"This allows damaged segments to be changed rapidly.",
"A set of drag flaps 38 at the stern of the craft are long enough to drag underneath the aft skirt segments ( FIG. 1 ).",
"The drag flaps 38 are bouyant, so that when the craft is floating or planing the drag flaps 38 lift the aft skirt segments clear of the water, to provide minimum drag.",
"The craft may conveniently be provided with one or more thrust reversers.",
"The thrust reversers may be formed integral with the air rudders or separately.",
"In the illustrated embodiment, a thrust reverser comprises a compound air rudder mounted in between the air fan 8 and the nozzle 6 of the fan duct 5 .",
"The compound rudder consists of two vertical control surfaces 30 mounted on a jockey bar.",
"The control surfaces 30 are normally fixed parallel to each other and the jockey bar is rotated about a vertical axis to provide a turning moment at the rear of the craft.",
"A separate control moves the control surfaces 30 relative to each other about vertical axes from the jockey bar, until their leading edges meet on a vertical line, so that the control surfaces 30 form a V in plan view ( FIG. 2 ).",
"This blocks the fan duct 5 and deflects the air flow from the fan 8 outwards towards side walls 35 of the fan duct 5 .",
"An aperture 32 in each side wall 35 has a number of vertical turning vanes 34 , which deflect the air flow forwards.",
"The reaction from the deflected air provides reverse thrust.",
"With the craft's steering in a neutral (straight-ahead) position, the reverse airflow is equal on both sides of the fan duct 5 and there is no turning moment on the rear of the craft.",
"Moving the steering away from the neutral position rotates the rudder jockey bar, whether the control surfaces 30 have been locked parallel ( FIG. 4 ) or moved to form a thrust reverser ( FIG. 2 ).",
"If the control surfaces 30 have been moved to form a thrust reverser, the outer edges of the V move across the side apertures 32 , so that the open (un-blocked) area on one side is increased, while the open area on the other is decreased.",
"The turning vanes 34 are at different angles, so that air emerging towards the back of the aperture exits at a greater angle to the craft axis than air emerging towards the front of the aperture.",
"Thus, more air flow emerges on one side of the fan duct 5 than the other and the side with the greater flow also has more air directed sideways, so that the lateral reaction forces are unbalanced.",
"This provides a turning moment at the rear of the craft, so that the craft can be steered while reverse thrust is operating.",
"Reverse thrust may be used to slow and stop the craft, or to reverse it.",
"Effective steering while reversing allows the craft to be maneuvered easily.",
"There is nothing to block the reverse flow apertures 32 or vanes 34 , either when the control surfaces 30 are locked parallel, or in a V. When the control surfaces 30 are locked parallel and steering is neutral, little or no air escapes out of the apertures 32 because the air has sufficient momentum to get past the apertures 32 .",
"At forward speed, air from outside the fan duct 5 provides an additional sealing pressure.",
"When the steering is moved away from neutral, some air is deflected by a vertical control surface 30 and out of one side of the fan duct 5 .",
"The reaction to this flow provides a powerful turning moment at the rear of the craft which, added to the reaction on the compound rudder, improves the maneuverability while the craft is stationary or traveling forwards, compared with a conventional craft.",
"The craft is also fitted with a pair of water rudders 36 , which operate in a conventional manner.",
"Conventional boats may have a throttle box with a foward/reverse movement.",
"Forward engages the gearbox forward gear before advancing the throttle cable.",
"Reverse engages the gearbox reverse gear before advancing the throttle cable and the propeller turns in the opposite direction to pull the boat back or slow it down.",
"This makes maneuvering the boat simple and quick.",
"Conventional hovercraft may have separate controls for throttle and thrust reverser(s), vectored thrust, elevons or skirt shifting mechanisms.",
"These are effective but require a trained operator.",
"The amphibious craft of the present invention may have a single throttle lever that controls the thrust reverser, engine throttle and a gearbox.",
"As the lever is moved forward from its neutral position, the vertical control surfaces 30 may be rotated until they are parallel to one another, forming a rudder assembly.",
"The same movement of the lever advances the engine throttle once the vertical control surfaces 30 have moved.",
"As the lever is moved backwards from its neutral position, the vertical control surfaces 30 may be rotated until they form a thrust reverser.",
"The same movement of the lever advances the engine throttle once the control surfaces 30 have moved.",
"The effect is that the craft can be moved forward, backward or slowed using the same control movement as a conventional boat throttle box.",
"Operators of craft constructed in accordance with this aspect of the present invention will accordingly require little further training to use the system.",
"The amphibious craft of the present invention may have a water thrust system.",
"This may be engaged or disengaged using the same control box.",
"The box may have a separate lever, button or other control to do this, or it may have a separate movement of the single control lever.",
"The control box may allow the lever to move in an H pattern in plan view.",
"From the neutral position, the lever can be moved sideways to change from one side of the H to the other.",
"The sideways movement may engage or disengage the water thrust system, so that forward/reverse movement on one side of the H has the water system engaged and on the other has the water system disengaged.",
"The stops on the travel of the lever may be at different positions around the H, allowing the maximum engine power to be limited for different configurations.",
"This system allows the operator to control the craft rapidly and easily, without using different controls for the various systems on the craft.",
"The steering system controls the compound air rudders and the water rudders simultaneously, so that steering is provided by a single control however the craft is operating."
] |
[0001] The invention pertains to machines for brewing and dispensing espresso drinks. In particular, the invention is an apparatus and associated method for controlling, automating, and duplicating the brewing conditions for multiple doses of espresso.
[0002] Machines for preparing espresso drinks in a commercial retail environment are well known. In general, these espresso machines include a heating source for generating steam and hot water in a reservoir, a basket for holding ground espresso, and a dispensing spout. There are several increasingly sophisticated means of controlling the flow of the hot water through the espresso, out the spout, and into the cup. Perhaps the simplest means is a manually-controlled valve which is opened to permit a pressurized flow of hot water through the grounds and out the spout into a cup below. More modern machines, such as the Hydra™ espresso machine manufactured by Synesso Incorporated of Seattle Wash., incorporate computer control of the valve. The operator of such machines either presses a button or operates a toggle switch, sensed by the computer to control the valve. Some espresso machines fully automate the brewing sequence, such that a single operation of the button provides a precise dose of water through the grounds, with attendant precise control of the water temperature and driving pressure. Commercial machines may include several dispensing heads.
[0003] A commercial establishment for preparing and selling espresso drinks faces several inter-related problems, each of which is influenced by the particular espresso machine that the establishment has chosen to adopt. The first problem is one of reliability and robustness of the espresso machine. Because it is often a primary source of business revenue, the espresso machine must enjoy high operational uptime, despite a large number of operations involving high temperature water, pressure, and steam. Electro-mechanical parts, such as switches, potentiometers, and rheostats, are particularly susceptible to failure simply because the user is operating them constantly.
[0004] The second problem is serviceability of the espresso machine. Because existing machines have become relatively complex, the electromechanical parts such as those described above are difficult to service. Such operating parts must be protected from physical and environmental damage. Thus, the parts are usually sealed within the machine and are difficult to access.
[0005] In addition, electromechanical parts used in existing machines, such as roller switches, reed switches, etc. involve springs and other parts which degrade or change characteristics over time. Such parts, even if they don't fail, often require physical calibration for the machine to operate properly. One such prior art part is a roller or reed switch connected to a user handle, or wand, for initiating an espresso “shot”. After a large number of operations, the roller or reed switch can unexpectedly break or otherwise lose its spring action and become inoperable. Such a breakdown is intolerable in a busy commercial environment, and so the switch must be routinely inspected, serviced, and calibrated. Another problem pertaining to reed switches in espresso machines is the difficulty of ensuring accuracy and consistency of operation across each of the manufactured machines. Most existing reed switches require calibration at the factory prior to shipping due to the variation in the reed switch manufacturing tolerances. Calibration of reed switches is especially critical for machines which use systems of reed switches that operate together to perform certain linear or proportional functions.
[0006] Another problem with existing espresso machines is that the operating mechanism that is available to the user is largely limited to an on/off switch or button. The competing problem to simplifying the operation for employees also serves to limit the ability of them to vary the espresso making process to account for changes in the coffee. The taste of the final espresso product can vary significantly with the type of coffee, the grind, and the age of the coffee, for example. Current machines have very limited capability for the experienced user to adjust the brew on the fly to account for these changes.
[0007] The inventors have recognized these problems in the prior art, and have arrived at a novel and ingenious solution. An improved manually operated control mechanism for an espresso machine is described here which incorporates a non-contact sensor for detecting the operating input from the user. This control mechanism is referred to as a group control head because in general the mechanism will be co-located with its respective espresso dispensing head. The sensor also has a capability for analog sensing of the input, so that an experienced user can vary the brewing process on the fly, and without the need for time-consuming programming or process set-up. The inventive group head control mechanism requires no calibration, is more reliable, and requires less servicing than prior art mechanisms. Thus, the invention simultaneously provides for a better coffee brew and increased product throughput.
[0008] In accordance with the principles of the present invention, an improved espresso brewing apparatus is described which incorporates a non-contact operating mechanism within its user control interface. The apparatus includes a novel and inventive group control head. The group head has a control handle or paddle which is connected to a magnet. When the control handle and magnet is rotated to a first position, a non-contact sensor such as a linear/proportional Hall Effect sensor senses the rotation. The sensor then provides a corresponding control input to the espresso machine dosing mechanism which may include a controller. A centering post in the mechanism provides an opposing biasing force on the magnet that returns the control handle to an idle position when the handle is released.
[0009] Also in accordance with the principles of the present invention, a group control head for dispensing a controlled dose of espresso from an espresso machine is described which comprises a base having a center axis, a top plate rigidly fixed to the base, the top plate comprising a pivot pin disposed on the center axis. The group head also includes a centering post disposed at a radial idle position offset orthogonally from the center axis, and at least one proximity sensor, such as a linear/proportional Hall Effect sensor disposed at a fixed angle from the radial idle position. An actuator is rotationally disposed on the pivot pin, the actuator including a magnet which is disposed near the radial idle position and adjacent to the centering post. A handle is affixed to the actuator. The handle is disposed to manually rotate the actuator away from the radial idle position in which the magnet is adjacent to the centering, wherein the centering post and magnet provide a biasing force that biases the actuator position to automatically return the actuator to the radial idle position. A second proximity sensor at a second fixed angle can be included to provide further operative utility.
[0010] Also in accordance with the principles of the present invention, an espresso machine which incorporates the above described group control head is described. The espresso machine also comprises an espresso dosing unit which includes a pressurized hot water brew tank, a filter for holding coffee grounds, a control valve disposed between the brew tank and the filter, and an outlet spout. A pump is disposed at an inlet of the brew tank. The machine also includes a controller that is in electrical communication with an input signal from the group control head and in controlling communication with the control valve and the pump. An actuation of the group control head handle actuates at least one of the controller, the pump and the control valve to provide a controlled dose of hot water from the source to the spout. Also in accordance with the principles of the present invention, a method is described for using the espresso machine as previously described. The method includes the steps of momentarily actuating the group head handle to an angular brew position and automatically controlling both of the pump and the valve to provide a controlled dose of hot water through the machine. A second actuation can control or stop the ongoing programmed sequence.
[0011] As used herein for purposes of the present disclosure, the term “processor” or “controller” is used generally to describe various apparatus relating to the operation of the inventive apparatus, system, or method. A processor can be implemented in numerous ways (e.g. such as with dedicated hardware) to perform various functions discussed herein. A processor is also one example of a controller which employs one or more microprocessors that may be programmed using software (e.g. microcode) to perform various functions discussed herein. A controller may be implemented with or without employing a processor, and may also be implemented as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions. Examples of controller components that may be employed in various embodiments of the present disclosure include, but are not limited to, conventional microprocessors, application specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).
[0012] It is understood that the term “memory” refers to computer storage memory of types generally known in the art. Memory may be volatile or non-volatile computer memory such as RAM, PROM, EPROM, and EEPROM, floppy disks, compact disks, optical disks, magnetic tape, etc. In some implementations the computer memory media may be encoded with one or more programs that, when executed on the one or more processors and controllers, perform at least some of the functions discussed herein. Various storage media may be fixed within a processor or controller or may be transportable, such that the one or more programs stored thereon can be loaded into a processor or controller so as to implement various aspects of the present invention. The terms “program” or “computer program” are used herein in a generic sense to refer to any type of computer code (e.g. software or microcode) that can be employed to program one or more processors or controllers.
[0013] In various implementations, there terms “outputs”, “inputs”, “signals”, and the like may be understood to be electrical or optical energy impulses which represent a particular detection or processing result.
IN THE DRAWINGS
[0014] FIG. 1 illustrates an embodiment of an espresso machine according to the present invention.
[0015] FIG. 2 illustrates the plumbing system of the FIG. 1 espresso machine.
[0016] FIG. 3 illustrates an exploded diagram of one embodiment of the inventive group control head.
[0017] FIGS. 4( a ), 4( b ) and 4( c ) illustrate the operation of the FIG. 3 group control head.
[0018] FIG. 5 is a system block diagram of one embodiment of the electrical sensing and control circuit.
[0019] FIG. 6( a ) and FIG. 6( b ) illustrate two embodiments of a visual display for the espresso machine of the present invention.
[0020] FIG. 7 illustrates a brewing sequence for the espresso machine.
[0021] FIG. 8 illustrates an embodiment of an inventive method for operating the espresso machine of the present invention.
[0022] FIG. 9 illustrates a flow chart method for saving and retrieving a set of brew parameters in the espresso machine.
[0023] FIG. 10 is a state machine diagram for a simplified method of saving a set of brew parameters to the espresso machine.
[0024] FIGS. 11( a ), 11( b ), 11( c ), and 11( d ) illustrate a set of state machine diagrams for a various operating modes of the espresso machine.
[0025] FIG. 12 illustrates a visual display for saving a set of brew parameters from one dosing unit to other dosing units in the espresso machine.
[0026] FIG. 13 illustrates a more detailed view of an external programming controller for the espresso machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Espresso Machine Including Improved Non-contact Group Control Head
[0027] Now turning to the illustrations, FIG. 1 shows an espresso machine of the present invention. Espresso machine 100 includes an espresso dosing unit 102 having at least one group control head 110 which controls the operation of the machine to provide an espresso dose. Espresso machine 100 includes an internal source of water and steam pressure. Each dose of espresso is dispensed from a brew tank 150 at the outlet of the water source. Brew tank 150 is sized to contain hot water under pressure with enough volume, for example about 1.9 liters, for one or more doses of espresso. Typically, brew tank 150 includes a heating element to maintain the water temperature at an optimal temperature for brewing.
[0028] At the outlet of brew tank 150 is a filter 160 for holding ground coffee. Filter 160 is sized to hold enough tamped-in grounds for one dose of espresso. Filter 160 is of course removable so that coffee grounds can be replaced after each use. At the outlet of filter 160 is an outlet spout 170 for guiding the dispensed dose of espresso into a cup, not shown, held or placed below the spout. For the purposes of this description, an espresso dosing unit 102 is generally understood to include at minimum the brew tank 150 , filter 160 and outlet spout 170 .
[0029] Many commercial espresso machines include a visual display 180 disposed on the group control head 110 , or on the machine 100 adjacent the dosing unit or group control head. Visual display 180 can display basic shot parameters such as time to completion, dose size, and the like. Because of the need for quick and efficient dosing of espresso shots in commercial settings, it is important that the information provided on visual display 180 is kept as simple, clear and as uncluttered with unneeded data as possible.
[0030] It may be noted that the type of grounds placed in the filter 160 may vary. The harvested source and variety of coffee, the texture of the grind, and the age of the coffee grounds affect the taste of the final product in several ways. The coffee variation may affect the tamp of the grounds in the filter 160 and the resulting pressure differential between the brew tank and the spout. The coffee variation also affects the interaction between the grounds and the hot water flowing through them. Each of these factors changes the taste of the dosed espresso. An experienced user desiring to optimize taste needs the ability to vary properties of the brew to account for these variations.
[0031] The espresso machine of FIG. 1 also illustrates additional dosing units which include additional group control heads such as second group control head 110 ′ and third group control head 110 ″. The additional dosing units allow for increased throughput of espresso drinks. Each of the additional dosing units may also include dedicated visual displays such as shown in FIG. 1 at second visual display 180 ′ and third visual display 180 ″. The number of dosing units is not important to the invention.
[0032] Any of the optional dosing units may be pre-programmed using an optional external programming controller 190 . Default brew parameters such dispensing temperature, dose size, and applied pressure profile may be entered via programming controller 190 . With reference to FIG. 13 , programming controller 190 includes a programmer display 192 , which may display text related to a current state of the selected dosing unit or may display text related to a programmed brewing sequence parameter. User selection of the text to be viewed on the controller 190 may be selected via one or more programmer selection buttons 194 disposed next to the corresponding text line, or may be selected via a set of up-and-down programmer scrolling arrows 196 . Adjustment of parameters may be entered via the scrolling arrows 196 . Other user interfaces such as keyboards, touch pad screens, and the like may be used as well for these functions.
[0033] It should be noted that efficient use of controller 190 may entail a more advanced operating skill, and may distract from the ongoing dosing unit operation. Thus, use of programming controller 190 may be generally more desirable during business idle time or downtime.
[0034] Now referring to FIG. 2 , a plumbing arrangement 200 that may be incorporated within the FIG. 1 espresso machine is shown. A single steam tank 202 is generally located within the main housing of the espresso machine, heated to provide a constant temperature and pressure steam source that is commonly used for foaming milk and the like. An external water source 210 , such as from building plumbing, and associated valve arrangement provides fill water for the steam tank 202 . The water source 210 is also used by a pump 204 as a source of water to brew tank 250 and optional brew tanks 250 ′ and 250 ″. Pump 204 may also operate under computer control to control or vary the pressure in brew tank 250 and consequently the pressure profile across the coffee grounds in the filter 260 as the shot is flowing. An optional bypass control valve 208 and associated plumbing from the pump 204 discharge, i.e. between brew tank 250 and pump, back to the pump 204 suction is also shown. Computer control may operate the optional bypass control valve 208 during the pump operation to establish a time-pressure profile across the filter by diverting the high pressure pump water away from the operating brew group.
[0035] As can be seen in FIG. 2 , flow of pressurized water from pump 204 to brew tank 250 may pass through the steam tank 202 . This feature permits feed water to be pre-heated before entering the brew tank 250 , which makes temperature control at the brew group more precise.
[0036] Brew tank 250 holds pressurized hot water that is ready for dispensing through the filter 260 . Brew tank 250 typically includes a heating element for continued precise temperature control, as well as a temperature sensor and an optional pressure sensor. Brew tank 250 or the dedicated plumbing leading to it may also include a flowmeter.
[0037] Control valve 206 starts and stops the pressurized hot water flow from brew tank 250 through filter 260 through the outlet spout 170 . In a preferred embodiment, control valve 206 is operated under control of an automated controller, which in turn operates responsive to an actuation signal input from the group control head. Control valve 206 under such control thus provides a controlled volume output of the shot.
[0038] If control valve 206 is opened without the pump 204 operating, a reduced flow through the brew tank still occurs. This state is useful at the beginning of a brew to pre-infuse dry coffee grounds with hot water before pumped flow begins. This state may also be useful at the end of the brew to avoid excessive “blonding” of the flow as the grounds are expended. The time between the stopping of the pump and final closing of the control valve establishes a low pressure finish. The value of the low pressure finish may be a percentage of the pumped flow volume to the total flow volume of the brew shot.
[0039] FIG. 3 illustrates an exploded diagram of a preferred embodiment of a group control head 300 assembly according to the present invention. The assembly is mounted to the espresso machine 100 via a base 302 . Base 302 may be generally cylindrically shaped with a center axis disposed in the vertical plane. Base 302 may optionally be part of brew tank 250 , and may include a shroud surrounding the lower vertical portion.
[0040] A top plate 324 is disposed on base 302 . Top plate 324 comprises a pivot pin 325 centered on the center axis. Pivot pin 325 is arranged to provide a rotational axis for an actuator 340 . In addition, a centering post 350 is disposed at a radial idle position on the top plate 324 , the post arranged orthogonally from the vertical center axis. Preferably, centering post 350 is disposed near an edge of top plate 324 . Centering post 350 is preferably constructed of a ferrous material that is magnetically attractive to a magnet.
[0041] Actuator 340 is disposed on top plate 325 at pivot pin 325 . Actuator 340 includes a mounting arm, at the end of which a magnet 342 is disposed. The arrangement of actuator 340 on top plate 325 is such that magnet 342 rests adjacent to but not touching center post 350 . Actuator 340 is also free to rotate about pivot pin 325 but is held in an idle position 400 , FIG. 4 , by the magnetic force between magnet and post. This biasing force opposes any rotational force which rotates the actuator 340 , and causes the actuator to return to the radial idle position when the rotational force is removed. This holding feature thus serves as an automatic centering feature.
[0042] Affixed to top plate 324 is at least one proximity sensor 375 which is operable to sense a position of the magnet 342 with respect to the sensor. Proximity sensor 375 is disposed at a fixed angle away from the radial idle position. When an actuating force rotates the actuator magnet 342 away from the idle position, magnet 342 is positioned near sensor 375 . An optional second proximity sensor 376 may be disposed at a second fixed angle from the radial idle position. The second fixed angle may be the opposite angle from the radial idle position. Similarly, when an actuating force rotates the actuator magnet 342 in the opposite direction away from the idle position, magnet 342 is positioned near and is detected by sensor 376 .
[0043] Proximity sensors 375 , 376 are preferably arranged on a proximity sensor board 374 which is held in fixed position above top plate 324 and actuator magnet 342 . Magnet 342 is thus free to rotate under the proximity sensor board. In addition, a preferred arrangement is of a single magnet 342 which serves as both an automatic centering magnet and a positioning source to be detected. The arrangement is simpler and requires fewer parts. Of course, the particular arrangement of magnet to sensor(s) may be modified within the scope of the invention.
[0044] A preferred type of proximity sensor 375 , 376 is a linear type Hall Effect sensor. Such a sensor is commonly understood to provide an analogue output which corresponds to the relative position of a magnet. One advantage of a Hall Effect sensor is that it is non-contact and so has no parts to wear out. The Hall Effect sensor requires minimal periodic adjustment or calibration, and optionally could be used with a comparator to provide a more precise positioning over a large number of cycles.
[0045] Importantly, the Hall Effect sensor provides an analogue output that contains more than a simple binary actuation signal or pattern of binary signals. The sensor can provide a signal input to a device controller which is representative of the magnitude of the magnet movement, the velocity of relative movement, and the duration of a held magnet rotation. Thus, the Hall Effect sensor provides the user with a more precise and useful control of the group head.
[0046] The user interface portion of the FIG. 3 group control head is a rotational handle 314 , which is fixed by screws or other means to actuator 340 . The handle 314 may comprise a protective shell which fits over the top plate 324 , actuator 340 and the arrangement of sensors 375 , 376 . A paddle 316 is preferably disposed on handle 314 extending away from the protective shell and in such a manner as to provide easy rotational actuation of the group control head.
[0047] In operation, the user experiences a resistive force not unlike a spring force when she rotates the paddle. When the paddle is released, the entire group head control assembly returns to the idle position due to the attraction of magnet and post.
[0048] FIGS. 4( a ), 4( b ) and 4( c ) illustrate the operation of the FIG. 3 group control head 300 , wherein magnet 342 may be positioned over an arc in proximity to, but not in contact with, at least one proximity sensor. At rest, the group control head is automatically centered and held in the idle position 400 as shown in FIG. 4( a ) . The magnetic attraction between magnet 342 and post 350 provides the holding force. The output of proximity sensor 375 and/or optional sensor 376 indicates that the magnet 342 is in the idle position 400 .
[0049] FIG. 4( b ) shows the group control head 300 in a brew position 410 . Here, the user has rotated paddle 316 in the clockwise, or left, direction such that proximity sensor 375 senses the proximity of magnet 342 . The user also experiences a counterclockwise resistive force not unlike a spring force when she rotates the paddle 316 , due to the ongoing attraction between displaced magnet 342 and post 350 . The attraction repositions the actuator 342 to the idle position 400 when the paddle 316 is released. The effect of the paddle rotation of FIG. 4( b ) is to send an input signal corresponding to the sensed magnet position to a controller. The controller in turn may begin a programmed sequence of outputs to the espresso machine to dispense a shot of coffee.
[0050] FIG. 4( c ) illustrates an optional control position 420 of the group control head 300 corresponding to a counterclockwise, or right, rotation of paddle 316 . Second proximity sensor 376 senses the proximity of magnet 342 . The user also experiences a clockwise counter-force not unlike a spring force when she rotates the paddle 316 , due to the ongoing attraction between displaced magnet 342 and post 350 . The attraction repositions the actuator 342 to the idle position 400 when the paddle 316 is released. The effect of the paddle rotation of FIG. 4( c ) is to send a second input signal corresponding to the sensed magnet position to a controller. The controller in turn may perform an auxiliary action, such as ending an ongoing shot.
[0051] The user of course experiences the above described group control head 300 as having one actuator which has a clockwise, or left, paddle position and a counter-clockwise, or right, paddle position. As will be further described, actuations of short duration and longer duration may provide different responses in the machine control. A short duration actuation may be referred to as a “bump”, while longer duration actuations may be referred to as a “hold” or a “long hold.” A bump may be, for example, a paddle rotation and release lasting less than 250 milliseconds. An example hold may be from greater than 250 milliseconds up to greater than about 2.5 seconds.
[0052] FIG. 5 illustrates a system block diagram of one embodiment of the electrical sensing and control circuit for an espresso machine electrical system 500 . The electrical system 500 can be arranged on a single central printed circuit board or may be distributed among several sub-units. For example, FIG. 5 shows one hardware controller 510 , but system 500 could equivalently include a separate controller 510 disposed on each group control head in the apparatus. Either the single visual display 520 as shown or a display 520 dedicated to each separate group control head may be used to convey status information. A power supply 540 provides electrical power to the system 500 .
[0053] The heart of system 500 is controller 510 , which can be any of a known CPU or other computer processing unit such as an application specific integrated circuit (ASIC), field programmable gate array (FPGA), or reduced instruction set computing (RISC) type. Controller 510 operates to control the espresso brewing process in response to various inputs. Controller 510 may also operate in accordance with a computer program stored in a computer memory 530 . Controller 510 and the computer program then provide a repeatable and coordinated sequence of outputs that generate a controlled dose of espresso. Controller 510 may also be arranged in a programming mode to accept programming instructions from external programming controller 190 and to store those instructions in memory 530 for later use. Similarly, controller 510 may provide a program control data set point or parameter from a user interface to memory 530 . Controller 510 may also provide output to a visual display 520 that is located near the respective group control head such that important operating status information can be seen at a glance.
[0054] Also shown in FIG. 5 is that memory 530 is preferably apportioned into several parts. A first part is the computer temporary brew memory 532 , which as will be described saves parameters related to the current brewing process. The temporary brew memory essentially contains a set of brewing parameters established at the last brew. For example, if the user shortens a pre-infusion period by actuating the group control head handle, that new pre-infusion duration is captured in the temporary brew memory. Each dosing unit has its own temporary brew memory.
[0055] Another part of memory 530 comprises a computer storage memory 534 for storing previously saved complete sets of brewing parameters. The portions may be arranged in pages, with a left portion and a right portion for each page. In one embodiment, each dosing unit is provided with from one to three pages. More preferably, computer storage memory 534 comprises at least two storage locations, without any paging arrangement. Shown in FIG. 5 is an exemplary embodiment of storage memory 534 having six storage locations 541 through 546 . Each portion or storage location is sized to contain one set of brewing parameters. Each dosing unit has its own computer storage memory 534 .
[0056] Outputs from each group head are provided as inputs to controller 510 . Examples of inputs are a group head water flow meter 502 and a brew tank temperature sensor 504 . Controller 510 may use these inputs to start or stop the brew program or to otherwise control various heating and pumping components. Controller 510 preferably operates under the further control of an internal clock or timer to shift between various phases of the brew process.
[0057] Controller 510 also accepts signal inputs from each respective group control head 300 via proximity sensor outputs 375 , 376 . The accepted signal inputs control the program sequence that provides the espresso dose. An example is a received input from non-contact proximity sensor 375 that corresponds to a single actuation of the group control head handle. Controller 510 then issues a coordinated program sequence of output instructions to provide the dose. The outputs can be one or more of a pump control output 522 , a control valve control output 524 , and a bypass valve output 526 .
[0058] A second input control example is a received signal input from the second non-contact proximity sensor 376 that corresponds to a different single actuation of the group control head handle. Controller 510 responsively issues an output to one or more of a pump control output 522 , a control valve control output 524 , and a bypass valve output 526 to, for example, immediately end the controlled dose.
[0059] FIG. 6( a ) and FIG. 6( b ) illustrate two embodiments of the information provided on the optional visual display 180 for the espresso machine of the present invention. The displayed information provides the user with the current status of the machine and group control head guidance instructions with simple indications.
[0060] FIG. 6( a ) shows an operational display 600 provided during normal operation or during a programmed brewing sequence. The most prominent feature of this display is a shot timer 602 . Shot timer 602 will typically display the total duration of the shot, e.g. 32 seconds, during idle times between brews. During the brew sequence, shot timer 602 preferably displays the elapsed time from the start of the shot, although similar indications of shot progression such as count-down time or time from the start of a particular sequence phase are included within the scope of this invention.
[0061] Mode icon 604 shows the espresso machine mode of operation, which may include a manual mode, a manual program or a volumetric program mode. Here shown on icon 604 is the volumetric program mode icon VP. An espresso machine operating in volumetric program mode is typically controlled on a flow basis as sensed by the flow meter. An espresso machine operating in manual program mode MP is typically controlled by the sequence timer with some control by the user. Manual mode M is typically a mode of operation under full control by the user.
[0062] Phase icon 606 indicates a relative duration of each phase of the brewing sequence. The phases will be described in more detail with reference to FIG. 7 . The embodiment shown uses simple bar graphs to display the relative length of each of three phases.
[0063] Memory storage location icon 608 shows the memory portion of computer storage memory 534 that is currently selected for use. Here, icon 608 is a dot which points to a first memory storage location. Additional storage location icons, if available, may be arrayed below icon 608 or along the right border of display 600 . If the storage memory location is ready to receive data, a save icon 610 is shown.
[0064] FIG. 6( b ) shows a save mode display 620 that is shown during the transfer of brew parameters between the temporary memory and/or storage memory locations. When in save mode, and when the storage memory location is ready to receive data, one display embodiment incorporates a save left icon 622 and a storage memory cycling icon 624 guides the user to save the current data via a left bump and to select the storage memory for saving by cycling through the locations with one or more right bumps of the group control head respectively. In this case, the “M” mode icon 604 indicates that the saving is being performed from a manual mode of operation.
[0065] FIG. 7 illustrates a brewing sequence 700 for the espresso machine. From an idle state, the sequence is started at start step 702 by the user operating the group control head paddle or by pushing a button. The controller 510 initiates the programmed sequence at step 716 using the currently-selected set of brew parameters and also begins to save brewing data into the temporary memory 532 .
[0066] The brewing phases then begin at a pre-infusion brew phase 717 . During this phase, controller 510 opens the dosing unit control valve 524 , 206 to pre-infuse the dry coffee grounds with unpressurized water from the brew tank 250 . This phase typically begins in response to the same first input signal received from the user at the start step 702 .
[0067] At the end of the pre-infusion phase, an optional pressure ramp up phase 720 begins. The transition from pre-infusion to pressure ramp up may be in response to a programmed sequence time or to a user input from the group control head paddle. Pressure ramp up phase 720 starts the pump 204 and optionally opens the bypass control valve 208 to gradually pressurize the brew tank 250 to drive water through the grounds.
[0068] In response to a programmed sequence time or to a user input from the group control head paddle, a full pressure brew phase 720 begins. During this phase, the bypass control valve is closed and the pump is running to provide maximum shot flow through the grounds.
[0069] Depending on the particular grounds in use, an undesirable “blonding” of the flow may occur as the grounds are used up during the full pressure brew phase 720 . To avoid the effects of blonding, the sequence may then transition to an optional pressure ramp down phase 724 . Like ramp up phase 720 , the pump is running and the bypass control valve is opened to gradually reduce pressure on the grounds. The beginning of this phase may occur in response to a programmed sequence time or to a user input from the group control head paddle.
[0070] A stop shot phase 726 ends the brewing sequence. This phase typically functions to ensure that the precise shot volume is dispensed. Here, the pump is not running but the control valve is still open. The transition into the stop shot phase 726 may be in response to a programmed sequence time or to a user input from the group control head paddle. Similarly, the stop shot phase is ended by closing control valve 524 , 206 when the full dose has been dispensed as sensed by elapsed time, flow meter volume, or by user input. The machine then re-enters an idle mode at end step 727 .
[0071] Shown next to each phase of the sequence is an exemplary operational display 600 on visual display 180 . Shown is the total time of the sequence at the beginning and end as well as the elapsed time during the sequence. Also shown is the Manual Programming MP operating mode and the stored parameter set that is in use. Optionally, display 180 may show a volume dispensed instead of an elapsed time during the brewing phases.
[0072] The above described sequence is driven by a set of parameters or settings which control each phase. For example, the set of parameters may include a pre-infusion time, a low pressure ramp up time, a full pump dispense time, a ramp down time, and a total dose water volume dispensed. Generally, a set can be defined with four parameters. End step 726 , for example, can be defined with the low pressure finish percent, which may be a percent of overall shot time or overall shot volume.
[0073] Method and Apparatus for Optimizing a Set of Brew Parameters
[0074] FIG. 8 illustrates a flow chart for an inventive method of operating the espresso machine of the present invention, and in particular a method 800 for optimizing and storing the conditions for a controlled dose of hot water dispensed from the machine. The method then saves the optimized set of brew parameters for a subsequent use of the espresso machine. Method 800 begins at start step 802 . The method then proceeds to a step 804 of providing the espresso machine apparatus as previously described, including the dosing unit, the group control head 110 , 300 , the pump 204 , the temporary brew memory, and the controller. Providing step 804 may also include the steps of activating the apparatus, initiating the program stored in memory, preheating and pre-pressurizing the system, and/or preparing and installing the grounds filter. After completion of providing step 804 , the espresso machine is ready to dispense espresso, and begins to monitor at the group control head proximity sensor 375 , 376 inputs.
[0075] Step 806 is for monitoring and sensing a momentary actuation or bump of the group control head handle to a particular angular brew position. Step 806 pauses at monitoring sub-step 807 until controller 510 senses an actuation. When an actuation is sensed, another sub-step, mode decision step 808 determines the type of actuation and continues the method accordingly. For example, a sensed bump actuation may send the method into the brew mode 812 , and a long duration actuation may send the method into a programming or saving mode of operation 912 . The saving mode of operation, and its return to the monitoring step 806 will be described in more detail.
[0076] An actuation direction decision step 810 immediately follows step 808 . The direction of actuation, clockwise/left (CW) or counter-clockwise/right (CCW), may cause the method 800 to respond differently depending on whether a shot is brewing at the time of actuation or not, i.e. in an idle state. If no shot is brewing at actuation, as sensed by the controller at shot brewing decision steps 814 and 820 , the direction may determine which of two sets of parameters is used for the subsequent shot, i.e. the set stored in the current computer temporary brew memory or a different set stored in the computer storage memory respective to the CW left or CCW right bump. In a preferred embodiment, a sensed CCW right bump with no shot brewing causes the controller to retrieve the set of brew parameters stored at the next sequential memory storage location 541 - 546 for that group head at cycling step 821 . That set is placed into the temporary brew memory at step 824 . If the CCW right bump is repeated, the brew parameters at the next sequential memory storage location 541 - 546 is retrieved into temporary memory at 821 , and so on. Thus, the operator experiences a cycling of stored recipes on that group head.
[0077] If a CW left bump is sensed while in the idle state, method 800 proceeds to begin the programmed sequence at step 816 according to the selected set of parameters stored from step 824 in the temporary computer brew memory. The programmed brew sequence then begins as described in FIG. 7 with the pre-infusion step 717 of opening the control valve to begin the controlled dose of hot water. Step 816 also initiates a saving into the computer temporary memory of subsequent actuation steps. Then the method 800 returns to the sensing/monitoring step 806 to await the next sensed actuation of the group control head paddle.
[0078] If no further actuations occur, the programmed sequence of FIG. 7 automatically completes itself and delivers a controlled dose in accordance with the selected set of parameters. The set of parameters saved to the temporary brew memory would in this case be identical to the selected set.
[0079] If the selected set of parameters is set to a null manual MAN setting or the mode of operation is in the Manual mode, the method 800 may continue in a completely manual sequence. The sequence still follows the FIG. 7 sequence, but the transition between each phase occurs at an actuation sensing and never at an elapsed time. In an example manual mode operation, the first momentary action of the group control head handle begins the pre-infusion step whereby the control valve is opened and the parameter saving is initiated. The controller would respond to subsequent CW momentary actuations of the handle by repeatedly proceeding along the cycle of step 808 , step 810 , step 814 , a proceed to next shot phase 818 , and a return to step 806 . Thus, the full pressure phase, and/or the optional pressure ramp up or ramp down phase is controlled by the repeated sensed CW actuations at next shot phase 818 . These phases involve starting and running the pump to provide the controlled dose of hot water through the dosing unit. At each phase transition, a parameter related to the duration of each phase is saved into the computer temporary memory at saving step 824 .
[0080] In one embodiment of the completely manual mode, the third actuation of the proceed to next shot phase 818 stops the pump to end the controlled dose of hot water. Optionally, a fourth actuation of the next shot phase 818 closes the control valve at the proper shot dose volume corresponding to end sequence step 726 . The duration of each of these phases is saved into the temporary memory at saving step 824 . The overall saving of these steps thus creates a complete set of brew parameters in memory. The saved set of brew parameters may be used in subsequent programmed brew sequences.
[0081] As can be seen in FIG. 8 , a CCW bump of the group control head handle sensed at step 810 while the shot is brewing as sensed at step 820 always causes the method to immediately proceed to stop shot step 822 . This step 822 stops the pump and closes the control valve to end any further flow through the dosing unit. A user may also perform this actuation if, for example, when the desired brew volume has already been reached but the flow is continuing under the ongoing programmed sequence.
[0082] FIG. 8 also illustrates how the method 800 may be used to dynamically adjust, while operating in the automatic programmed brew sequence mode, a set of parameters that have already been saved in memory. In this situation, the espresso machine is prepared to dispense the next dose using a previously saved set of parameters. When the momentary actuation is repeated and sensed at step 806 , the control valve is re-opened and the controller newly initiates the saving of parameters into the temporary memory. The new programmed brew sequence begins again. If no further actuations are sensed during the brew, then the programmed brew sequence automatically controls the control valve and pump to replicate the previous controlled dose of hot water.
[0083] But if the user desires to adjust, i.e. shorten, one or more of the sequence phases, then she merely again bumps the paddle CW to truncate that phase and immediately start the next phase at step 818 . This action may, for example be a repeat of the third momentary actuation step, which stops the pump and therefore stops the replication. The phase duration as defined by the actuation is saved into the temporary memory as part of a new, i.e. second, set of brew parameters. In one embodiment the saving at step 824 further comprises the step of overwriting the previous set of brew parameters with the second set of parameters in the temporary memory. This second set can then be used for subsequent brews. In a preferred embodiment, adjustment of every brew phase is enabled for Manual mode of operation, and a limited adjustment of only the low pressure finish phase, step 724 of FIG. 7 , is enabled during Manual Program mode of operation.
[0084] A summary of the FIG. 8 operation is illustrated in state table 801 . There shown is the response in the espresso machine corresponding to each particular operation of the group head control handle during the normal, or brew mode of operation.
[0085] The espresso machine apparatus that is previously described may be modified to use the method 800 for storing and adjusting the dosing conditions. In addition, the machine may optionally comprise visual display 180 , which displays the phase of the sequence as the sequence proceeds. After the sequence is complete, the visual display 180 may display an indication that the phases have been saved as a new set of parameters.
Example
[0086] The barista prepares the espresso dosing unit and refreshes the grounds in the filter. She decides to manually brew a shot. The barista bumps the group control head paddle to the left to begin pre-infusion and watches for the first drips to pass the filter basket. Once the basket is saturated, she bumps the paddle left again to add pump pressure. The shot speed begins to increase and the color of the flow begins to lighten toward the end of the shot. She bumps the paddle left again to return to line pressure, then bumps it right to end the shot.
[0087] Example parameters saved into temporary memory for this manual shot are 6.2 seconds pre-infusion and 60 milliliters water volume with a 97% low pressure finish. This set of parameters is now available to save for future replication.
[0088] Of course, if the sequence is not progressing satisfactorily, a bump of the paddle to the right while the shot is in progress immediately ends the shot.
[0089] Method and Apparatus for Saving an Optimized Set of Brew Parameters
[0090] FIG. 9 continues the FIG. 8 method flow, further describing a method 900 for storing brewing parameters in an espresso machine. The method starts when the first sensed actuation of the group control head handle at step 806 enters the machine into a program and save mode of operation 912 . This path is shown by the indicator AP. An example first actuation is a long hold, e.g. greater than 250 milliseconds, to enter this mode.
[0091] Responsive to entering the program and save mode of operation 912 , the current set of brew or shot parameters is obtained from the computer temporary brew memory at step 902 . The visual display 180 corresponding to the dosing unit may begin to flash the save icon 610 at this time to indicate the saving/programming mode of operation. One object of this invention is that this current set of shot parameters can then be assigned to as many computer storage memory locations on as many different group control heads in the system as desired. In addition, the visual display 180 may also begin to indicate the current set of brew parameters. Of course, if the operator desires to store a set of brew parameters that is not currently in the computer temporary brew memory, she may transfer the desired set of parameters from a computer storage location to the temporary brew memory prior to the obtaining step above. Preferably, this is done by selecting the computer storage location with the desired parameters with one or more right bumps from idle, step 821 , and then running that shot with a left bump, step 816 shown in FIG. 8 .
[0092] Also responsive to entering the program and save mode of operation 912 at the first sensed actuation, the controller selects a default or initial computer storage memory location at initial storage memory step 903 . This default computer storage location may be pre-selected to appear each time the save mode is entered, or may simply be the last storage memory location used. If the espresso machine has multiple dosing units, the controller may select a default memory location at each group control head. Preferably, the visual di splay(s) 180 displays the active computer storage memory location at this step. The group control head of the first sensed actuation may optionally display brew parameters from the set in the temporary brew memory or the computer storage memory at the obtaining step.
[0093] Method for Storing Brewing Parameters, Single Dosing Unit
[0094] After entering the save mode of operation 912 , the method proceeds to the step of saving the set of parameters from the last shot brewed, i.e. the parameters in the computer temporary brew memory, into a computer storage memory location. In one simple embodiment, the operator merely bumps the group control head handle to the left, sensed as a second actuation by the controller. The method flow shows the bump sensed as a left actuation at direction step 906 and as a bump at duration step 910 . The left bump causes the controller to save the set of brew parameters into the default or initial storage memory from step 903 .
[0095] The operator may wish to save the set of brew parameters into a different computer storage memory location than the default location. The operator selects a different location by scrolling through the available locations with one or more right bumps of the group control head handle. The controller senses the input at direction step 906 and duration step 911 to scroll to the next available storage memory at step 914 . Step 914 preferably includes the display of the computer storage memory location on visual display 180 , as exemplified in FIG. 6( b ) . A subsequent left bump, steps 906 , 910 saves the set of parameters to the selected location at step 908 . It is preferable that the bumps for scrolling and saving are in opposite directions of the handle, but the particular directions described above may be swapped within the scope of the invention.
[0096] The operator exits the save mode of operation at step 940 and returns to the brew mode of operation. The controller may exit the save mode in several ways, e.g. by a time-out or immediately upon the saving step. Preferably, an affirmative actuation triggers the exit, such as a group head control handle “right hold” actuation, as shown by the path of direction step 906 and as a hold at duration step 911 .
[0097] An additional function may be provided while in the save mode of operation. The controller may cycle to another of a group mode at cycle mode step 909 , e.g. Manual Mode or Manual Program Mode or Volumetric Program Mode, responsive to a sensed left hold from the group control head handle via direction step 906 and duration step 910 . When a set of parameters is subsequently saved, the set will correspond to that particular group mode.
[0098] A summary of the FIG. 9 operation is illustrated in state table 901 . There shown is the response in the espresso machine corresponding to each particular operation of the group head control handle during the program and save mode of operation.
[0099] Transferring a Set of Brew Parameters Between Espresso Dosing Units
[0100] If the espresso machine is a multi-head device having a plurality of previously described espresso dosing units, the machine may be arranged to transfer a desired set of brewing parameters from one of the dosing units to another. In this embodiment, a controller 510 is in communication with all of the group control heads, temporary memories, and storage memories. A visual display is optionally associated with each dosing unit.
[0101] The system is arranged such that when a program and save mode of operation is entered at any of the dosing units, for example by the method flow chart of FIG. 9 , controller 510 activates all of the dosing units for saving.
[0102] FIG. 12 illustrates one embodiment of the group display 1200 . After entering the save mode 900 and obtaining the desired set of brew parameters with one of the group control heads, all of the visual displays 180 , 180 ′, 180 ″ will display a save screen 620 , 620 ′, 620 ″ and a flashing save icon 610 . Any of the other group control heads can be scrolled as described above to select that dosing unit's desired storage location for saving. Then each group control head can separately save the desired set of brew parameters to the selected memory and exit the save mode as described above. Exiting from the save mode alternatively may be accomplished all at once by exiting the save mode, step 940 , at the source group control head.
[0103] After either of the above described transferring steps, a programmed brew sequence may be initiated at any of the dosing units according to the transferred set of brew parameters. When a subsequent group control handle bump for another of the dosing units is sensed at its step 806 , then a new programmed brew sequence is initiated according to the transferred set of parameters. The espresso machine then automatically conducts the programmed sequence at step 812 to dispense the new dose of espresso. Thus the conditions for the desired dose are replicated across the dosing units.
[0104] FIG. 10 illustrates example visual display graphics and state machine diagram 1000 that accompany the program and save mode of operation. Prior to entering the save mode, the espresso machine is in the brew mode of operation 1001 , and typically runs a shot to automatically save the last shot into the computer temporary brew memory at step 1002 . The operator then performs a right hold, e.g. for 2.5 seconds, at enter save mode step 1004 , whereupon the visual display 180 begins to flash the save icon. The operator then optionally bumps right one or more times at step 1006 to change the desired computer storage memory location for saving. When the desired location is selected, the operator bumps left at save step 1008 to save the shot parameters to the location. The operator then exits the save mode at step 1010 with a right hold, e.g. for 2.5 seconds.
[0105] After the save mode of operation ends at exit step 940 , the espresso machine is then ready to enter the brew mode again with the newly saved and selected set of brew parameters. If a different set of brew parameters is desired, the operator simply bumps right one or more times to cycle through the recipes, and stops when the desired recipe is reached. When a subsequent group control handle bump is sensed at step 806 , then the new programmed brew sequence is initiated according to this new second set of parameters. The espresso machine then automatically conducts the programmed sequence at step 812 to dispense the new dose of espresso.
[0106] FIGS. 11( a ) through 11( d ) illustrate an additional series of state machine diagrams for the operation of the espresso machine. FIG. 11( a ) illustrates program mode adjustment state machine 1102 . When the controller senses a left hold, e.g. 2.5 seconds, on a group control head handle, the controller enters the cycle program mode. Subsequent left holds cause the controller to cycle its program mode through the available programs, here shown the modes Manual 1104 , Manual Program 1106 , Volumetric Program 1108 , and cycle back to Manual 1110 . Further detail about operating in these modes is shown in FIG. 11( b )-( d ) .
[0107] FIG. 11( b ) illustrates one exemplary operation of the Manual Mode 1120 , a mode that allows the operator complete control of the shot parameters. Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1122 . The controller begins the pre-infusion operation, and awaits subsequent bumps left before advancing the shot to the next phases of pressure ramp-up step 1124 , full pressure brew step 1126 , and pressure ramp-down step 1128 respectively. The shot is stopped at step 1129 at a sensed bump right. The brew parameters are retained within the computer temporary brew memory. Visual display 180 may display the current phase and parameters during the shot.
[0108] FIG. 11( c ) illustrates one exemplary operation of the Manual Program Mode 1130 , a mode that allows the operator limited control of the shot parameters. Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1132 . The controller automatically advances the shot to the next phases of pressure ramp-up step 1134 , full pressure brew step 1136 , and pressure ramp-down step 1138 . The shot is stopped at step 1139 at a sensed bump right. The operator may adjust the “blonding” of the shot at step 1136 with a left bump to truncate the shot pressure, and then may end the shot at the desired volume (if necessary) with a right bump at stop step 1139 . Visual display 180 may display the current phase and parameters during the shot.
[0109] FIG. 11( d ) illustrates one exemplary operation of the Volumetric Program Mode 1140 , a mode that allows the operator control of the start of the shot only. Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1142 . The controller then automatically advances the shot to each next phase at pressure ramp-up step 1144 , full pressure brew step 1146 , and pressure ramp-down step 1148 according to the program brew parameters in use. The shot is automatically stopped at step 1149 upon reaching the pre-programmed volume as sensed by the flowmeter. In this program mode, the operator may truncate the shot at any time with a bump right. The visual display 180 may display the current phase and parameters during the shot.
[0110] The functionality of the various program modes corresponds to the method flow steps as shown in FIG. 8 . For example, a sensed CCW actuation at step 810 with a shot brewing at step 820 which immediately ends the shot at step 822 . This corresponds to the right bumps at FIG. 11 steps 1129 and 1139 .
[0111] When the paddle is released, the save mode of operation then exits at exit step 940 . The espresso machine is then ready to enter the brew mode again with the newly saved and selected set of brew parameters. When a subsequent group control handle bump is sensed at step 806 , then a new programmed brew sequence is initiated according to this new second set of parameters. The espresso machine then automatically conducts the programmed sequence starting at step 812 to dispense the new dose of espresso.
[0112] Retrieving a Stored Set of Parameters for Use
[0113] FIG. 8 at state machine table 801 also illustrates a method for obtaining from storage memory a set of parameters for use, where the set of parameters has been previously stored in one of the page portions instead of the temporary brew memory. This functionality is enabled simply by cycling through the memory storage locations by means of scrolling with the group control head handle. In the FIG. 9 embodiment, the group control head handle is bumped right one or more times to cycle through the storage locations, up to six. When cycled, visual display 180 preferably highlights the particular location. A subsequent bump to the opposite left side then starts the shot using that selected recipe. The shot parameters are also transferred to the temporary brew memory during the shot, for subsequent saving and use.
Example
[0114] Some example settings for a page in computer storage memory appear in Table 1 below:
[0000]
Brew Group 2 (Volumetric Mode)
Program 1
Pre-infuse
4.0
Ramp Up
1.8
% of Shot Brewed
91%
Total Water Volume
350
[0115] A note from the morning barista says that they made a great shot earlier in the day and saved it in Brew Group 2 Program 1. We are currently using Program 2 on the second group, so the first step is to cycle to the Program 1 by bumping the group head control handle five times until Program 1 is highlighted on visual display 180 ′. Then we prepare a filter puck and bump left. The programmed sequence will run through 4 seconds of pre-infusion, ramp up for 1.8 seconds, and then run the pump until 91% of the total flow meter count of 350, corresponding to about 60 ml of water, has been dispensed. The pump will then shut off and the shot will finish at line pressure.
[0116] An espresso machine apparatus as described in FIGS. 1 through 6 comprises each of the elements that are necessary to perform the methods described above. An optional external programming controller 190 , described in FIG. 13 may be used in concert with the group control heads, controller, memories, and programmed sequences for additional flexibility in programming.
[0117] FIG. 13 shows an embodiment of the optional external programming controller 190 that may be used with the inventive espresso machine. Controller 190 is preferably handheld and communicatively connected to the controller 510 by wired or wireless means. Controller 190 includes three main features. Programmer display 192 displays information related to the stored programs. Programmer selection buttons 194 are arranged next to the display to enable the user to select particular items in display 192 . Programmer scrolling arrows 196 enable the user to adjust values of the displayed items.
[0118] If no useful set of brewing parameters yet exists in computer storage memory, or if it is desired to enter the values without brewing, one or more of the parameter set values may be more easily entered via the controller 190 . For example, the user wishes to adjust the volume of the shot on number 2 brew group, i.e. dosing unit. She scrolls with the scrolling arrows 196 until Brew Group 2 is displayed. The desired set of brew parameters resides in the memory storage location 1, so she presses the button 194 that is adjacent that label. Then she presses the scrolling arrows to adjust the volume to the desired amount. Another press of the button 194 deselects the line and updates the set of brew parameters at that memory location. As previously described, this new set of brew parameters can be saved to any of the other memory locations in any of the other brew groups, and can be used with the group control head controls during the next brew. The entry of data using programmer 190 may also be conducted in concert with selection and saving of that data via the group control head operations as described above.
[0119] Modifications to the device, method, and displays as described above are encompassed within the scope of the invention. For example, various configurations of the plumbing and electrical systems which fulfill the objectives of the described invention fall within the scope of the claims. Also, the particular appearance and arrangement of the apparatus may differ.
[0000]
Table of Elements
Number
Name
100
Espresso machine
102
Espresso dosing unit
110
Group control head
110′
Second group control head
110″
Third group control head
150
Brew tank
160
Filter
170
Outlet spout
180
Visual display
180′
Second visual display
180″
Third visual display
190
External programming controller
192
Programmer display
194
Programmer selection buttons
196
Programmer scrolling arrows
200
Espresso machine
202
Steam tank
204
Pump
206
Control valve
208
Bypass control valve
210
Water source
250
Brew tank
250′
Second brew tank
250″
Third brew tank
260
Filter
300
Group control head
302
Base
314
Handle
316
paddle
324
Top plate
325
Pivot pin
340
Actuator
342
Magnet
350
Centering post
374
Proximity sensor board
375
First proximity sensor
376
Second proximity sensor
400
Idle position
410
Brew position
420
Control position
500
Espresso machine electrical system
502
Group head flow meter
504
Brew tank temperature sensor
510
Controller
520
Visual display
522
Pump control output
524
Control valve control output
526
Bypass valve output
530
Computer memory
532
Computer temporary brew memory
534
Computer storage memory
Computer storage memory page
Page left portion
Page right portion
540
Power supply
541-546
Computer storage memory storage locations
600
Operational display of programmed sequence
602
Shot timer display
604
Mode icon
606
Brew sequence phase display
608
Memory storage location icon
610
Save icon
620
Save mode display of brew parameter set transfer
620′
Second save mode display (not used)
620″
Third save mode display (not used)
622
Save left icon
624
Storage memory cycling icon
700
Espresso machine brewing sequence
702
Brewing start step
716
Brewing initiation step
717
Pre-infusion brew phase
720
Pressure ramp up phase
722
Full pressure brew phase
724
Pressure ramp down phase
726
Stop shot phase
727
End step
800
Method for providing hot water dose
802
Method start step
804
Providing an espresso machine step
806
sensing step
807
Monitoring step
808
mode decision step
810
actuation direction decision step
812
brew mode
814
shot brewing decision step
816
begin programmed sequence step
818
Proceed to next phase in sequence step
820
shot brewing decision step
821
Cycle recipe step
822
stop shot step
824
save into temporary memory step
900
Method for storing brewing parameters in an espresso machine
901
Saving method state table
902
Obtain brew parameters step
903
initial computer storage memory location step
906
Sense actuator direction step
908
Save to selected storage memory step
909
Group mode cycling step
910
Duration step
911
Duration step
912
Enter program and save mode of operation
914
scroll to the next available storage memory at step
940
Exit from program and save mode of operation
1000
Visual display state machine diagram, save mode
1001
Initial brew mode of operation
1002
Save last shot into computer temporary brew memory step
1004
enter save mode step
1006
change computer storage memory location step
1008
save to active computer storage memory step
1010
Exit save mode step
1102
Program mode adjustment state machine
1104
Manual mode
1106
Manual program mode
1108
Volumetric program mode
1110
Manual mode cycle
1120
Manual (M) mode of operation
1122
M start and pre-infusion step
1124
M pressure ramp-up step
1126
M full pressure brew step
1128
M pressure ramp-down step
1129
M stop step
1130
Manual Program (MP) mode of operation
1132
MP start and pre-infusion step
1134
MP pressure ramp-up step
1136
MP full pressure brew step
1138
MP pressure ramp-down step
1139
MP stop step
1140
Volumetric Program (VP) mode of operation
1142
VP start and pre-infusion step
1144
VP pressure ramp-up step
1146
VP full pressure brew step
1148
VP pressure ramp-down step
1149
VP stop step
1200
Groups display | An espresso machine that includes a group control head for controlling the brewing and dispensing of espresso drinks. In particular, the group control head includes a novel arrangement of proximity switches, magnets, and centering post that allows for a more efficient workflow in the controlling, automating, and duplicating the brewing of multiple doses of espresso. An associated method for using the group control head is also described. | Provide a concise summary of the essential information conveyed in the given context. | [
"[0001] The invention pertains to machines for brewing and dispensing espresso drinks.",
"In particular, the invention is an apparatus and associated method for controlling, automating, and duplicating the brewing conditions for multiple doses of espresso.",
"[0002] Machines for preparing espresso drinks in a commercial retail environment are well known.",
"In general, these espresso machines include a heating source for generating steam and hot water in a reservoir, a basket for holding ground espresso, and a dispensing spout.",
"There are several increasingly sophisticated means of controlling the flow of the hot water through the espresso, out the spout, and into the cup.",
"Perhaps the simplest means is a manually-controlled valve which is opened to permit a pressurized flow of hot water through the grounds and out the spout into a cup below.",
"More modern machines, such as the Hydra™ espresso machine manufactured by Synesso Incorporated of Seattle Wash.",
", incorporate computer control of the valve.",
"The operator of such machines either presses a button or operates a toggle switch, sensed by the computer to control the valve.",
"Some espresso machines fully automate the brewing sequence, such that a single operation of the button provides a precise dose of water through the grounds, with attendant precise control of the water temperature and driving pressure.",
"Commercial machines may include several dispensing heads.",
"[0003] A commercial establishment for preparing and selling espresso drinks faces several inter-related problems, each of which is influenced by the particular espresso machine that the establishment has chosen to adopt.",
"The first problem is one of reliability and robustness of the espresso machine.",
"Because it is often a primary source of business revenue, the espresso machine must enjoy high operational uptime, despite a large number of operations involving high temperature water, pressure, and steam.",
"Electro-mechanical parts, such as switches, potentiometers, and rheostats, are particularly susceptible to failure simply because the user is operating them constantly.",
"[0004] The second problem is serviceability of the espresso machine.",
"Because existing machines have become relatively complex, the electromechanical parts such as those described above are difficult to service.",
"Such operating parts must be protected from physical and environmental damage.",
"Thus, the parts are usually sealed within the machine and are difficult to access.",
"[0005] In addition, electromechanical parts used in existing machines, such as roller switches, reed switches, etc.",
"involve springs and other parts which degrade or change characteristics over time.",
"Such parts, even if they don't fail, often require physical calibration for the machine to operate properly.",
"One such prior art part is a roller or reed switch connected to a user handle, or wand, for initiating an espresso “shot.”",
"After a large number of operations, the roller or reed switch can unexpectedly break or otherwise lose its spring action and become inoperable.",
"Such a breakdown is intolerable in a busy commercial environment, and so the switch must be routinely inspected, serviced, and calibrated.",
"Another problem pertaining to reed switches in espresso machines is the difficulty of ensuring accuracy and consistency of operation across each of the manufactured machines.",
"Most existing reed switches require calibration at the factory prior to shipping due to the variation in the reed switch manufacturing tolerances.",
"Calibration of reed switches is especially critical for machines which use systems of reed switches that operate together to perform certain linear or proportional functions.",
"[0006] Another problem with existing espresso machines is that the operating mechanism that is available to the user is largely limited to an on/off switch or button.",
"The competing problem to simplifying the operation for employees also serves to limit the ability of them to vary the espresso making process to account for changes in the coffee.",
"The taste of the final espresso product can vary significantly with the type of coffee, the grind, and the age of the coffee, for example.",
"Current machines have very limited capability for the experienced user to adjust the brew on the fly to account for these changes.",
"[0007] The inventors have recognized these problems in the prior art, and have arrived at a novel and ingenious solution.",
"An improved manually operated control mechanism for an espresso machine is described here which incorporates a non-contact sensor for detecting the operating input from the user.",
"This control mechanism is referred to as a group control head because in general the mechanism will be co-located with its respective espresso dispensing head.",
"The sensor also has a capability for analog sensing of the input, so that an experienced user can vary the brewing process on the fly, and without the need for time-consuming programming or process set-up.",
"The inventive group head control mechanism requires no calibration, is more reliable, and requires less servicing than prior art mechanisms.",
"Thus, the invention simultaneously provides for a better coffee brew and increased product throughput.",
"[0008] In accordance with the principles of the present invention, an improved espresso brewing apparatus is described which incorporates a non-contact operating mechanism within its user control interface.",
"The apparatus includes a novel and inventive group control head.",
"The group head has a control handle or paddle which is connected to a magnet.",
"When the control handle and magnet is rotated to a first position, a non-contact sensor such as a linear/proportional Hall Effect sensor senses the rotation.",
"The sensor then provides a corresponding control input to the espresso machine dosing mechanism which may include a controller.",
"A centering post in the mechanism provides an opposing biasing force on the magnet that returns the control handle to an idle position when the handle is released.",
"[0009] Also in accordance with the principles of the present invention, a group control head for dispensing a controlled dose of espresso from an espresso machine is described which comprises a base having a center axis, a top plate rigidly fixed to the base, the top plate comprising a pivot pin disposed on the center axis.",
"The group head also includes a centering post disposed at a radial idle position offset orthogonally from the center axis, and at least one proximity sensor, such as a linear/proportional Hall Effect sensor disposed at a fixed angle from the radial idle position.",
"An actuator is rotationally disposed on the pivot pin, the actuator including a magnet which is disposed near the radial idle position and adjacent to the centering post.",
"A handle is affixed to the actuator.",
"The handle is disposed to manually rotate the actuator away from the radial idle position in which the magnet is adjacent to the centering, wherein the centering post and magnet provide a biasing force that biases the actuator position to automatically return the actuator to the radial idle position.",
"A second proximity sensor at a second fixed angle can be included to provide further operative utility.",
"[0010] Also in accordance with the principles of the present invention, an espresso machine which incorporates the above described group control head is described.",
"The espresso machine also comprises an espresso dosing unit which includes a pressurized hot water brew tank, a filter for holding coffee grounds, a control valve disposed between the brew tank and the filter, and an outlet spout.",
"A pump is disposed at an inlet of the brew tank.",
"The machine also includes a controller that is in electrical communication with an input signal from the group control head and in controlling communication with the control valve and the pump.",
"An actuation of the group control head handle actuates at least one of the controller, the pump and the control valve to provide a controlled dose of hot water from the source to the spout.",
"Also in accordance with the principles of the present invention, a method is described for using the espresso machine as previously described.",
"The method includes the steps of momentarily actuating the group head handle to an angular brew position and automatically controlling both of the pump and the valve to provide a controlled dose of hot water through the machine.",
"A second actuation can control or stop the ongoing programmed sequence.",
"[0011] As used herein for purposes of the present disclosure, the term “processor”",
"or “controller”",
"is used generally to describe various apparatus relating to the operation of the inventive apparatus, system, or method.",
"A processor can be implemented in numerous ways (e.g. such as with dedicated hardware) to perform various functions discussed herein.",
"A processor is also one example of a controller which employs one or more microprocessors that may be programmed using software (e.g. microcode) to perform various functions discussed herein.",
"A controller may be implemented with or without employing a processor, and may also be implemented as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions.",
"Examples of controller components that may be employed in various embodiments of the present disclosure include, but are not limited to, conventional microprocessors, application specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).",
"[0012] It is understood that the term “memory”",
"refers to computer storage memory of types generally known in the art.",
"Memory may be volatile or non-volatile computer memory such as RAM, PROM, EPROM, and EEPROM, floppy disks, compact disks, optical disks, magnetic tape, etc.",
"In some implementations the computer memory media may be encoded with one or more programs that, when executed on the one or more processors and controllers, perform at least some of the functions discussed herein.",
"Various storage media may be fixed within a processor or controller or may be transportable, such that the one or more programs stored thereon can be loaded into a processor or controller so as to implement various aspects of the present invention.",
"The terms “program”",
"or “computer program”",
"are used herein in a generic sense to refer to any type of computer code (e.g. software or microcode) that can be employed to program one or more processors or controllers.",
"[0013] In various implementations, there terms “outputs”, “inputs”, “signals”, and the like may be understood to be electrical or optical energy impulses which represent a particular detection or processing result.",
"IN THE DRAWINGS [0014] FIG. 1 illustrates an embodiment of an espresso machine according to the present invention.",
"[0015] FIG. 2 illustrates the plumbing system of the FIG. 1 espresso machine.",
"[0016] FIG. 3 illustrates an exploded diagram of one embodiment of the inventive group control head.",
"[0017] FIGS. 4( a ), 4( b ) and 4( c ) illustrate the operation of the FIG. 3 group control head.",
"[0018] FIG. 5 is a system block diagram of one embodiment of the electrical sensing and control circuit.",
"[0019] FIG. 6( a ) and FIG. 6( b ) illustrate two embodiments of a visual display for the espresso machine of the present invention.",
"[0020] FIG. 7 illustrates a brewing sequence for the espresso machine.",
"[0021] FIG. 8 illustrates an embodiment of an inventive method for operating the espresso machine of the present invention.",
"[0022] FIG. 9 illustrates a flow chart method for saving and retrieving a set of brew parameters in the espresso machine.",
"[0023] FIG. 10 is a state machine diagram for a simplified method of saving a set of brew parameters to the espresso machine.",
"[0024] FIGS. 11( a ), 11( b ), 11( c ), and 11( d ) illustrate a set of state machine diagrams for a various operating modes of the espresso machine.",
"[0025] FIG. 12 illustrates a visual display for saving a set of brew parameters from one dosing unit to other dosing units in the espresso machine.",
"[0026] FIG. 13 illustrates a more detailed view of an external programming controller for the espresso machine.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Espresso Machine Including Improved Non-contact Group Control Head [0027] Now turning to the illustrations, FIG. 1 shows an espresso machine of the present invention.",
"Espresso machine 100 includes an espresso dosing unit 102 having at least one group control head 110 which controls the operation of the machine to provide an espresso dose.",
"Espresso machine 100 includes an internal source of water and steam pressure.",
"Each dose of espresso is dispensed from a brew tank 150 at the outlet of the water source.",
"Brew tank 150 is sized to contain hot water under pressure with enough volume, for example about 1.9 liters, for one or more doses of espresso.",
"Typically, brew tank 150 includes a heating element to maintain the water temperature at an optimal temperature for brewing.",
"[0028] At the outlet of brew tank 150 is a filter 160 for holding ground coffee.",
"Filter 160 is sized to hold enough tamped-in grounds for one dose of espresso.",
"Filter 160 is of course removable so that coffee grounds can be replaced after each use.",
"At the outlet of filter 160 is an outlet spout 170 for guiding the dispensed dose of espresso into a cup, not shown, held or placed below the spout.",
"For the purposes of this description, an espresso dosing unit 102 is generally understood to include at minimum the brew tank 150 , filter 160 and outlet spout 170 .",
"[0029] Many commercial espresso machines include a visual display 180 disposed on the group control head 110 , or on the machine 100 adjacent the dosing unit or group control head.",
"Visual display 180 can display basic shot parameters such as time to completion, dose size, and the like.",
"Because of the need for quick and efficient dosing of espresso shots in commercial settings, it is important that the information provided on visual display 180 is kept as simple, clear and as uncluttered with unneeded data as possible.",
"[0030] It may be noted that the type of grounds placed in the filter 160 may vary.",
"The harvested source and variety of coffee, the texture of the grind, and the age of the coffee grounds affect the taste of the final product in several ways.",
"The coffee variation may affect the tamp of the grounds in the filter 160 and the resulting pressure differential between the brew tank and the spout.",
"The coffee variation also affects the interaction between the grounds and the hot water flowing through them.",
"Each of these factors changes the taste of the dosed espresso.",
"An experienced user desiring to optimize taste needs the ability to vary properties of the brew to account for these variations.",
"[0031] The espresso machine of FIG. 1 also illustrates additional dosing units which include additional group control heads such as second group control head 110 ′ and third group control head 110 ″.",
"The additional dosing units allow for increased throughput of espresso drinks.",
"Each of the additional dosing units may also include dedicated visual displays such as shown in FIG. 1 at second visual display 180 ′ and third visual display 180 ″.",
"The number of dosing units is not important to the invention.",
"[0032] Any of the optional dosing units may be pre-programmed using an optional external programming controller 190 .",
"Default brew parameters such dispensing temperature, dose size, and applied pressure profile may be entered via programming controller 190 .",
"With reference to FIG. 13 , programming controller 190 includes a programmer display 192 , which may display text related to a current state of the selected dosing unit or may display text related to a programmed brewing sequence parameter.",
"User selection of the text to be viewed on the controller 190 may be selected via one or more programmer selection buttons 194 disposed next to the corresponding text line, or may be selected via a set of up-and-down programmer scrolling arrows 196 .",
"Adjustment of parameters may be entered via the scrolling arrows 196 .",
"Other user interfaces such as keyboards, touch pad screens, and the like may be used as well for these functions.",
"[0033] It should be noted that efficient use of controller 190 may entail a more advanced operating skill, and may distract from the ongoing dosing unit operation.",
"Thus, use of programming controller 190 may be generally more desirable during business idle time or downtime.",
"[0034] Now referring to FIG. 2 , a plumbing arrangement 200 that may be incorporated within the FIG. 1 espresso machine is shown.",
"A single steam tank 202 is generally located within the main housing of the espresso machine, heated to provide a constant temperature and pressure steam source that is commonly used for foaming milk and the like.",
"An external water source 210 , such as from building plumbing, and associated valve arrangement provides fill water for the steam tank 202 .",
"The water source 210 is also used by a pump 204 as a source of water to brew tank 250 and optional brew tanks 250 ′ and 250 ″.",
"Pump 204 may also operate under computer control to control or vary the pressure in brew tank 250 and consequently the pressure profile across the coffee grounds in the filter 260 as the shot is flowing.",
"An optional bypass control valve 208 and associated plumbing from the pump 204 discharge, i.e. between brew tank 250 and pump, back to the pump 204 suction is also shown.",
"Computer control may operate the optional bypass control valve 208 during the pump operation to establish a time-pressure profile across the filter by diverting the high pressure pump water away from the operating brew group.",
"[0035] As can be seen in FIG. 2 , flow of pressurized water from pump 204 to brew tank 250 may pass through the steam tank 202 .",
"This feature permits feed water to be pre-heated before entering the brew tank 250 , which makes temperature control at the brew group more precise.",
"[0036] Brew tank 250 holds pressurized hot water that is ready for dispensing through the filter 260 .",
"Brew tank 250 typically includes a heating element for continued precise temperature control, as well as a temperature sensor and an optional pressure sensor.",
"Brew tank 250 or the dedicated plumbing leading to it may also include a flowmeter.",
"[0037] Control valve 206 starts and stops the pressurized hot water flow from brew tank 250 through filter 260 through the outlet spout 170 .",
"In a preferred embodiment, control valve 206 is operated under control of an automated controller, which in turn operates responsive to an actuation signal input from the group control head.",
"Control valve 206 under such control thus provides a controlled volume output of the shot.",
"[0038] If control valve 206 is opened without the pump 204 operating, a reduced flow through the brew tank still occurs.",
"This state is useful at the beginning of a brew to pre-infuse dry coffee grounds with hot water before pumped flow begins.",
"This state may also be useful at the end of the brew to avoid excessive “blonding”",
"of the flow as the grounds are expended.",
"The time between the stopping of the pump and final closing of the control valve establishes a low pressure finish.",
"The value of the low pressure finish may be a percentage of the pumped flow volume to the total flow volume of the brew shot.",
"[0039] FIG. 3 illustrates an exploded diagram of a preferred embodiment of a group control head 300 assembly according to the present invention.",
"The assembly is mounted to the espresso machine 100 via a base 302 .",
"Base 302 may be generally cylindrically shaped with a center axis disposed in the vertical plane.",
"Base 302 may optionally be part of brew tank 250 , and may include a shroud surrounding the lower vertical portion.",
"[0040] A top plate 324 is disposed on base 302 .",
"Top plate 324 comprises a pivot pin 325 centered on the center axis.",
"Pivot pin 325 is arranged to provide a rotational axis for an actuator 340 .",
"In addition, a centering post 350 is disposed at a radial idle position on the top plate 324 , the post arranged orthogonally from the vertical center axis.",
"Preferably, centering post 350 is disposed near an edge of top plate 324 .",
"Centering post 350 is preferably constructed of a ferrous material that is magnetically attractive to a magnet.",
"[0041] Actuator 340 is disposed on top plate 325 at pivot pin 325 .",
"Actuator 340 includes a mounting arm, at the end of which a magnet 342 is disposed.",
"The arrangement of actuator 340 on top plate 325 is such that magnet 342 rests adjacent to but not touching center post 350 .",
"Actuator 340 is also free to rotate about pivot pin 325 but is held in an idle position 400 , FIG. 4 , by the magnetic force between magnet and post.",
"This biasing force opposes any rotational force which rotates the actuator 340 , and causes the actuator to return to the radial idle position when the rotational force is removed.",
"This holding feature thus serves as an automatic centering feature.",
"[0042] Affixed to top plate 324 is at least one proximity sensor 375 which is operable to sense a position of the magnet 342 with respect to the sensor.",
"Proximity sensor 375 is disposed at a fixed angle away from the radial idle position.",
"When an actuating force rotates the actuator magnet 342 away from the idle position, magnet 342 is positioned near sensor 375 .",
"An optional second proximity sensor 376 may be disposed at a second fixed angle from the radial idle position.",
"The second fixed angle may be the opposite angle from the radial idle position.",
"Similarly, when an actuating force rotates the actuator magnet 342 in the opposite direction away from the idle position, magnet 342 is positioned near and is detected by sensor 376 .",
"[0043] Proximity sensors 375 , 376 are preferably arranged on a proximity sensor board 374 which is held in fixed position above top plate 324 and actuator magnet 342 .",
"Magnet 342 is thus free to rotate under the proximity sensor board.",
"In addition, a preferred arrangement is of a single magnet 342 which serves as both an automatic centering magnet and a positioning source to be detected.",
"The arrangement is simpler and requires fewer parts.",
"Of course, the particular arrangement of magnet to sensor(s) may be modified within the scope of the invention.",
"[0044] A preferred type of proximity sensor 375 , 376 is a linear type Hall Effect sensor.",
"Such a sensor is commonly understood to provide an analogue output which corresponds to the relative position of a magnet.",
"One advantage of a Hall Effect sensor is that it is non-contact and so has no parts to wear out.",
"The Hall Effect sensor requires minimal periodic adjustment or calibration, and optionally could be used with a comparator to provide a more precise positioning over a large number of cycles.",
"[0045] Importantly, the Hall Effect sensor provides an analogue output that contains more than a simple binary actuation signal or pattern of binary signals.",
"The sensor can provide a signal input to a device controller which is representative of the magnitude of the magnet movement, the velocity of relative movement, and the duration of a held magnet rotation.",
"Thus, the Hall Effect sensor provides the user with a more precise and useful control of the group head.",
"[0046] The user interface portion of the FIG. 3 group control head is a rotational handle 314 , which is fixed by screws or other means to actuator 340 .",
"The handle 314 may comprise a protective shell which fits over the top plate 324 , actuator 340 and the arrangement of sensors 375 , 376 .",
"A paddle 316 is preferably disposed on handle 314 extending away from the protective shell and in such a manner as to provide easy rotational actuation of the group control head.",
"[0047] In operation, the user experiences a resistive force not unlike a spring force when she rotates the paddle.",
"When the paddle is released, the entire group head control assembly returns to the idle position due to the attraction of magnet and post.",
"[0048] FIGS. 4( a ), 4( b ) and 4( c ) illustrate the operation of the FIG. 3 group control head 300 , wherein magnet 342 may be positioned over an arc in proximity to, but not in contact with, at least one proximity sensor.",
"At rest, the group control head is automatically centered and held in the idle position 400 as shown in FIG. 4( a ) .",
"The magnetic attraction between magnet 342 and post 350 provides the holding force.",
"The output of proximity sensor 375 and/or optional sensor 376 indicates that the magnet 342 is in the idle position 400 .",
"[0049] FIG. 4( b ) shows the group control head 300 in a brew position 410 .",
"Here, the user has rotated paddle 316 in the clockwise, or left, direction such that proximity sensor 375 senses the proximity of magnet 342 .",
"The user also experiences a counterclockwise resistive force not unlike a spring force when she rotates the paddle 316 , due to the ongoing attraction between displaced magnet 342 and post 350 .",
"The attraction repositions the actuator 342 to the idle position 400 when the paddle 316 is released.",
"The effect of the paddle rotation of FIG. 4( b ) is to send an input signal corresponding to the sensed magnet position to a controller.",
"The controller in turn may begin a programmed sequence of outputs to the espresso machine to dispense a shot of coffee.",
"[0050] FIG. 4( c ) illustrates an optional control position 420 of the group control head 300 corresponding to a counterclockwise, or right, rotation of paddle 316 .",
"Second proximity sensor 376 senses the proximity of magnet 342 .",
"The user also experiences a clockwise counter-force not unlike a spring force when she rotates the paddle 316 , due to the ongoing attraction between displaced magnet 342 and post 350 .",
"The attraction repositions the actuator 342 to the idle position 400 when the paddle 316 is released.",
"The effect of the paddle rotation of FIG. 4( c ) is to send a second input signal corresponding to the sensed magnet position to a controller.",
"The controller in turn may perform an auxiliary action, such as ending an ongoing shot.",
"[0051] The user of course experiences the above described group control head 300 as having one actuator which has a clockwise, or left, paddle position and a counter-clockwise, or right, paddle position.",
"As will be further described, actuations of short duration and longer duration may provide different responses in the machine control.",
"A short duration actuation may be referred to as a “bump”, while longer duration actuations may be referred to as a “hold”",
"or a “long hold.”",
"A bump may be, for example, a paddle rotation and release lasting less than 250 milliseconds.",
"An example hold may be from greater than 250 milliseconds up to greater than about 2.5 seconds.",
"[0052] FIG. 5 illustrates a system block diagram of one embodiment of the electrical sensing and control circuit for an espresso machine electrical system 500 .",
"The electrical system 500 can be arranged on a single central printed circuit board or may be distributed among several sub-units.",
"For example, FIG. 5 shows one hardware controller 510 , but system 500 could equivalently include a separate controller 510 disposed on each group control head in the apparatus.",
"Either the single visual display 520 as shown or a display 520 dedicated to each separate group control head may be used to convey status information.",
"A power supply 540 provides electrical power to the system 500 .",
"[0053] The heart of system 500 is controller 510 , which can be any of a known CPU or other computer processing unit such as an application specific integrated circuit (ASIC), field programmable gate array (FPGA), or reduced instruction set computing (RISC) type.",
"Controller 510 operates to control the espresso brewing process in response to various inputs.",
"Controller 510 may also operate in accordance with a computer program stored in a computer memory 530 .",
"Controller 510 and the computer program then provide a repeatable and coordinated sequence of outputs that generate a controlled dose of espresso.",
"Controller 510 may also be arranged in a programming mode to accept programming instructions from external programming controller 190 and to store those instructions in memory 530 for later use.",
"Similarly, controller 510 may provide a program control data set point or parameter from a user interface to memory 530 .",
"Controller 510 may also provide output to a visual display 520 that is located near the respective group control head such that important operating status information can be seen at a glance.",
"[0054] Also shown in FIG. 5 is that memory 530 is preferably apportioned into several parts.",
"A first part is the computer temporary brew memory 532 , which as will be described saves parameters related to the current brewing process.",
"The temporary brew memory essentially contains a set of brewing parameters established at the last brew.",
"For example, if the user shortens a pre-infusion period by actuating the group control head handle, that new pre-infusion duration is captured in the temporary brew memory.",
"Each dosing unit has its own temporary brew memory.",
"[0055] Another part of memory 530 comprises a computer storage memory 534 for storing previously saved complete sets of brewing parameters.",
"The portions may be arranged in pages, with a left portion and a right portion for each page.",
"In one embodiment, each dosing unit is provided with from one to three pages.",
"More preferably, computer storage memory 534 comprises at least two storage locations, without any paging arrangement.",
"Shown in FIG. 5 is an exemplary embodiment of storage memory 534 having six storage locations 541 through 546 .",
"Each portion or storage location is sized to contain one set of brewing parameters.",
"Each dosing unit has its own computer storage memory 534 .",
"[0056] Outputs from each group head are provided as inputs to controller 510 .",
"Examples of inputs are a group head water flow meter 502 and a brew tank temperature sensor 504 .",
"Controller 510 may use these inputs to start or stop the brew program or to otherwise control various heating and pumping components.",
"Controller 510 preferably operates under the further control of an internal clock or timer to shift between various phases of the brew process.",
"[0057] Controller 510 also accepts signal inputs from each respective group control head 300 via proximity sensor outputs 375 , 376 .",
"The accepted signal inputs control the program sequence that provides the espresso dose.",
"An example is a received input from non-contact proximity sensor 375 that corresponds to a single actuation of the group control head handle.",
"Controller 510 then issues a coordinated program sequence of output instructions to provide the dose.",
"The outputs can be one or more of a pump control output 522 , a control valve control output 524 , and a bypass valve output 526 .",
"[0058] A second input control example is a received signal input from the second non-contact proximity sensor 376 that corresponds to a different single actuation of the group control head handle.",
"Controller 510 responsively issues an output to one or more of a pump control output 522 , a control valve control output 524 , and a bypass valve output 526 to, for example, immediately end the controlled dose.",
"[0059] FIG. 6( a ) and FIG. 6( b ) illustrate two embodiments of the information provided on the optional visual display 180 for the espresso machine of the present invention.",
"The displayed information provides the user with the current status of the machine and group control head guidance instructions with simple indications.",
"[0060] FIG. 6( a ) shows an operational display 600 provided during normal operation or during a programmed brewing sequence.",
"The most prominent feature of this display is a shot timer 602 .",
"Shot timer 602 will typically display the total duration of the shot, e.g. 32 seconds, during idle times between brews.",
"During the brew sequence, shot timer 602 preferably displays the elapsed time from the start of the shot, although similar indications of shot progression such as count-down time or time from the start of a particular sequence phase are included within the scope of this invention.",
"[0061] Mode icon 604 shows the espresso machine mode of operation, which may include a manual mode, a manual program or a volumetric program mode.",
"Here shown on icon 604 is the volumetric program mode icon VP.",
"An espresso machine operating in volumetric program mode is typically controlled on a flow basis as sensed by the flow meter.",
"An espresso machine operating in manual program mode MP is typically controlled by the sequence timer with some control by the user.",
"Manual mode M is typically a mode of operation under full control by the user.",
"[0062] Phase icon 606 indicates a relative duration of each phase of the brewing sequence.",
"The phases will be described in more detail with reference to FIG. 7 .",
"The embodiment shown uses simple bar graphs to display the relative length of each of three phases.",
"[0063] Memory storage location icon 608 shows the memory portion of computer storage memory 534 that is currently selected for use.",
"Here, icon 608 is a dot which points to a first memory storage location.",
"Additional storage location icons, if available, may be arrayed below icon 608 or along the right border of display 600 .",
"If the storage memory location is ready to receive data, a save icon 610 is shown.",
"[0064] FIG. 6( b ) shows a save mode display 620 that is shown during the transfer of brew parameters between the temporary memory and/or storage memory locations.",
"When in save mode, and when the storage memory location is ready to receive data, one display embodiment incorporates a save left icon 622 and a storage memory cycling icon 624 guides the user to save the current data via a left bump and to select the storage memory for saving by cycling through the locations with one or more right bumps of the group control head respectively.",
"In this case, the “M”",
"mode icon 604 indicates that the saving is being performed from a manual mode of operation.",
"[0065] FIG. 7 illustrates a brewing sequence 700 for the espresso machine.",
"From an idle state, the sequence is started at start step 702 by the user operating the group control head paddle or by pushing a button.",
"The controller 510 initiates the programmed sequence at step 716 using the currently-selected set of brew parameters and also begins to save brewing data into the temporary memory 532 .",
"[0066] The brewing phases then begin at a pre-infusion brew phase 717 .",
"During this phase, controller 510 opens the dosing unit control valve 524 , 206 to pre-infuse the dry coffee grounds with unpressurized water from the brew tank 250 .",
"This phase typically begins in response to the same first input signal received from the user at the start step 702 .",
"[0067] At the end of the pre-infusion phase, an optional pressure ramp up phase 720 begins.",
"The transition from pre-infusion to pressure ramp up may be in response to a programmed sequence time or to a user input from the group control head paddle.",
"Pressure ramp up phase 720 starts the pump 204 and optionally opens the bypass control valve 208 to gradually pressurize the brew tank 250 to drive water through the grounds.",
"[0068] In response to a programmed sequence time or to a user input from the group control head paddle, a full pressure brew phase 720 begins.",
"During this phase, the bypass control valve is closed and the pump is running to provide maximum shot flow through the grounds.",
"[0069] Depending on the particular grounds in use, an undesirable “blonding”",
"of the flow may occur as the grounds are used up during the full pressure brew phase 720 .",
"To avoid the effects of blonding, the sequence may then transition to an optional pressure ramp down phase 724 .",
"Like ramp up phase 720 , the pump is running and the bypass control valve is opened to gradually reduce pressure on the grounds.",
"The beginning of this phase may occur in response to a programmed sequence time or to a user input from the group control head paddle.",
"[0070] A stop shot phase 726 ends the brewing sequence.",
"This phase typically functions to ensure that the precise shot volume is dispensed.",
"Here, the pump is not running but the control valve is still open.",
"The transition into the stop shot phase 726 may be in response to a programmed sequence time or to a user input from the group control head paddle.",
"Similarly, the stop shot phase is ended by closing control valve 524 , 206 when the full dose has been dispensed as sensed by elapsed time, flow meter volume, or by user input.",
"The machine then re-enters an idle mode at end step 727 .",
"[0071] Shown next to each phase of the sequence is an exemplary operational display 600 on visual display 180 .",
"Shown is the total time of the sequence at the beginning and end as well as the elapsed time during the sequence.",
"Also shown is the Manual Programming MP operating mode and the stored parameter set that is in use.",
"Optionally, display 180 may show a volume dispensed instead of an elapsed time during the brewing phases.",
"[0072] The above described sequence is driven by a set of parameters or settings which control each phase.",
"For example, the set of parameters may include a pre-infusion time, a low pressure ramp up time, a full pump dispense time, a ramp down time, and a total dose water volume dispensed.",
"Generally, a set can be defined with four parameters.",
"End step 726 , for example, can be defined with the low pressure finish percent, which may be a percent of overall shot time or overall shot volume.",
"[0073] Method and Apparatus for Optimizing a Set of Brew Parameters [0074] FIG. 8 illustrates a flow chart for an inventive method of operating the espresso machine of the present invention, and in particular a method 800 for optimizing and storing the conditions for a controlled dose of hot water dispensed from the machine.",
"The method then saves the optimized set of brew parameters for a subsequent use of the espresso machine.",
"Method 800 begins at start step 802 .",
"The method then proceeds to a step 804 of providing the espresso machine apparatus as previously described, including the dosing unit, the group control head 110 , 300 , the pump 204 , the temporary brew memory, and the controller.",
"Providing step 804 may also include the steps of activating the apparatus, initiating the program stored in memory, preheating and pre-pressurizing the system, and/or preparing and installing the grounds filter.",
"After completion of providing step 804 , the espresso machine is ready to dispense espresso, and begins to monitor at the group control head proximity sensor 375 , 376 inputs.",
"[0075] Step 806 is for monitoring and sensing a momentary actuation or bump of the group control head handle to a particular angular brew position.",
"Step 806 pauses at monitoring sub-step 807 until controller 510 senses an actuation.",
"When an actuation is sensed, another sub-step, mode decision step 808 determines the type of actuation and continues the method accordingly.",
"For example, a sensed bump actuation may send the method into the brew mode 812 , and a long duration actuation may send the method into a programming or saving mode of operation 912 .",
"The saving mode of operation, and its return to the monitoring step 806 will be described in more detail.",
"[0076] An actuation direction decision step 810 immediately follows step 808 .",
"The direction of actuation, clockwise/left (CW) or counter-clockwise/right (CCW), may cause the method 800 to respond differently depending on whether a shot is brewing at the time of actuation or not, i.e. in an idle state.",
"If no shot is brewing at actuation, as sensed by the controller at shot brewing decision steps 814 and 820 , the direction may determine which of two sets of parameters is used for the subsequent shot, i.e. the set stored in the current computer temporary brew memory or a different set stored in the computer storage memory respective to the CW left or CCW right bump.",
"In a preferred embodiment, a sensed CCW right bump with no shot brewing causes the controller to retrieve the set of brew parameters stored at the next sequential memory storage location 541 - 546 for that group head at cycling step 821 .",
"That set is placed into the temporary brew memory at step 824 .",
"If the CCW right bump is repeated, the brew parameters at the next sequential memory storage location 541 - 546 is retrieved into temporary memory at 821 , and so on.",
"Thus, the operator experiences a cycling of stored recipes on that group head.",
"[0077] If a CW left bump is sensed while in the idle state, method 800 proceeds to begin the programmed sequence at step 816 according to the selected set of parameters stored from step 824 in the temporary computer brew memory.",
"The programmed brew sequence then begins as described in FIG. 7 with the pre-infusion step 717 of opening the control valve to begin the controlled dose of hot water.",
"Step 816 also initiates a saving into the computer temporary memory of subsequent actuation steps.",
"Then the method 800 returns to the sensing/monitoring step 806 to await the next sensed actuation of the group control head paddle.",
"[0078] If no further actuations occur, the programmed sequence of FIG. 7 automatically completes itself and delivers a controlled dose in accordance with the selected set of parameters.",
"The set of parameters saved to the temporary brew memory would in this case be identical to the selected set.",
"[0079] If the selected set of parameters is set to a null manual MAN setting or the mode of operation is in the Manual mode, the method 800 may continue in a completely manual sequence.",
"The sequence still follows the FIG. 7 sequence, but the transition between each phase occurs at an actuation sensing and never at an elapsed time.",
"In an example manual mode operation, the first momentary action of the group control head handle begins the pre-infusion step whereby the control valve is opened and the parameter saving is initiated.",
"The controller would respond to subsequent CW momentary actuations of the handle by repeatedly proceeding along the cycle of step 808 , step 810 , step 814 , a proceed to next shot phase 818 , and a return to step 806 .",
"Thus, the full pressure phase, and/or the optional pressure ramp up or ramp down phase is controlled by the repeated sensed CW actuations at next shot phase 818 .",
"These phases involve starting and running the pump to provide the controlled dose of hot water through the dosing unit.",
"At each phase transition, a parameter related to the duration of each phase is saved into the computer temporary memory at saving step 824 .",
"[0080] In one embodiment of the completely manual mode, the third actuation of the proceed to next shot phase 818 stops the pump to end the controlled dose of hot water.",
"Optionally, a fourth actuation of the next shot phase 818 closes the control valve at the proper shot dose volume corresponding to end sequence step 726 .",
"The duration of each of these phases is saved into the temporary memory at saving step 824 .",
"The overall saving of these steps thus creates a complete set of brew parameters in memory.",
"The saved set of brew parameters may be used in subsequent programmed brew sequences.",
"[0081] As can be seen in FIG. 8 , a CCW bump of the group control head handle sensed at step 810 while the shot is brewing as sensed at step 820 always causes the method to immediately proceed to stop shot step 822 .",
"This step 822 stops the pump and closes the control valve to end any further flow through the dosing unit.",
"A user may also perform this actuation if, for example, when the desired brew volume has already been reached but the flow is continuing under the ongoing programmed sequence.",
"[0082] FIG. 8 also illustrates how the method 800 may be used to dynamically adjust, while operating in the automatic programmed brew sequence mode, a set of parameters that have already been saved in memory.",
"In this situation, the espresso machine is prepared to dispense the next dose using a previously saved set of parameters.",
"When the momentary actuation is repeated and sensed at step 806 , the control valve is re-opened and the controller newly initiates the saving of parameters into the temporary memory.",
"The new programmed brew sequence begins again.",
"If no further actuations are sensed during the brew, then the programmed brew sequence automatically controls the control valve and pump to replicate the previous controlled dose of hot water.",
"[0083] But if the user desires to adjust, i.e. shorten, one or more of the sequence phases, then she merely again bumps the paddle CW to truncate that phase and immediately start the next phase at step 818 .",
"This action may, for example be a repeat of the third momentary actuation step, which stops the pump and therefore stops the replication.",
"The phase duration as defined by the actuation is saved into the temporary memory as part of a new, i.e. second, set of brew parameters.",
"In one embodiment the saving at step 824 further comprises the step of overwriting the previous set of brew parameters with the second set of parameters in the temporary memory.",
"This second set can then be used for subsequent brews.",
"In a preferred embodiment, adjustment of every brew phase is enabled for Manual mode of operation, and a limited adjustment of only the low pressure finish phase, step 724 of FIG. 7 , is enabled during Manual Program mode of operation.",
"[0084] A summary of the FIG. 8 operation is illustrated in state table 801 .",
"There shown is the response in the espresso machine corresponding to each particular operation of the group head control handle during the normal, or brew mode of operation.",
"[0085] The espresso machine apparatus that is previously described may be modified to use the method 800 for storing and adjusting the dosing conditions.",
"In addition, the machine may optionally comprise visual display 180 , which displays the phase of the sequence as the sequence proceeds.",
"After the sequence is complete, the visual display 180 may display an indication that the phases have been saved as a new set of parameters.",
"Example [0086] The barista prepares the espresso dosing unit and refreshes the grounds in the filter.",
"She decides to manually brew a shot.",
"The barista bumps the group control head paddle to the left to begin pre-infusion and watches for the first drips to pass the filter basket.",
"Once the basket is saturated, she bumps the paddle left again to add pump pressure.",
"The shot speed begins to increase and the color of the flow begins to lighten toward the end of the shot.",
"She bumps the paddle left again to return to line pressure, then bumps it right to end the shot.",
"[0087] Example parameters saved into temporary memory for this manual shot are 6.2 seconds pre-infusion and 60 milliliters water volume with a 97% low pressure finish.",
"This set of parameters is now available to save for future replication.",
"[0088] Of course, if the sequence is not progressing satisfactorily, a bump of the paddle to the right while the shot is in progress immediately ends the shot.",
"[0089] Method and Apparatus for Saving an Optimized Set of Brew Parameters [0090] FIG. 9 continues the FIG. 8 method flow, further describing a method 900 for storing brewing parameters in an espresso machine.",
"The method starts when the first sensed actuation of the group control head handle at step 806 enters the machine into a program and save mode of operation 912 .",
"This path is shown by the indicator AP.",
"An example first actuation is a long hold, e.g. greater than 250 milliseconds, to enter this mode.",
"[0091] Responsive to entering the program and save mode of operation 912 , the current set of brew or shot parameters is obtained from the computer temporary brew memory at step 902 .",
"The visual display 180 corresponding to the dosing unit may begin to flash the save icon 610 at this time to indicate the saving/programming mode of operation.",
"One object of this invention is that this current set of shot parameters can then be assigned to as many computer storage memory locations on as many different group control heads in the system as desired.",
"In addition, the visual display 180 may also begin to indicate the current set of brew parameters.",
"Of course, if the operator desires to store a set of brew parameters that is not currently in the computer temporary brew memory, she may transfer the desired set of parameters from a computer storage location to the temporary brew memory prior to the obtaining step above.",
"Preferably, this is done by selecting the computer storage location with the desired parameters with one or more right bumps from idle, step 821 , and then running that shot with a left bump, step 816 shown in FIG. 8 .",
"[0092] Also responsive to entering the program and save mode of operation 912 at the first sensed actuation, the controller selects a default or initial computer storage memory location at initial storage memory step 903 .",
"This default computer storage location may be pre-selected to appear each time the save mode is entered, or may simply be the last storage memory location used.",
"If the espresso machine has multiple dosing units, the controller may select a default memory location at each group control head.",
"Preferably, the visual di splay(s) 180 displays the active computer storage memory location at this step.",
"The group control head of the first sensed actuation may optionally display brew parameters from the set in the temporary brew memory or the computer storage memory at the obtaining step.",
"[0093] Method for Storing Brewing Parameters, Single Dosing Unit [0094] After entering the save mode of operation 912 , the method proceeds to the step of saving the set of parameters from the last shot brewed, i.e. the parameters in the computer temporary brew memory, into a computer storage memory location.",
"In one simple embodiment, the operator merely bumps the group control head handle to the left, sensed as a second actuation by the controller.",
"The method flow shows the bump sensed as a left actuation at direction step 906 and as a bump at duration step 910 .",
"The left bump causes the controller to save the set of brew parameters into the default or initial storage memory from step 903 .",
"[0095] The operator may wish to save the set of brew parameters into a different computer storage memory location than the default location.",
"The operator selects a different location by scrolling through the available locations with one or more right bumps of the group control head handle.",
"The controller senses the input at direction step 906 and duration step 911 to scroll to the next available storage memory at step 914 .",
"Step 914 preferably includes the display of the computer storage memory location on visual display 180 , as exemplified in FIG. 6( b ) .",
"A subsequent left bump, steps 906 , 910 saves the set of parameters to the selected location at step 908 .",
"It is preferable that the bumps for scrolling and saving are in opposite directions of the handle, but the particular directions described above may be swapped within the scope of the invention.",
"[0096] The operator exits the save mode of operation at step 940 and returns to the brew mode of operation.",
"The controller may exit the save mode in several ways, e.g. by a time-out or immediately upon the saving step.",
"Preferably, an affirmative actuation triggers the exit, such as a group head control handle “right hold”",
"actuation, as shown by the path of direction step 906 and as a hold at duration step 911 .",
"[0097] An additional function may be provided while in the save mode of operation.",
"The controller may cycle to another of a group mode at cycle mode step 909 , e.g. Manual Mode or Manual Program Mode or Volumetric Program Mode, responsive to a sensed left hold from the group control head handle via direction step 906 and duration step 910 .",
"When a set of parameters is subsequently saved, the set will correspond to that particular group mode.",
"[0098] A summary of the FIG. 9 operation is illustrated in state table 901 .",
"There shown is the response in the espresso machine corresponding to each particular operation of the group head control handle during the program and save mode of operation.",
"[0099] Transferring a Set of Brew Parameters Between Espresso Dosing Units [0100] If the espresso machine is a multi-head device having a plurality of previously described espresso dosing units, the machine may be arranged to transfer a desired set of brewing parameters from one of the dosing units to another.",
"In this embodiment, a controller 510 is in communication with all of the group control heads, temporary memories, and storage memories.",
"A visual display is optionally associated with each dosing unit.",
"[0101] The system is arranged such that when a program and save mode of operation is entered at any of the dosing units, for example by the method flow chart of FIG. 9 , controller 510 activates all of the dosing units for saving.",
"[0102] FIG. 12 illustrates one embodiment of the group display 1200 .",
"After entering the save mode 900 and obtaining the desired set of brew parameters with one of the group control heads, all of the visual displays 180 , 180 ′, 180 ″ will display a save screen 620 , 620 ′, 620 ″ and a flashing save icon 610 .",
"Any of the other group control heads can be scrolled as described above to select that dosing unit's desired storage location for saving.",
"Then each group control head can separately save the desired set of brew parameters to the selected memory and exit the save mode as described above.",
"Exiting from the save mode alternatively may be accomplished all at once by exiting the save mode, step 940 , at the source group control head.",
"[0103] After either of the above described transferring steps, a programmed brew sequence may be initiated at any of the dosing units according to the transferred set of brew parameters.",
"When a subsequent group control handle bump for another of the dosing units is sensed at its step 806 , then a new programmed brew sequence is initiated according to the transferred set of parameters.",
"The espresso machine then automatically conducts the programmed sequence at step 812 to dispense the new dose of espresso.",
"Thus the conditions for the desired dose are replicated across the dosing units.",
"[0104] FIG. 10 illustrates example visual display graphics and state machine diagram 1000 that accompany the program and save mode of operation.",
"Prior to entering the save mode, the espresso machine is in the brew mode of operation 1001 , and typically runs a shot to automatically save the last shot into the computer temporary brew memory at step 1002 .",
"The operator then performs a right hold, e.g. for 2.5 seconds, at enter save mode step 1004 , whereupon the visual display 180 begins to flash the save icon.",
"The operator then optionally bumps right one or more times at step 1006 to change the desired computer storage memory location for saving.",
"When the desired location is selected, the operator bumps left at save step 1008 to save the shot parameters to the location.",
"The operator then exits the save mode at step 1010 with a right hold, e.g. for 2.5 seconds.",
"[0105] After the save mode of operation ends at exit step 940 , the espresso machine is then ready to enter the brew mode again with the newly saved and selected set of brew parameters.",
"If a different set of brew parameters is desired, the operator simply bumps right one or more times to cycle through the recipes, and stops when the desired recipe is reached.",
"When a subsequent group control handle bump is sensed at step 806 , then the new programmed brew sequence is initiated according to this new second set of parameters.",
"The espresso machine then automatically conducts the programmed sequence at step 812 to dispense the new dose of espresso.",
"[0106] FIGS. 11( a ) through 11( d ) illustrate an additional series of state machine diagrams for the operation of the espresso machine.",
"FIG. 11( a ) illustrates program mode adjustment state machine 1102 .",
"When the controller senses a left hold, e.g. 2.5 seconds, on a group control head handle, the controller enters the cycle program mode.",
"Subsequent left holds cause the controller to cycle its program mode through the available programs, here shown the modes Manual 1104 , Manual Program 1106 , Volumetric Program 1108 , and cycle back to Manual 1110 .",
"Further detail about operating in these modes is shown in FIG. 11( b )-( d ) .",
"[0107] FIG. 11( b ) illustrates one exemplary operation of the Manual Mode 1120 , a mode that allows the operator complete control of the shot parameters.",
"Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1122 .",
"The controller begins the pre-infusion operation, and awaits subsequent bumps left before advancing the shot to the next phases of pressure ramp-up step 1124 , full pressure brew step 1126 , and pressure ramp-down step 1128 respectively.",
"The shot is stopped at step 1129 at a sensed bump right.",
"The brew parameters are retained within the computer temporary brew memory.",
"Visual display 180 may display the current phase and parameters during the shot.",
"[0108] FIG. 11( c ) illustrates one exemplary operation of the Manual Program Mode 1130 , a mode that allows the operator limited control of the shot parameters.",
"Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1132 .",
"The controller automatically advances the shot to the next phases of pressure ramp-up step 1134 , full pressure brew step 1136 , and pressure ramp-down step 1138 .",
"The shot is stopped at step 1139 at a sensed bump right.",
"The operator may adjust the “blonding”",
"of the shot at step 1136 with a left bump to truncate the shot pressure, and then may end the shot at the desired volume (if necessary) with a right bump at stop step 1139 .",
"Visual display 180 may display the current phase and parameters during the shot.",
"[0109] FIG. 11( d ) illustrates one exemplary operation of the Volumetric Program Mode 1140 , a mode that allows the operator control of the start of the shot only.",
"Starting from an idle state at steps 802 , 804 , the operator bumps left to start the shot by pre-infusion at start step 1142 .",
"The controller then automatically advances the shot to each next phase at pressure ramp-up step 1144 , full pressure brew step 1146 , and pressure ramp-down step 1148 according to the program brew parameters in use.",
"The shot is automatically stopped at step 1149 upon reaching the pre-programmed volume as sensed by the flowmeter.",
"In this program mode, the operator may truncate the shot at any time with a bump right.",
"The visual display 180 may display the current phase and parameters during the shot.",
"[0110] The functionality of the various program modes corresponds to the method flow steps as shown in FIG. 8 .",
"For example, a sensed CCW actuation at step 810 with a shot brewing at step 820 which immediately ends the shot at step 822 .",
"This corresponds to the right bumps at FIG. 11 steps 1129 and 1139 .",
"[0111] When the paddle is released, the save mode of operation then exits at exit step 940 .",
"The espresso machine is then ready to enter the brew mode again with the newly saved and selected set of brew parameters.",
"When a subsequent group control handle bump is sensed at step 806 , then a new programmed brew sequence is initiated according to this new second set of parameters.",
"The espresso machine then automatically conducts the programmed sequence starting at step 812 to dispense the new dose of espresso.",
"[0112] Retrieving a Stored Set of Parameters for Use [0113] FIG. 8 at state machine table 801 also illustrates a method for obtaining from storage memory a set of parameters for use, where the set of parameters has been previously stored in one of the page portions instead of the temporary brew memory.",
"This functionality is enabled simply by cycling through the memory storage locations by means of scrolling with the group control head handle.",
"In the FIG. 9 embodiment, the group control head handle is bumped right one or more times to cycle through the storage locations, up to six.",
"When cycled, visual display 180 preferably highlights the particular location.",
"A subsequent bump to the opposite left side then starts the shot using that selected recipe.",
"The shot parameters are also transferred to the temporary brew memory during the shot, for subsequent saving and use.",
"Example [0114] Some example settings for a page in computer storage memory appear in Table 1 below: [0000] Brew Group 2 (Volumetric Mode) Program 1 Pre-infuse 4.0 Ramp Up 1.8 % of Shot Brewed 91% Total Water Volume 350 [0115] A note from the morning barista says that they made a great shot earlier in the day and saved it in Brew Group 2 Program 1.",
"We are currently using Program 2 on the second group, so the first step is to cycle to the Program 1 by bumping the group head control handle five times until Program 1 is highlighted on visual display 180 ′.",
"Then we prepare a filter puck and bump left.",
"The programmed sequence will run through 4 seconds of pre-infusion, ramp up for 1.8 seconds, and then run the pump until 91% of the total flow meter count of 350, corresponding to about 60 ml of water, has been dispensed.",
"The pump will then shut off and the shot will finish at line pressure.",
"[0116] An espresso machine apparatus as described in FIGS. 1 through 6 comprises each of the elements that are necessary to perform the methods described above.",
"An optional external programming controller 190 , described in FIG. 13 may be used in concert with the group control heads, controller, memories, and programmed sequences for additional flexibility in programming.",
"[0117] FIG. 13 shows an embodiment of the optional external programming controller 190 that may be used with the inventive espresso machine.",
"Controller 190 is preferably handheld and communicatively connected to the controller 510 by wired or wireless means.",
"Controller 190 includes three main features.",
"Programmer display 192 displays information related to the stored programs.",
"Programmer selection buttons 194 are arranged next to the display to enable the user to select particular items in display 192 .",
"Programmer scrolling arrows 196 enable the user to adjust values of the displayed items.",
"[0118] If no useful set of brewing parameters yet exists in computer storage memory, or if it is desired to enter the values without brewing, one or more of the parameter set values may be more easily entered via the controller 190 .",
"For example, the user wishes to adjust the volume of the shot on number 2 brew group, i.e. dosing unit.",
"She scrolls with the scrolling arrows 196 until Brew Group 2 is displayed.",
"The desired set of brew parameters resides in the memory storage location 1, so she presses the button 194 that is adjacent that label.",
"Then she presses the scrolling arrows to adjust the volume to the desired amount.",
"Another press of the button 194 deselects the line and updates the set of brew parameters at that memory location.",
"As previously described, this new set of brew parameters can be saved to any of the other memory locations in any of the other brew groups, and can be used with the group control head controls during the next brew.",
"The entry of data using programmer 190 may also be conducted in concert with selection and saving of that data via the group control head operations as described above.",
"[0119] Modifications to the device, method, and displays as described above are encompassed within the scope of the invention.",
"For example, various configurations of the plumbing and electrical systems which fulfill the objectives of the described invention fall within the scope of the claims.",
"Also, the particular appearance and arrangement of the apparatus may differ.",
"[0000] Table of Elements Number Name 100 Espresso machine 102 Espresso dosing unit 110 Group control head 110′ Second group control head 110″ Third group control head 150 Brew tank 160 Filter 170 Outlet spout 180 Visual display 180′ Second visual display 180″ Third visual display 190 External programming controller 192 Programmer display 194 Programmer selection buttons 196 Programmer scrolling arrows 200 Espresso machine 202 Steam tank 204 Pump 206 Control valve 208 Bypass control valve 210 Water source 250 Brew tank 250′ Second brew tank 250″ Third brew tank 260 Filter 300 Group control head 302 Base 314 Handle 316 paddle 324 Top plate 325 Pivot pin 340 Actuator 342 Magnet 350 Centering post 374 Proximity sensor board 375 First proximity sensor 376 Second proximity sensor 400 Idle position 410 Brew position 420 Control position 500 Espresso machine electrical system 502 Group head flow meter 504 Brew tank temperature sensor 510 Controller 520 Visual display 522 Pump control output 524 Control valve control output 526 Bypass valve output 530 Computer memory 532 Computer temporary brew memory 534 Computer storage memory Computer storage memory page Page left portion Page right portion 540 Power supply 541-546 Computer storage memory storage locations 600 Operational display of programmed sequence 602 Shot timer display 604 Mode icon 606 Brew sequence phase display 608 Memory storage location icon 610 Save icon 620 Save mode display of brew parameter set transfer 620′ Second save mode display (not used) 620″ Third save mode display (not used) 622 Save left icon 624 Storage memory cycling icon 700 Espresso machine brewing sequence 702 Brewing start step 716 Brewing initiation step 717 Pre-infusion brew phase 720 Pressure ramp up phase 722 Full pressure brew phase 724 Pressure ramp down phase 726 Stop shot phase 727 End step 800 Method for providing hot water dose 802 Method start step 804 Providing an espresso machine step 806 sensing step 807 Monitoring step 808 mode decision step 810 actuation direction decision step 812 brew mode 814 shot brewing decision step 816 begin programmed sequence step 818 Proceed to next phase in sequence step 820 shot brewing decision step 821 Cycle recipe step 822 stop shot step 824 save into temporary memory step 900 Method for storing brewing parameters in an espresso machine 901 Saving method state table 902 Obtain brew parameters step 903 initial computer storage memory location step 906 Sense actuator direction step 908 Save to selected storage memory step 909 Group mode cycling step 910 Duration step 911 Duration step 912 Enter program and save mode of operation 914 scroll to the next available storage memory at step 940 Exit from program and save mode of operation 1000 Visual display state machine diagram, save mode 1001 Initial brew mode of operation 1002 Save last shot into computer temporary brew memory step 1004 enter save mode step 1006 change computer storage memory location step 1008 save to active computer storage memory step 1010 Exit save mode step 1102 Program mode adjustment state machine 1104 Manual mode 1106 Manual program mode 1108 Volumetric program mode 1110 Manual mode cycle 1120 Manual (M) mode of operation 1122 M start and pre-infusion step 1124 M pressure ramp-up step 1126 M full pressure brew step 1128 M pressure ramp-down step 1129 M stop step 1130 Manual Program (MP) mode of operation 1132 MP start and pre-infusion step 1134 MP pressure ramp-up step 1136 MP full pressure brew step 1138 MP pressure ramp-down step 1139 MP stop step 1140 Volumetric Program (VP) mode of operation 1142 VP start and pre-infusion step 1144 VP pressure ramp-up step 1146 VP full pressure brew step 1148 VP pressure ramp-down step 1149 VP stop step 1200 Groups display"
] |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/990,994 filed Feb. 1, 2011, which is a 371 of PCT/EP2009/055469 filed May 6, 2009, now U.S. Pat. No. 8,720,435, which claims the priority benefit of German Appln. No. 10 2008 022 987.3 filed May 9, 2008, which are hereby incorporated by reference to the maximum extent allowable by law.
FIELD OF THE INVENTION
The present invention relates to nebulisers for ventilation machines and in particular to nebulisers for introducing an active ingredient in aerosol form into the respiratory air that is supplied to a patient for assisted or substitute ventilation. A nebuliser is hereby to be understood as any device for generating an aerosol. A ventilation machine is to be understood as a ventilation device that supplies patients intubated or tracheotomised using an endotracheal tube with a flaw of air of up to 120 l/min, preferably between 1 and 50 l/min, at a pressure of between 0 and 100 mbar and preferably between 3 and 45 mbar.
The present invention furthermore also relates to a ventilation machine comprising such a nebuliser.
BACKGROUND
Nebulisers for ventilation machines are well known in the prior art. For example, WO 2005/048982 A2 discloses such a nebuliser. This nebuliser comprises a body having a first connection that comprises two connecting pieces for connecting the nebuliser to an air supply line and an air exhaust line of the ventilation device. Opposite the first connection, the body comprises a second connection that again has two connecting pieces which are to be connected via a Y-piece and two tubes with a line leading to the patient. Two separate flow channels that are connected via a connecting channel are formed in the body, one (first one) of which serves the flow of respiratory air from the air supply line to the patient and the other (second one) of which serves the flow of consumed air from the patient into the air exhaust line. A non-return valve that allows a flow solely in the direction of the patient is disposed in the first flow channel upstream of a connection of a nebulising device to the first flow channel. Furthermore, the nebulising device is coupled perpendicular, similar to a T connection, to the first flow channel, with the aerosol being supplied in a direction perpendicular to the direction of flow in this first flow channel.
The problem with this design is on the one hand that owing to the non-return valve, an element is integrated in the air supply line, i.e. in the line that leads to the patient, which could have serious consequences should it malfunction.
There is on the other hand the problem that the aerosol is introduced into the flow perpendicular to the direction of flow of the respiratory air through the body, and thus a high deposition of the aerosol on the surfaces of the flow channel occurs, which has a high loss associated therewith.
It is known from other fields of technology to prevent deposition of the aerosol on surfaces in particular of the nebulisation chamber in that the nebulising device nebulises in a direction that is parallel to a flow towards the patient. US-A-2003/0072717, for example, discloses an inhalation device wherein a nebulising device is arranged in a closed and bypassed housing. The housing is disposed in a flow channel of the inhalator, which comprises a mouthpiece. The nebulising device thereby nebulises in the direction of the mouthpiece. However, dead volumes, flow resistance by the nebulising device as well as the filling thereof only play minor roles therein. In ventilation machines, however, the nebulisers must meet predefined criteria in this regard. EP-A-1 818 070 also discloses an inhalation therapy device having such a nebulisation direction, in this case, however, for premature babies. The system (requires the patient to be able to breathe on their own and) is specifically adapted to the small line cross-sections with an inner diameter of between 2 mm and 3.5 mm for premature babies such that air may easily pass around the nebulisation device without flow resistance occurring. Furthermore, since the patient is able to breathe on their own, the system operates at a low pressure of up to 15 mbar. Moreover, filling of the nebuliser with a fluid to be nebulised is not necessary or intended when the system is in operation since operation can be interrupted for filling and/or a loss in pressure in the system can be accepted without risk. Therefore, the above-described and comparable systems from the prior art were not transferable for use in ventilation machines.
SUMMARY
The object of the present invention is therefore to create a nebuliser for ventilation machines, wherein the deposition of aerosol on the surfaces of the flow channel and the losses associated therewith are reduced and failures of vulnerable elements can be avoided. The mode of operation of the ventilation machine must at the same time not be impaired by the nebuliser, i.e. no flow resistance may be generated, the nebuliser must be airtight at a certain positive pressure (for example 100 mbar), filling of the nebuliser with the fluid to be nebulised must also be possible during operation of the ventilation device without a loss in pressure in the system, and a dead space in the nebuliser must not take up too much volume, etc.
This object is solved by a nebuliser having the features of patent claim 1 . Advantageous further developments of the present invention are mentioned in the sub-claims.
The idea forming the basis for the present invention is to reposition the nebulising device in the flow channel such that the aerosol generation occurs by nebulising the fluid parallel to the direction of flow in the flow channel, instead of coupling the nebulising device perpendicular to the direction of flow by means of a T-piece-like arrangement, such as is the case in the prior art.
The present invention accordingly proposes a nebuliser for ventilation machines, which comprises a body having a first connection for connecting (for example indirectly via a tube) the nebuliser to a ventilation device and a second connection for connecting (for example indirectly via a tube) the nebuliser to a line leading to the patient, said body forming a flow channel, and in particular only one flow channel, from the first connection to the second connection. That is to say, in a specific embodiment, the body forms only one flow channel, through which respiratory air flows from the first connection to the second connection during inhalation and consumed air flows from the second connection to the first connection during exhalation. The line that leads to the patient can be composed of the so-called catheter mount (double swivel connector) and the endotracheal tube as well as optionally of other elements. In a specific embodiment, the connection to the ventilation device can be effected by way of both the air supply line for supplying respiratory air as well as the air exhaust line for expelling consumed air such that the nebuliser simultaneously forms a Y-piece. However, it goes without saying that the first connection of the body may also be connected only to the air supply line, such that a possible Y-piece is arranged only downstream of the second connection. The nebuliser of the present invention furthermore comprises a nebulising device for nebulising a fluid. The fluid is preferably a liquid composition that preferably contains at least one active ingredient (see below). A nebulising device is to be understood as any aerosol generator or producer by means of which the fluid can be transformed into an aerosol form. According to the invention, the nebuliser is characterised in that the nebulising device is disposed in the flow channel between the first connection and the second connection, and is configured such that the fluid can be nebulised substantially parallel to, and preferably in, the direction of flow from the first connection to the second connection. In other words, respiratory air passes around the nebulising device in the inhalation cycle and the fluid to be nebulised is nebulised parallel to, and preferably in, the direction of the respiratory air flow such that an aerosol flow is generated parallel to, preferably in, the direction of flow of the first respiratory air, as a result of which the impaction and thus deposition on surfaces in the flow channel is reduced and the aerosol can be supplied to the line system and transported to the patient with the smallest amount of loss possible. The wording “substantially” is to be understood in this respect such that the aerosol flow may also have a deviation of up to 45° to the direction of flow of the respiratory air.
So as to regulate the respiratory air, ventilation devices produce a continuous basic flow (a so-called “bias flow”). Outside of an inhalation cycle, wherein respiratory air is transported to the patient via the air supply line, this bias flow, which may be in the magnitude of up to 30 l/min, normally flows directly into the air exhaust line from the air supply line. To achieve this without the bias flow passing the nebulising device and nebulised fluid thus permanently flowing into the air exhaust line, which would lead to a significant inefficiency of the system, the nebuliser of the present invention preferably comprises a first connection that is designed to connect with an air supply line coming from the ventilation device and an air exhaust line leading to the ventilation device in such a manner that a side-flow channel (bypass) from the air supply line to the air exhaust line is formed on the side of the nebulising device that is opposite the second connection.
The air supply line and the air exhaust line can thereby be formed by a common tube that is divided into two sections. This division may be formed either by a partition in the tube or by a coaxial tube, i.e. two tubes arranged one inside the other. The common tube is to be connected to the first connection of the nebuliser. The first connection and the common tube are thereby configured in such a manner that a bypass is formed between the nebulising device and the front face of the partition and/or of the inner tube of the coaxial tube, which is facing the nebulising device. The bypass allows the bias flow to flow, outside of an inhalation cycle, directly into the air exhaust line from the air supply line without flushing any possibly nebulised fluid into the air exhaust line. The efficiency of the system can be significantly improved as a result.
It is, of course, alternatively also conceivable for the air supply line and the air exhaust line to each be formed by a separate tube. In this design, it is preferred for the first connection to have a first connecting piece for connection to the air supply line and a second connecting piece for connection to the air exhaust line, each of which may be formed by a tube. The bypass is then formed in the body itself between the first connecting piece and the second connecting piece and, outside of an inhalation cycle, allows a flow from the air supply line into the air exhaust line. This design furthermore leads to a tilt-stable unit of the nebuliser being formed by the two connecting pieces and the opposite second connection.
As already mentioned at the start, the nebuliser must also allow filling of a fluid container during ventilation without a loss of pressure in the system. Therefore a vibrating membrane (oscillating membrane) is Preferably used as the nebulising device, the membrane being provided with a plurality of openings (micro openings) for nebulising the fluid. The membrane is preferably arranged perpendicular to the direction of flow from the first connection to the second connection so as to achieve nebulisation in the direction of flow or parallel to the direction of flow. The wording “substantially” is to be understood in this respect such that the membrane may also be arranged in the flow channel at a slight gradient deviating by up to 45° from the perpendicular. From the point of view of flow technology, the membrane is thereby preferably designed so as to be circular, however it may also be oval. Owing to this design of the aerosol generator (nebulising device) with a membrane comprising very small openings, through which a flow out of the flow channel and out of the system is not possible, it is ensured in a simple manner that a loss in pressure via the nebulising device is prevented, even when the fluid container is opened, for example the lid of the fluid container is unscrewed for filling.
Furthermore, a fluid container for receiving the fluid to be nebulised, which is connected to the body, is provided, as is a nebulisation chamber into which the fluid is to be nebulised, with the membrane being arranged between the fluid container and the nebulisation chamber. The fluid container is connected to the body in such a manner that it can be coupled and uncoupled. Instead of directly accommodating the fluid, the fluid container may also have a fluid communication interface and be configured to receive a fluid-containing ampoule that comes into fluid connection with the fluid container via the fluid communication interface. The fluid communication interface may, for example, be formed by an opening device (a hollow spike) and may be configured to receive a fluid-containing ampoule to be opened by the opening device, similar to that described, for example, in WO 2007/020073 for a conventional nebuliser/aerosol generator, to which reference is made for further details. It is also conceivable for the fluid container to have a hollow needle and for a valve to be provided in the ampoule, which is opened by the needle when the ampoule is received by the fluid container.
In order to further minimise deposition and thus loss at the surfaces of the flow channel, it is, as mentioned, particularly preferred to nebulise the fluid in the inhalation cycle in the direction of flow of the respiratory air, for which purpose the nebulisation chamber is preferably disposed between the membrane and the second connection that is to be connected to the line leading to the patient.
It is furthermore necessary for the fluid container to supply a constant dosage to the nebuliser membrane up to a gradient of 45° in every direction about the direction of flow from the first to the second connection so that a reliable and uniform nebulisation or aerosol generation can take place. For this purpose, the unit consisting of the body and the fluid container can, as already mentioned, on the one hand be configured in a tilt-stable manner by the two connecting pieces and the opposite second connection. To further meet this requirement, it is, however, preferred for the fluid container to have a tapering in the direction of the membrane, which opens out into a fluid chamber that is closed by the membrane, with the tapering extending at least obliquely from a cylindrical portion of the fluid container to the fluid chamber.
It is particularly preferred for a partial section of the tapering that is facing away from the membrane to extend with an angle range of between 10° and 40° to the vertical and, in the case of a perpendicularly arranged membrane, preferably also to the membrane, i.e. a lower portion of the fluid container that is closed in cross-section is configured, for example, in the shape of a cone and the central axis of the cone has an angle range of between 10° and 30° to the vertical and, in the case of a perpendicularly arranged membrane, preferably also to the membrane.
As already mentioned at the start, the nebulising device, and in particular the membrane, is arranged in the flow channel such that air may flow around it. This flow-around portion of the flow channel is preferably configured in the radial direction between the membrane and the body in such a manner that a cross-sectional area of the flow-around portion substantially corresponds to the smallest cross-sectional area of a line of the ventilation device that leads to the patient, even though minor deviations are possible. The cross-sectional area of the flow portion is preferably larger than the smallest cross-section of a line, however is in any case at least almost the same. The cross-sectional area for adults is thereby in the range of approximately 400 mm 2 . For small children, the cross-sectional area is in the range of approximately 80 to 180 mm 2 . It is thereby prevented in the simplest manner that the flow resistance is increased too much owing to the integration of the nebuliser in the air supply and patient line and could lead to an impairment of the function of the ventilation device and/or the ventilation machine.
It is particularly preferred to hang the membrane in a frame surrounding the membrane by means of spokes, with the frame preferably also being circular or oval for reasons of flow technology, and preferably being configured with the same design as the membrane. Thus, a region though which a flow may pass is also formed between the frame and the membrane, and this region may form at least part of the flow-around portion of the flow channel. Further portions through which a flow may pass may optionally be provided between the frame and the body, and these portions may supplement the part of the flow-around portion provided between the membrane and the frame so as to achieve the desired cross-sectional area for the flow-around portion. Furthermore, the dead space resulting owing to the nebulisation chamber can be reduced by this design and the cross-section of the flow channel past the nebulising device can at the same time be increased without significantly increasing the external dimensions of the nebuliser.
In order to further increase the efficiency of the system, it may be preferred to control the nebuliser by way of a common or cooperating control with the ventilation device so that nebulisation of the fluid and thus aerosol generation can only be triggered during an inhalation cycle, i.e. nebulisation by the nebulising device only occurs when the patient inhales, be it assisted or forced by the ventilation device.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and features of the present invention, which can be combined alone or in combination with the above features, are apparent from the following description of preferred embodiments. This description is carried out with reference to the accompanying drawings, in which:
FIG. 1 shows a perspective view of a nebuliser according to a first embodiment, which is schematically coupled to a ventilation device;
FIG. 2 shows a top view of the nebuliser of FIG. 1 ;
FIG. 3 shows an upside down side view of the nebuliser in FIG. 1 ;
FIG. 4 shows a longitudinal section through the nebuliser of FIG. 1 along the line A-A in FIG. 2 ;
FIG. 5 shows a longitudinal section of the nebuliser of FIG. 1 along line B-B in FIG. 3 ;
FIGS. 6 a - f show (a) a longitudinal section through the nebuliser of FIG. 1 along line A-A in FIG. 2 and (b) a longitudinal section of the nebuliser of FIG. 1 along line B-B in FIG. 3 , both with a fluid flow during an inhalation cycle, and (c)-(d) show the same sections during an exhalation cycle, and (e)-(f) show the same sections between an exhalation cycle and an inhalation cycle;
FIG. 7 shows a longitudinal section though a nebuliser according to a second embodiment corresponding to the section in FIG. 4 ;
FIG. 8 schematically shows an alternative fluid container according to the invention; and
FIG. 9 schematically shows a further alternative of a fluid container according to the invention.
DETAILED DESCRIPTION
In the different views, the same or corresponding elements are provided with identical reference numbers.
The nebuliser of the first embodiment as shown in FIGS. 1 to 5 is composed of three main components: a first body part 1 , a second body part 2 and a nebulising device 3 . The first and second body parts 1 and 2 , which together form the body, are preferably made of plastic and are preferably produced in an injection moulding process.
The first body part 1 comprises a first connection 10 , which is composed of two connecting pieces 11 , 12 . As is apparent from FIG. 1 , the first connecting piece 11 is configured so as to connect with an air supply line of the ventilation device 100 . The second connecting piece 12 is in turn coupled to an air exhaust line 102 of the ventilation device 100 . The air supply line 101 and the air exhaust line 102 are thereby each formed by a separate tube (not shown), which may have, for example, an inner diameter of 22 mm for adults or an inner diameter of 10 mm and 15 mm for children. The connecting pieces 11 , 12 are each configured such that it is possible to couple these conventional tubes to the connecting pieces. A bypass 13 is furthermore formed in the first body part 1 , said bypass being arranged before (i.e. upstream in the direction of flow of the respiratory air) the nebulising device 3 . This bypass ensures that a basic flow generated by the ventilation device 100 to regulate the respiratory air to a patient 104 can flow, outside of an inhalation cycle and/or an exhalation cycle of the patient 104 , directly from the air supply line 101 into the air exhaust line 102 via the connecting piece 11 , the bypass 13 and the connecting piece 12 , without passing the nebulising device 3 (cf. FIGS. 6 e and f ). This basic flow has flow rate of up to 30 l/min. This basic flow is often also referred to as a “bias flow”.
The first body part 1 furthermore also comprises a fluid container 14 for receiving a fluid to be nebulised. Possible fluids that are preferably in liquid form in the present embodiment are listed after the description of the preferred embodiments. The fluid container 14 is preferably an integral component of the first body part 1 , however, it may also be configured such that it can be partially or completely coupled and uncoupled. It is also conceivable that the fluid container does not directly accommodate the fluid to be nebulised but rather that a device, for example a spike, is provided in the fluid container so as to open, for example pierce, an ampoule that can be inserted into the fluid container, out of which the fluid to be nebulised can be supplied to the nebulising device 3 and the later described fluid chamber 24 .
According to the shown embodiment, the fluid container 14 has a substantially cylindrical portion 15 that has a substantially circular cross-section. An external screw thread 16 is formed on the outer circumferential surface of the cylindrical portion 15 at the end of the cylindrical portion 15 which is facing away from the nebulising device 3 . An internal screw thread 17 of a lid 18 , which is formed on the inner circumferential surface of the lid 18 , can be engaged with this external screw thread 16 so that the lid 18 can be screwed onto the cylindrical portion 15 of the fluid container 14 . The lid furthermore comprises a circumferential collar 19 on its inner surface, which, when the lid 18 is screwed on, sealingly engages, either directly or indirectly via a sealing material, with the inner surface of the cylindrical portion 14 . Furthermore, the cylindrical portion 15 comprises a surrounding groove 20 , in which one end of a lid securing means 21 (see FIG. 1 ) can be fixed, the other end of which can be attached to the mushroom-shaped projection 22 of the lid 8 .
A tapering portion 23 is located at the end of the cylindrical portion 15 which is facing away from the lid, said tapering portion tapering in the direction of the nebulising device 3 and opening out into a fluid chamber 24 . In the shown embodiment, the tapered portion 23 is composed in cross-section of a wall 26 extending substantially parallel to the progression of the later described membrane 37 as well as a wall 25 extending at an angle of between 40 and 50° to the vertical and/or to the membrane 37 , and has a substantially conical form. The peak of the cone is thereby substantially in the fluid chamber 24 .
A fluid container 14 filled with fluid F is visible, for example, in FIG. 1 .
The first body part 1 furthermore comprises a surrounding collar 27 at its opposite end to the first connection 10 , which collar 27 can be coupled to the second body part 2 (see below). A sealing material 28 is injection moulded radially inside this collar 27 or is produced in a two-component process together with the first body part 1 that is made of a hard resilient plastic. This sealing material 28 comprises a circumferential projection 29 . Also provided is a surrounding sealing lip 30 that abuts the fluid chamber 24 and is pressed against the membrane 37 for sealing such that the fluid chamber 24 is tightly sealed by the membrane 37 and the sealing lip 30 .
The second body part 2 comprises the second connection 31 , which is formed by a connecting piece 32 . This connecting piece 32 is preferably designed in a similar manner to the tube to be respectively connected to the connecting pieces 11 and 12 , which forms lines 101 and 102 . By means hereof, it can be ensured that the shown nebuliser can only be integrated into the ventilation device in the proper manner. Other designs for achieving this are also conceivable. It is only important that the connections 31 and 10 are not designed in an identical manner in order to rule out the possibility that one of lines 101 , 102 , each formed by tubes, is connected to the connecting piece 32 or that the second line 103 that leads to the patient 104 is connected to one of the connecting pieces 11 or 12 .
The second body part 2 further comprises a plurality of locking means distributed over its circumference, in this case locking catches 33 . In the shown embodiment, six such locking catches 33 or snap-in hooks are provided. However, fewer or more such devices are also conceivable. The locking catches 33 are thereby designed in such a manner that in the assembled state, they can be engaged with the surrounding collar 27 of the first body part 1 in that they grip behind the collar 27 so that the first and second body parts 1 and 2 can be connected with one another. Radially inside the locking means 33 , the second body part 2 furthermore comprises two surrounding, concentrically arranged webs 34 and 35 which are adapted in terms of their distance in the radial direction to the width of the projection 29 of the sealing material 28 in the radial direction such that upon engagement of the first and second body parts 1 and 2 , a labyrinth seal is formed between the projection 29 and the two webs 34 and 35 .
The second body part 2 furthermore comprises at least two, preferably four and possibly more supporting projections 36 for holding the aerosol generator 3 (nebulising device) (see below). These are uniformly arranged over the circumference of the second locking body 2 in pairs diametrically opposite one another and in the case of four elements, each at 90° intervals.
The second body may be designed so as to be rotationally symmetrical such that it can be connected to the first body part 1 at any orientation about its central axis.
The nebulising device 3 comprises a membrane 37 having a plurality of minute openings or holes in the micro range, which completely penetrate the membrane. The membrane 37 is preferably vibratable by means of a piezoelectric member, i.e. it can be caused to oscillate. Owing to the oscillation of the membrane, liquid on one side of the membrane, i.e. from the fluid chamber 24 , will pass through the openings (not shown) and, on the other side of the membrane 37 , is nebulised into a nebulisation chamber 38 formed in the body. This general principle is explained in more detail for example in U.S. Pat. No. 5,518,179, and thus a detailed description of this mode of operation will not be provided here.
According to the invention, the membrane 37 , which is a flat and even element, is held in a frame (not shown) by means of spokes (not shown in the drawings). The membrane 37 and the frame are designed so as to be substantially circular or annular. According to the preferred embodiment, the frame is insert-moulded with a soft resilient material 40 , which is the same as or similar to the sealing material 38 and which surrounds the frame as well as parts of its connection 41 , shown in FIG. 5 , for control and power supply of the nebulising device 3 . Except for the spokes along the entire circumference of the membrane, a clearance 42 is formed between the membrane 37 and the radially inner circumferential surface of the frame surrounding the membrane 37 , which consists of the frame and the insert mould 40 , said clearance forming part of a flow-around portion in the flow channel of the body 1 , 2 that is explained later.
Furthermore, with the exception of the region of the connection 41 , a further clearance 43 is formed in the assembled state between the outer surface of the frame, which consists of the insert mould 40 and the frame, and the inner circumferential surface of the body (here the first body part), said clearance 43 forming a further part of the mentioned flow-around portion. For assembly, the nebulising device 3 , which is pre-assembled, is aligned with the connection 41 according to a recess and is inserted into the first body part 1 , whereby the surrounding sealing lip 30 surrounds the part of the membrane 37 which is provided with openings. The second body part 2 is then attached, whereby the projections 36 press against the frame insert-moulded with the resilient material 40 and urge it in the direction of the first body part 1 . The nebulising device 3 is thereby pushed in the direction of the sealing lip 30 and the membrane is thus pushed against this surrounding sealing lip 30 such that a seal is formed against the membrane or the area surrounding the membrane and the fluid chamber 24 is tightly sealed. The nebuliser is supplied ready-assembled and can also not be opened or taken apart.
Furthermore, the concentric webs 34 and 35 engage with projection 29 of the sealing material 28 and form the labyrinth seal, with the pressure of the seals against the corresponding components being maintained owing to the locking of the locking catches 33 by gripping behind the collar 27 . In the region of connection 41 , where part of the nebulising device exits the body 1 , 2 , a seal occurs between the soft resilient plastic 40 and the webs of the second locking part 2 and a projection 44 surrounding a recess in the first locking part 1 for receiving the connection 41 , such that a sufficient seal is also provided here.
In the assembled state, the body 1 , 2 forms a flow channel from connection 10 via connecting piece 11 to the second connection 31 which consists of connecting piece 32 , whereby air flows around the nebulising device 3 along flow-around channels 42 , 43 . The direction of flow or the airflow during the inhalation phase is shown by means of arrows in FIGS. 6 a and b , and the direction of flow or the airflow during the exhalation phase is shown by means of arrows in FIGS. 6 c and d . It is thereby apparent that the direction of flow into the connecting piece 11 and out of the connecting piece 32 is the same and that the membrane 37 and/or the plane in which the membrane 37 lies is arranged perpendicular to this direction of flow or to the central axis of the respective connecting piece 11 , 12 or 31 . In the shown embodiment, this results in a fluid contained in the fluid container 14 being nebulised through the openings of the membrane into the nebulisation chamber 38 in the direction of flow, i.e. parallel thereto. The deposition of fluid on the surfaces of the flow channel or in the subsequent tubes is consequently reduced and the efficiency of the system is increased.
This design furthermore allows a bias flow to flow from the air supply line 101 into the air exhaust line 102 via the bypass 13 without passing the nebulising device 3 and in particular the nebulisation chamber 38 , and thus this bias flow does not flush any aerosol (nebulised fluid) generated by the nebulising device 3 into the air exhaust line 102 outside of an inhalation cycle and/or exhalation cycle, as a result of which the efficiency of the system is further increased (see FIGS. 6 e and f ).
A unit that is stable against tilting is furthermore formed by the three connecting pieces 11 , 12 and 32 and the integral connection of the fluid container 14 to the body 1 , 2 , said tilt-stable unit being of benefit for the flow behaviour of the preferably liquid fluid out of the fluid container 14 into the fluid chamber 24 and up to the membrane 37 . A uniform and consistent supply of the fluid is furthermore facilitated by the design of the tapered portion 23 and in particular the incline of the wall 25 , and thus even if the nebuliser shown in FIG. 4 is rotated about the central axis of the connecting piece 32 by 45° in one of the two directions, the presence of the liquid on the membrane 37 can still be reliably ensured.
The cross-sectional area of the flow-around channel 42 and 43 is thereby designed such that it is not significantly smaller than and is not significantly larger (the latter so as not to create an unnecessarily large dead volume that must be displaced during exhalation by the patient in the case of assisted respiration) than the smallest cross-sectional area in the lines of the ventilation device that lead to the patient 104 (lines 101 and 103 ). The lines leading to the patient 103 can be composed of a so-called catheter mount (double swivel connector) and an endotracheal tube. This prevents an increased flow resistance as well as an increased dead volume, which can both have a negative effect on the functionality of the ventilation device.
Furthermore, a tightness is achieved owing to the sealing material 28 and the insert mould 40 of the frame 39 , which can also withstand a pressure of up to 100 mbar. Owing to the use of the membrane with the minute openings, a pressure loss in the system when the fluid container 14 is open is also ruled out. A flow out of the flow channel and into the fluid container 14 is not possible through the minute openings.
The nebulising device 3 can furthermore be coupled to the control of the ventilation device 100 via the connection 41 so as to trigger the nebulising device 3 only in the inhalation cycle. That is to say only when the patient 104 inhales, be it assisted or forced by the ventilation device 100 , is the membrane vibrated so that nebulisation of the fluid F in the fluid container 14 occurs. The efficiency can thereby be increased even further.
As was explained with reference to the first embodiment, the air supply line 101 and the air exhaust line 102 in the shown nebuliser are each formed by a separate tube, with the tubes being coupled to the connecting pieces 11 and 12 , respectively. In the second and alternative embodiment as shown in FIG. 7 , the first connection 10 comprises only one connecting piece 45 , into which a corresponding connecting piece 105 of a first line 101 , 102 of the ventilation device 100 can be inserted. It is also apparent from FIG. 7 that the second connection 31 comprises a connecting piece 32 having dimensions which are substantially identical to the connecting piece 105 so that the nebuliser of the present invention can be coupled into existing tube systems without any problems and can also only be assembled with the intended orientation. The lines 101 (air supply/air exhaust), 102 (air exhaust/air supply) are hereby formed in a common tube in the form of a coaxial tube, with the air supply line 101 being formed by a tube having a smaller diameter that is arranged in a tube 102 having a larger diameter and is held concentrically by means of a holder 107 . The air exhaust line is formed by the clearance between the inner tube and the outer wall of the outer tube 101 . The design can, however, also be reversed, as indicated above. The front face 106 of the inner tube 101 that is directed towards the nebuliser ends at a distance ahead of the membrane 37 and the nebulisation chamber 38 such that the bypass 13 (shown by means of arrows in FIG. 7 ) is formed in the clearance between the front face 106 and the nebulising device 3 .
The embodiment according to FIG. 7 does not otherwise significantly differ from the embodiment in FIGS. 1 to 6 , and thus no further explanation will be provided and reference is merely made to the embodiment as described above.
It is obvious that the present invention is not limited to the described embodiments but that various modifications may be carried out. For example, instead of the coaxial tube of FIG. 7 , a tube may also be provided with a partition so as to form the two lines 101 , 102 . A third variant is a system consisting of two tubes (air supply and air exhaust) that are inseparably connected to a Y-piece. The installation situation of the aerosol generating means in this case also corresponds to FIG. 7 . Instead of arranging the membrane 37 vertically, it is also conceivable to arrange it perpendicular to the direction of flow at a certain gradient that may deviate by up to 45° from the vertical. It is mainly important that the nebulising device in the form of the membrane lies in the flow path and that air passes around it. According to the invention, the fluid container is designed differently, with the fluid container not necessarily having to accommodate the fluid itself, but may rather have appropriate devices so as to accommodate a container directly containing the fluid, or the fluid container may itself be designed such that it can be coupled and uncoupled via an interface. For example, the tapered portion 121 in FIG. 8 could be sealed facing away from the membrane and provided with a hollow needle 122 which, upon coupling of the cylindrical portion 120 , opens a valve 123 that may consist of a ball 126 and a device which urges the ball 126 against a valve seat, for example a spring 125 that rests upon a fixed bearing 124 in the cylindrical portion 120 , which can also be referred to herein as an ampoule, at its end facing away from the valve seat, as a result of which the fluid can flow all at once or gradually into the fluid chamber 24 or the tapered part 121 . The valve can thereby be automatically opened, for example directly upon placement of the cylindrical part 120 on the tapered part 121 , for example by means of a screw thread 127 , as soon as a substantially sealing connection between these elements has been established (see the schematic representation in FIG. 8 ). The provision of a spike 128 is also conceivable, via which an ampoule 129 , which contains the fluid, is pierced. The latter is schematically shown in FIG. 9 , whereby the spike pierces the bottom 130 of the ampoule 129 and folds it back so that fluid can flow into the fluid chamber 24 . The spike is configured hollow for this purpose.
Furthermore, the use of a different nebulising device to the one shown is, in principle, also conceivable, for example nozzle nebulisers could also be used provided that the direction of nebulisation is substantially in, i.e. parallel to, the direction of flow between connections 10 and 31 . It is furthermore also conceivable to arrange the nebuliser in the line 101 and to design the connection of lines 101 , 102 and 103 via a Y-piece. However, efficiency is then reduced since the bias flow would always transport aerosol into the air exhaust line 102 unless a triggering of the nebulising device 3 in accordance with the inhalation cycle is provided so that during the bias flow, nebulisation does not occur without inhalation. It would also be conceivable, in principle, to arrange the nebuliser after a Y-piece, i.e. the nebuliser such as shown in FIG. 7 could be directly connected to a Y-piece, i.e. between the y-piece and the line 103 (catheter mount and endotracheal tube) as well as the lines 101 , 102 that are coupled to the Y-piece. However, in particular the integration of the Y-piece and nebuliser, as is described in the first embodiment, is particularly preferred.
Finally, the following active ingredient classes or substances can be nebulised by the nebuliser of the present invention, however this list is not exhaustive:
The active compounds include, for example, substances selected from the group consisting of anti-inflammatory compounds, glucocorticoids, anti-allergy medicaments, antioxidants, vitamins, leukotriene antagonists, anti-infective agents, antibiotics, antifungicides, antiviral agents, mucolytic agents, decongestants, antiseptics, cytostatic agents, immunomodulators, vaccines, wound-healing agents, local anaesthetics, oligonucleotides, peptides, proteins and plant extracts.
Examples of possibly useful anti-inflammatory compounds are glucocorticoids and non-steroidal anti-inflammatory agents, such as betamethasone, beclomethasone, budesonide, ciclesonide, dexamethasone, desoxymethasone, fluoconolone acetonide, flucinonide, flunisolide, fluticasone, icomethasone, rofleponide, triamcinolone acetonide, fluorcortin butyl, hydrocortisone, hydroxycortisone-17-butyrate, prednicarbate, 6-methylprednisolone aceponate, mometasone furoate, dehydroepiandrosterone sulphate (DHEAS), elastane, prostaglandin, leukotrine, bradykinin antagonists, non-steroidal anti-inflammatory drugs (NSAIDs), such as ibuprofen, including all pharmaceutically acceptable salts, esters, isomers, stereoisomers, diastereomers, epimers, solvates or other hydrates thereof, prodrugs, derivatives or any other chemical or physical forms of effective compounds, which comprise the corresponding effective residues.
Examples of anti-infective agents, the class or therapeutic category of which is understood herein as including compounds that are effective against bacterial, fungal and viral infections, i.e. including the classes of microbicides, antibiotics, fungicides, antiseptics and anti-viral agents, are
penicillins, including benzylpenicillins (penicillin G sodium, clemizone penicillin, benzathine penicillin G), phenoxypenicillins (penicillin V, propicillin), amino-benzylpenicillins (ampicillin, amoxicillin, bacampicillin), acylaminopenicillins (azlocillin, mezlocillin, piperacillin, apalcillin), carboxypenicillins (carbenicillin, ticarcillin, temocillin), isoxazolylpenicillins (oxacillin, cloxacillin, dicloxacillin, flucloxacillin), and amiidine penicillins (mecillinam); cephalosporins, including cefazolins (cefazolin, cefazedone); cefuroximes (cerufoxime, cefamdole, cefotiam), cefoxitins (cefoxitin, cefotetan, latamoxef, flomoxef), cefotaximes (cefotaxime, ceftriaxone, ceftizoxime, cefmenoxime), ceftazidimes (ceftazidime, cefpirome, cefepime), cefalexins (cefalexin, cefaclor, cefadroxil, cefradine, loracarbef, cefprozil) and cefiximes (cefixime, cefpodoxime proxetil, cefuroxime axetil, cefetamet pivoxil, cefotiam hexetil), loracarbef, cefepime, clavulanic acid/amoxicillin, ceftobiprole; synergists, including beta-lactamase inhibitors, such as clavulanic acid, sulbactam and tazobactam; carbapenems, including imipenem, cilastin, meropenem, doripenem, tebipenem, ertapenem, ritipenam and biapenem; monobactams, including aztreonam; aminoglycosides such as apramycin, gentamicin, amikacin, isepamicin, arbekacin, tobramycin, netilmicin, spectinomycin, streptomycin, capreomycin, neomycin, paromoycin and kanamycin; macrolides, including erythromycin, clarithromycin, roxithromycin, azithromycin, dithromycin, josamycin, spiramycin and telithromycin; gyrase inhibitors or fluroquinolones, including ciprofloxacin, gatifloxacin, norfloacin, ofloxycin, levofloxacin, perfloxacin, lomefloxacin, garenoxacin, clinafloxacin, sitafloxacin, prulifloxacin, olamufloxacin, caderofloxacin, gemifloxacin, balofloxacin, trovafloxacin and moxifloxacin; tetracyclines, including tetracycline, oxytetracycline, rolitetracycline, minocycline, doxycycline, tigecycline and aminocycline; glycopeptides, including vacomycin, teicoplanin, ristocetin, avoparcin, oritavancin, ramoplanin and peptide 4; polypeptides, including plectasin, dalbavancin, daptomycin, oritavancin, ramoplanin, dalbavancin, telavancin, bacitracin, tyrothricin, neomycin, kanamycin, mupirocin, paromomycin, polymyxin B and colistin; sulfonamides, including sulfadiazine, sulfamethoxazole, sulfalene, co-trimoxazole, co-trimetrol, co-trimoxazine, co-tetraxazine; azoles, including clotrimazole, oxiconazole, miconazole, ketoconazole, itraconazole, fluconazole, metronidazole, tinidazole, bifonazole, ravuconazole, posaconazole, voriconazole and ornidazole and other anti-fungicides including flucytosine, griseofluvine, tonoftal, naftifine, terbinafine, amorolfine, ciclopiroxolamine, echinocandin, such as micafungin, caspofungin, anidulafungin; nitrofurans, including nitrofurantoin and nitrofuranzone; polyenes, including amphotericin B, natamycin, nystatin, flucocytosine; other antibiotics, including tithromycin, lincomycin, clindamycin, oxazolindiones (linzezolids), ranbezolid, streptogramin A+B, pristinamycin aA+B, virginiamycin A+B, dalfopristin/quinupristin (synercid), chloramphenicol, ethambutol, pyrazinamide, terizidone, dapsone, prothionamide, fosfomycin, fucidic acid, rifampicin, isoniazid, cycloserine, terizidone, ansamycin, lysostaphin, iclaprim, mirocin B17, clerocidin, filgrastim and pentamidine; antiviral agents, including aziclovir, ganciclovir, birivudin, valaciclovir, zidovudine, didanosine, thiacytidine, stavudine, lamivudine, zalcitabine, ribavirin, nevirapirine, delaviridine, trifluridine, ritonavir, saquinavir, indinavir, foscarnet, amantadine, podophyllotoxin, vidarabine, tromantadine and proteinase inhibitors; antiseptics, including acridine derivatives, iodine povidone, benzoates, rivanol, chlorhexidine, quaternary ammonium compounds, cetrimides, biphenylol, chlorophene and octenidine; plant extracts or components, such as plant extracts of camomile, hamamelis, Echinacea, calendula, thyme, papain, pelargonium, pine trees, essential oils, myrtol, pinene, limonene, cineole, thymol, menthol, camphor, tannin, alpha-hederin, bisabolol, lycopodine, vitapherole; wound-healing compounds, including dexpanthenol, allantoin, vitamins, hyaluronic acid, alpha-antitrypsin, inorganic and organic zinc salts/compounds, bismuth salts and selenium salts; interferons (alpha, beta, gamma), tumour necrosis factors, cytokines, interleukins; immunomodulators, including methotrexate, azathioprine, cyclosporine, tacrolismus, sirolismus, rapamycin, mofetil, mofetil-mycophenolate; cytostatic agents and metastasis inhibitors; alkylating agents, such as nimustine, melphanalan, carmustine, lomustine, cyclophosphosphamide, ifosfamide, trofosamide, chlorambucil, busulfan, treosulfan, prednimustine, thiotepa; anti-metabolites, for example cytarabine, fluorouracil, methotrexate, mercaptopurine, thioguanine; alkaloids such as vinblastine, vincristine, vindesine; antibiotics such as, for example, alcarubicin, bleomycin, dactinomycin, daunorubicin, doxorubicin, epirubicin, idarubicin, mitomycin, plicamycin; complexes of elements of the transition groups (for example, Ti, Zr, V, Nb, Ta, Mo, W, Pt) such as carboplatin, cis-platin and metallocene compounds such as, for example, titanocene dichloride; amsacrine, dacarbazine, estramustine, etoposide, beraprost, hydroxycarbamide, mitoxanthrone, procarbazine, temiposide; paclitaxel, iressa, zactima, poly-ADP-ribose-polymerase (PRAP) enzyme inhibitors, banoxantrone, gemcitabine, pemetrexed, bevacizumab, ranibizumab.
Examples of potentially useful mucolytic agents are DNase, P2Y2-agonists (denufosol), medicaments that affect the penetration of chlorine and sodium, such as, for example, N-(3,5-diamino-6-chloropyrazine-2-carbonyl)-N′-{4-[4-(2,3-dihydroxypropoxy)-phenyl]butyl}guanidine-methane sulfonate (PARION 552-02) heparinoids, guaifenesin, acetylcysteine, carbocysteine, ambroxol, bromhexine, tyloxapol, lecithins, myrtol and recombinant surfactant proteins.
Examples of potentially useful vasoconstrictors and decongestants that may be useful for reducing swelling of the mucous membrane are phenylephrine, naphazoline, tramazoline, tetryzoline, oxymetazoline, fenoxazoline, xylometazoline, epinephrine, isoprenaline, hexoprenaline and ephedrine.
Examples of potentially useful local anaesthetics include benzocaine, tetracaine, procaine, lidocaine and bupivacaine.
Examples of potentially useful anti-allergy agents include the aforementioned glucocorticoids, cromolyn sodium, nedocromil, cetrizine, loratidine, montelukast, roflumilast, ziluton, omalizumab, heparinoids and other antihistamines, including azelastine, cetirizine, desloratadine, ebastine, fexofenadine, levocetirizine, loratadine.
Antisense oligonucleotides are short, synthetic strands of DNA (or analogues) which are complementary or opposite to the target sequence (DNA, RNA) and which are designed such that they stop a biological process such as transcription, translation or splicing. The inhibition of gene expression hereby caused makes oligonucleotides useful for the treatment of many illnesses, depending on their composition, and numerous compounds are currently being clinically tested, such as, for example, ALN-RSV01 for the treatment of respiratory syncytial virus, AVE-7279 for the treatment of asthma and allergies, TPI-ASM8 for the treatment of allergic asthma and 1018-ISS for the treatment of cancer.
Examples of potentially useful peptides and proteins include amino acids, such as, for example, L-arginine, L-lysine, antibodies to toxins produced by microorganisms, antimicrobial peptides such as cecropins, defensins, thionins and cathelicidins.
For each of these and other explicitly mentioned examples of medicinal substances that are potentially useful for carrying out the invention, the compound names specified herein should be understood as also including any pharmaceutically acceptable salts, solvates or other hydrates, prodrugs, isomers or any other chemical or physical forms of the relevant compounds which contain the corresponding active residues. | Atomizer for a ventilation machine with a ventilator, including a body with a first connection for connecting the atomizer to a ventilator and a second connection for connecting the atomizer to a line leading to a patient, wherein the body forms a flow channel from the first connection to the second connection; and an atomizing device for atomizing a fluid; wherein the atomizing device is disposed between the first connection and the second connection in the flow channel and adapted so that the fluid can be atomized substantially parallel to, and preferably in, the flow direction from the first connection to the second connection. | Identify the most important aspect in the document and summarize the concept accordingly. | [
"CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. application Ser.",
"No. 12/990,994 filed Feb. 1, 2011, which is a 371 of PCT/EP2009/055469 filed May 6, 2009, now U.S. Pat. No. 8,720,435, which claims the priority benefit of German Appln.",
"No. 10 2008 022 987.3 filed May 9, 2008, which are hereby incorporated by reference to the maximum extent allowable by law.",
"FIELD OF THE INVENTION The present invention relates to nebulisers for ventilation machines and in particular to nebulisers for introducing an active ingredient in aerosol form into the respiratory air that is supplied to a patient for assisted or substitute ventilation.",
"A nebuliser is hereby to be understood as any device for generating an aerosol.",
"A ventilation machine is to be understood as a ventilation device that supplies patients intubated or tracheotomised using an endotracheal tube with a flaw of air of up to 120 l/min, preferably between 1 and 50 l/min, at a pressure of between 0 and 100 mbar and preferably between 3 and 45 mbar.",
"The present invention furthermore also relates to a ventilation machine comprising such a nebuliser.",
"BACKGROUND Nebulisers for ventilation machines are well known in the prior art.",
"For example, WO 2005/048982 A2 discloses such a nebuliser.",
"This nebuliser comprises a body having a first connection that comprises two connecting pieces for connecting the nebuliser to an air supply line and an air exhaust line of the ventilation device.",
"Opposite the first connection, the body comprises a second connection that again has two connecting pieces which are to be connected via a Y-piece and two tubes with a line leading to the patient.",
"Two separate flow channels that are connected via a connecting channel are formed in the body, one (first one) of which serves the flow of respiratory air from the air supply line to the patient and the other (second one) of which serves the flow of consumed air from the patient into the air exhaust line.",
"A non-return valve that allows a flow solely in the direction of the patient is disposed in the first flow channel upstream of a connection of a nebulising device to the first flow channel.",
"Furthermore, the nebulising device is coupled perpendicular, similar to a T connection, to the first flow channel, with the aerosol being supplied in a direction perpendicular to the direction of flow in this first flow channel.",
"The problem with this design is on the one hand that owing to the non-return valve, an element is integrated in the air supply line, i.e. in the line that leads to the patient, which could have serious consequences should it malfunction.",
"There is on the other hand the problem that the aerosol is introduced into the flow perpendicular to the direction of flow of the respiratory air through the body, and thus a high deposition of the aerosol on the surfaces of the flow channel occurs, which has a high loss associated therewith.",
"It is known from other fields of technology to prevent deposition of the aerosol on surfaces in particular of the nebulisation chamber in that the nebulising device nebulises in a direction that is parallel to a flow towards the patient.",
"US-A-2003/0072717, for example, discloses an inhalation device wherein a nebulising device is arranged in a closed and bypassed housing.",
"The housing is disposed in a flow channel of the inhalator, which comprises a mouthpiece.",
"The nebulising device thereby nebulises in the direction of the mouthpiece.",
"However, dead volumes, flow resistance by the nebulising device as well as the filling thereof only play minor roles therein.",
"In ventilation machines, however, the nebulisers must meet predefined criteria in this regard.",
"EP-A-1 818 070 also discloses an inhalation therapy device having such a nebulisation direction, in this case, however, for premature babies.",
"The system (requires the patient to be able to breathe on their own and) is specifically adapted to the small line cross-sections with an inner diameter of between 2 mm and 3.5 mm for premature babies such that air may easily pass around the nebulisation device without flow resistance occurring.",
"Furthermore, since the patient is able to breathe on their own, the system operates at a low pressure of up to 15 mbar.",
"Moreover, filling of the nebuliser with a fluid to be nebulised is not necessary or intended when the system is in operation since operation can be interrupted for filling and/or a loss in pressure in the system can be accepted without risk.",
"Therefore, the above-described and comparable systems from the prior art were not transferable for use in ventilation machines.",
"SUMMARY The object of the present invention is therefore to create a nebuliser for ventilation machines, wherein the deposition of aerosol on the surfaces of the flow channel and the losses associated therewith are reduced and failures of vulnerable elements can be avoided.",
"The mode of operation of the ventilation machine must at the same time not be impaired by the nebuliser, i.e. no flow resistance may be generated, the nebuliser must be airtight at a certain positive pressure (for example 100 mbar), filling of the nebuliser with the fluid to be nebulised must also be possible during operation of the ventilation device without a loss in pressure in the system, and a dead space in the nebuliser must not take up too much volume, etc.",
"This object is solved by a nebuliser having the features of patent claim 1 .",
"Advantageous further developments of the present invention are mentioned in the sub-claims.",
"The idea forming the basis for the present invention is to reposition the nebulising device in the flow channel such that the aerosol generation occurs by nebulising the fluid parallel to the direction of flow in the flow channel, instead of coupling the nebulising device perpendicular to the direction of flow by means of a T-piece-like arrangement, such as is the case in the prior art.",
"The present invention accordingly proposes a nebuliser for ventilation machines, which comprises a body having a first connection for connecting (for example indirectly via a tube) the nebuliser to a ventilation device and a second connection for connecting (for example indirectly via a tube) the nebuliser to a line leading to the patient, said body forming a flow channel, and in particular only one flow channel, from the first connection to the second connection.",
"That is to say, in a specific embodiment, the body forms only one flow channel, through which respiratory air flows from the first connection to the second connection during inhalation and consumed air flows from the second connection to the first connection during exhalation.",
"The line that leads to the patient can be composed of the so-called catheter mount (double swivel connector) and the endotracheal tube as well as optionally of other elements.",
"In a specific embodiment, the connection to the ventilation device can be effected by way of both the air supply line for supplying respiratory air as well as the air exhaust line for expelling consumed air such that the nebuliser simultaneously forms a Y-piece.",
"However, it goes without saying that the first connection of the body may also be connected only to the air supply line, such that a possible Y-piece is arranged only downstream of the second connection.",
"The nebuliser of the present invention furthermore comprises a nebulising device for nebulising a fluid.",
"The fluid is preferably a liquid composition that preferably contains at least one active ingredient (see below).",
"A nebulising device is to be understood as any aerosol generator or producer by means of which the fluid can be transformed into an aerosol form.",
"According to the invention, the nebuliser is characterised in that the nebulising device is disposed in the flow channel between the first connection and the second connection, and is configured such that the fluid can be nebulised substantially parallel to, and preferably in, the direction of flow from the first connection to the second connection.",
"In other words, respiratory air passes around the nebulising device in the inhalation cycle and the fluid to be nebulised is nebulised parallel to, and preferably in, the direction of the respiratory air flow such that an aerosol flow is generated parallel to, preferably in, the direction of flow of the first respiratory air, as a result of which the impaction and thus deposition on surfaces in the flow channel is reduced and the aerosol can be supplied to the line system and transported to the patient with the smallest amount of loss possible.",
"The wording “substantially”",
"is to be understood in this respect such that the aerosol flow may also have a deviation of up to 45° to the direction of flow of the respiratory air.",
"So as to regulate the respiratory air, ventilation devices produce a continuous basic flow (a so-called “bias flow”).",
"Outside of an inhalation cycle, wherein respiratory air is transported to the patient via the air supply line, this bias flow, which may be in the magnitude of up to 30 l/min, normally flows directly into the air exhaust line from the air supply line.",
"To achieve this without the bias flow passing the nebulising device and nebulised fluid thus permanently flowing into the air exhaust line, which would lead to a significant inefficiency of the system, the nebuliser of the present invention preferably comprises a first connection that is designed to connect with an air supply line coming from the ventilation device and an air exhaust line leading to the ventilation device in such a manner that a side-flow channel (bypass) from the air supply line to the air exhaust line is formed on the side of the nebulising device that is opposite the second connection.",
"The air supply line and the air exhaust line can thereby be formed by a common tube that is divided into two sections.",
"This division may be formed either by a partition in the tube or by a coaxial tube, i.e. two tubes arranged one inside the other.",
"The common tube is to be connected to the first connection of the nebuliser.",
"The first connection and the common tube are thereby configured in such a manner that a bypass is formed between the nebulising device and the front face of the partition and/or of the inner tube of the coaxial tube, which is facing the nebulising device.",
"The bypass allows the bias flow to flow, outside of an inhalation cycle, directly into the air exhaust line from the air supply line without flushing any possibly nebulised fluid into the air exhaust line.",
"The efficiency of the system can be significantly improved as a result.",
"It is, of course, alternatively also conceivable for the air supply line and the air exhaust line to each be formed by a separate tube.",
"In this design, it is preferred for the first connection to have a first connecting piece for connection to the air supply line and a second connecting piece for connection to the air exhaust line, each of which may be formed by a tube.",
"The bypass is then formed in the body itself between the first connecting piece and the second connecting piece and, outside of an inhalation cycle, allows a flow from the air supply line into the air exhaust line.",
"This design furthermore leads to a tilt-stable unit of the nebuliser being formed by the two connecting pieces and the opposite second connection.",
"As already mentioned at the start, the nebuliser must also allow filling of a fluid container during ventilation without a loss of pressure in the system.",
"Therefore a vibrating membrane (oscillating membrane) is Preferably used as the nebulising device, the membrane being provided with a plurality of openings (micro openings) for nebulising the fluid.",
"The membrane is preferably arranged perpendicular to the direction of flow from the first connection to the second connection so as to achieve nebulisation in the direction of flow or parallel to the direction of flow.",
"The wording “substantially”",
"is to be understood in this respect such that the membrane may also be arranged in the flow channel at a slight gradient deviating by up to 45° from the perpendicular.",
"From the point of view of flow technology, the membrane is thereby preferably designed so as to be circular, however it may also be oval.",
"Owing to this design of the aerosol generator (nebulising device) with a membrane comprising very small openings, through which a flow out of the flow channel and out of the system is not possible, it is ensured in a simple manner that a loss in pressure via the nebulising device is prevented, even when the fluid container is opened, for example the lid of the fluid container is unscrewed for filling.",
"Furthermore, a fluid container for receiving the fluid to be nebulised, which is connected to the body, is provided, as is a nebulisation chamber into which the fluid is to be nebulised, with the membrane being arranged between the fluid container and the nebulisation chamber.",
"The fluid container is connected to the body in such a manner that it can be coupled and uncoupled.",
"Instead of directly accommodating the fluid, the fluid container may also have a fluid communication interface and be configured to receive a fluid-containing ampoule that comes into fluid connection with the fluid container via the fluid communication interface.",
"The fluid communication interface may, for example, be formed by an opening device (a hollow spike) and may be configured to receive a fluid-containing ampoule to be opened by the opening device, similar to that described, for example, in WO 2007/020073 for a conventional nebuliser/aerosol generator, to which reference is made for further details.",
"It is also conceivable for the fluid container to have a hollow needle and for a valve to be provided in the ampoule, which is opened by the needle when the ampoule is received by the fluid container.",
"In order to further minimise deposition and thus loss at the surfaces of the flow channel, it is, as mentioned, particularly preferred to nebulise the fluid in the inhalation cycle in the direction of flow of the respiratory air, for which purpose the nebulisation chamber is preferably disposed between the membrane and the second connection that is to be connected to the line leading to the patient.",
"It is furthermore necessary for the fluid container to supply a constant dosage to the nebuliser membrane up to a gradient of 45° in every direction about the direction of flow from the first to the second connection so that a reliable and uniform nebulisation or aerosol generation can take place.",
"For this purpose, the unit consisting of the body and the fluid container can, as already mentioned, on the one hand be configured in a tilt-stable manner by the two connecting pieces and the opposite second connection.",
"To further meet this requirement, it is, however, preferred for the fluid container to have a tapering in the direction of the membrane, which opens out into a fluid chamber that is closed by the membrane, with the tapering extending at least obliquely from a cylindrical portion of the fluid container to the fluid chamber.",
"It is particularly preferred for a partial section of the tapering that is facing away from the membrane to extend with an angle range of between 10° and 40° to the vertical and, in the case of a perpendicularly arranged membrane, preferably also to the membrane, i.e. a lower portion of the fluid container that is closed in cross-section is configured, for example, in the shape of a cone and the central axis of the cone has an angle range of between 10° and 30° to the vertical and, in the case of a perpendicularly arranged membrane, preferably also to the membrane.",
"As already mentioned at the start, the nebulising device, and in particular the membrane, is arranged in the flow channel such that air may flow around it.",
"This flow-around portion of the flow channel is preferably configured in the radial direction between the membrane and the body in such a manner that a cross-sectional area of the flow-around portion substantially corresponds to the smallest cross-sectional area of a line of the ventilation device that leads to the patient, even though minor deviations are possible.",
"The cross-sectional area of the flow portion is preferably larger than the smallest cross-section of a line, however is in any case at least almost the same.",
"The cross-sectional area for adults is thereby in the range of approximately 400 mm 2 .",
"For small children, the cross-sectional area is in the range of approximately 80 to 180 mm 2 .",
"It is thereby prevented in the simplest manner that the flow resistance is increased too much owing to the integration of the nebuliser in the air supply and patient line and could lead to an impairment of the function of the ventilation device and/or the ventilation machine.",
"It is particularly preferred to hang the membrane in a frame surrounding the membrane by means of spokes, with the frame preferably also being circular or oval for reasons of flow technology, and preferably being configured with the same design as the membrane.",
"Thus, a region though which a flow may pass is also formed between the frame and the membrane, and this region may form at least part of the flow-around portion of the flow channel.",
"Further portions through which a flow may pass may optionally be provided between the frame and the body, and these portions may supplement the part of the flow-around portion provided between the membrane and the frame so as to achieve the desired cross-sectional area for the flow-around portion.",
"Furthermore, the dead space resulting owing to the nebulisation chamber can be reduced by this design and the cross-section of the flow channel past the nebulising device can at the same time be increased without significantly increasing the external dimensions of the nebuliser.",
"In order to further increase the efficiency of the system, it may be preferred to control the nebuliser by way of a common or cooperating control with the ventilation device so that nebulisation of the fluid and thus aerosol generation can only be triggered during an inhalation cycle, i.e. nebulisation by the nebulising device only occurs when the patient inhales, be it assisted or forced by the ventilation device.",
"BRIEF DESCRIPTION OF THE DRAWINGS Further advantages and features of the present invention, which can be combined alone or in combination with the above features, are apparent from the following description of preferred embodiments.",
"This description is carried out with reference to the accompanying drawings, in which: FIG. 1 shows a perspective view of a nebuliser according to a first embodiment, which is schematically coupled to a ventilation device;",
"FIG. 2 shows a top view of the nebuliser of FIG. 1 ;",
"FIG. 3 shows an upside down side view of the nebuliser in FIG. 1 ;",
"FIG. 4 shows a longitudinal section through the nebuliser of FIG. 1 along the line A-A in FIG. 2 ;",
"FIG. 5 shows a longitudinal section of the nebuliser of FIG. 1 along line B-B in FIG. 3 ;",
"FIGS. 6 a - f show (a) a longitudinal section through the nebuliser of FIG. 1 along line A-A in FIG. 2 and (b) a longitudinal section of the nebuliser of FIG. 1 along line B-B in FIG. 3 , both with a fluid flow during an inhalation cycle, and (c)-(d) show the same sections during an exhalation cycle, and (e)-(f) show the same sections between an exhalation cycle and an inhalation cycle;",
"FIG. 7 shows a longitudinal section though a nebuliser according to a second embodiment corresponding to the section in FIG. 4 ;",
"FIG. 8 schematically shows an alternative fluid container according to the invention;",
"and FIG. 9 schematically shows a further alternative of a fluid container according to the invention.",
"DETAILED DESCRIPTION In the different views, the same or corresponding elements are provided with identical reference numbers.",
"The nebuliser of the first embodiment as shown in FIGS. 1 to 5 is composed of three main components: a first body part 1 , a second body part 2 and a nebulising device 3 .",
"The first and second body parts 1 and 2 , which together form the body, are preferably made of plastic and are preferably produced in an injection moulding process.",
"The first body part 1 comprises a first connection 10 , which is composed of two connecting pieces 11 , 12 .",
"As is apparent from FIG. 1 , the first connecting piece 11 is configured so as to connect with an air supply line of the ventilation device 100 .",
"The second connecting piece 12 is in turn coupled to an air exhaust line 102 of the ventilation device 100 .",
"The air supply line 101 and the air exhaust line 102 are thereby each formed by a separate tube (not shown), which may have, for example, an inner diameter of 22 mm for adults or an inner diameter of 10 mm and 15 mm for children.",
"The connecting pieces 11 , 12 are each configured such that it is possible to couple these conventional tubes to the connecting pieces.",
"A bypass 13 is furthermore formed in the first body part 1 , said bypass being arranged before (i.e. upstream in the direction of flow of the respiratory air) the nebulising device 3 .",
"This bypass ensures that a basic flow generated by the ventilation device 100 to regulate the respiratory air to a patient 104 can flow, outside of an inhalation cycle and/or an exhalation cycle of the patient 104 , directly from the air supply line 101 into the air exhaust line 102 via the connecting piece 11 , the bypass 13 and the connecting piece 12 , without passing the nebulising device 3 (cf.",
"FIGS. 6 e and f ).",
"This basic flow has flow rate of up to 30 l/min.",
"This basic flow is often also referred to as a “bias flow.”",
"The first body part 1 furthermore also comprises a fluid container 14 for receiving a fluid to be nebulised.",
"Possible fluids that are preferably in liquid form in the present embodiment are listed after the description of the preferred embodiments.",
"The fluid container 14 is preferably an integral component of the first body part 1 , however, it may also be configured such that it can be partially or completely coupled and uncoupled.",
"It is also conceivable that the fluid container does not directly accommodate the fluid to be nebulised but rather that a device, for example a spike, is provided in the fluid container so as to open, for example pierce, an ampoule that can be inserted into the fluid container, out of which the fluid to be nebulised can be supplied to the nebulising device 3 and the later described fluid chamber 24 .",
"According to the shown embodiment, the fluid container 14 has a substantially cylindrical portion 15 that has a substantially circular cross-section.",
"An external screw thread 16 is formed on the outer circumferential surface of the cylindrical portion 15 at the end of the cylindrical portion 15 which is facing away from the nebulising device 3 .",
"An internal screw thread 17 of a lid 18 , which is formed on the inner circumferential surface of the lid 18 , can be engaged with this external screw thread 16 so that the lid 18 can be screwed onto the cylindrical portion 15 of the fluid container 14 .",
"The lid furthermore comprises a circumferential collar 19 on its inner surface, which, when the lid 18 is screwed on, sealingly engages, either directly or indirectly via a sealing material, with the inner surface of the cylindrical portion 14 .",
"Furthermore, the cylindrical portion 15 comprises a surrounding groove 20 , in which one end of a lid securing means 21 (see FIG. 1 ) can be fixed, the other end of which can be attached to the mushroom-shaped projection 22 of the lid 8 .",
"A tapering portion 23 is located at the end of the cylindrical portion 15 which is facing away from the lid, said tapering portion tapering in the direction of the nebulising device 3 and opening out into a fluid chamber 24 .",
"In the shown embodiment, the tapered portion 23 is composed in cross-section of a wall 26 extending substantially parallel to the progression of the later described membrane 37 as well as a wall 25 extending at an angle of between 40 and 50° to the vertical and/or to the membrane 37 , and has a substantially conical form.",
"The peak of the cone is thereby substantially in the fluid chamber 24 .",
"A fluid container 14 filled with fluid F is visible, for example, in FIG. 1 .",
"The first body part 1 furthermore comprises a surrounding collar 27 at its opposite end to the first connection 10 , which collar 27 can be coupled to the second body part 2 (see below).",
"A sealing material 28 is injection moulded radially inside this collar 27 or is produced in a two-component process together with the first body part 1 that is made of a hard resilient plastic.",
"This sealing material 28 comprises a circumferential projection 29 .",
"Also provided is a surrounding sealing lip 30 that abuts the fluid chamber 24 and is pressed against the membrane 37 for sealing such that the fluid chamber 24 is tightly sealed by the membrane 37 and the sealing lip 30 .",
"The second body part 2 comprises the second connection 31 , which is formed by a connecting piece 32 .",
"This connecting piece 32 is preferably designed in a similar manner to the tube to be respectively connected to the connecting pieces 11 and 12 , which forms lines 101 and 102 .",
"By means hereof, it can be ensured that the shown nebuliser can only be integrated into the ventilation device in the proper manner.",
"Other designs for achieving this are also conceivable.",
"It is only important that the connections 31 and 10 are not designed in an identical manner in order to rule out the possibility that one of lines 101 , 102 , each formed by tubes, is connected to the connecting piece 32 or that the second line 103 that leads to the patient 104 is connected to one of the connecting pieces 11 or 12 .",
"The second body part 2 further comprises a plurality of locking means distributed over its circumference, in this case locking catches 33 .",
"In the shown embodiment, six such locking catches 33 or snap-in hooks are provided.",
"However, fewer or more such devices are also conceivable.",
"The locking catches 33 are thereby designed in such a manner that in the assembled state, they can be engaged with the surrounding collar 27 of the first body part 1 in that they grip behind the collar 27 so that the first and second body parts 1 and 2 can be connected with one another.",
"Radially inside the locking means 33 , the second body part 2 furthermore comprises two surrounding, concentrically arranged webs 34 and 35 which are adapted in terms of their distance in the radial direction to the width of the projection 29 of the sealing material 28 in the radial direction such that upon engagement of the first and second body parts 1 and 2 , a labyrinth seal is formed between the projection 29 and the two webs 34 and 35 .",
"The second body part 2 furthermore comprises at least two, preferably four and possibly more supporting projections 36 for holding the aerosol generator 3 (nebulising device) (see below).",
"These are uniformly arranged over the circumference of the second locking body 2 in pairs diametrically opposite one another and in the case of four elements, each at 90° intervals.",
"The second body may be designed so as to be rotationally symmetrical such that it can be connected to the first body part 1 at any orientation about its central axis.",
"The nebulising device 3 comprises a membrane 37 having a plurality of minute openings or holes in the micro range, which completely penetrate the membrane.",
"The membrane 37 is preferably vibratable by means of a piezoelectric member, i.e. it can be caused to oscillate.",
"Owing to the oscillation of the membrane, liquid on one side of the membrane, i.e. from the fluid chamber 24 , will pass through the openings (not shown) and, on the other side of the membrane 37 , is nebulised into a nebulisation chamber 38 formed in the body.",
"This general principle is explained in more detail for example in U.S. Pat. No. 5,518,179, and thus a detailed description of this mode of operation will not be provided here.",
"According to the invention, the membrane 37 , which is a flat and even element, is held in a frame (not shown) by means of spokes (not shown in the drawings).",
"The membrane 37 and the frame are designed so as to be substantially circular or annular.",
"According to the preferred embodiment, the frame is insert-moulded with a soft resilient material 40 , which is the same as or similar to the sealing material 38 and which surrounds the frame as well as parts of its connection 41 , shown in FIG. 5 , for control and power supply of the nebulising device 3 .",
"Except for the spokes along the entire circumference of the membrane, a clearance 42 is formed between the membrane 37 and the radially inner circumferential surface of the frame surrounding the membrane 37 , which consists of the frame and the insert mould 40 , said clearance forming part of a flow-around portion in the flow channel of the body 1 , 2 that is explained later.",
"Furthermore, with the exception of the region of the connection 41 , a further clearance 43 is formed in the assembled state between the outer surface of the frame, which consists of the insert mould 40 and the frame, and the inner circumferential surface of the body (here the first body part), said clearance 43 forming a further part of the mentioned flow-around portion.",
"For assembly, the nebulising device 3 , which is pre-assembled, is aligned with the connection 41 according to a recess and is inserted into the first body part 1 , whereby the surrounding sealing lip 30 surrounds the part of the membrane 37 which is provided with openings.",
"The second body part 2 is then attached, whereby the projections 36 press against the frame insert-moulded with the resilient material 40 and urge it in the direction of the first body part 1 .",
"The nebulising device 3 is thereby pushed in the direction of the sealing lip 30 and the membrane is thus pushed against this surrounding sealing lip 30 such that a seal is formed against the membrane or the area surrounding the membrane and the fluid chamber 24 is tightly sealed.",
"The nebuliser is supplied ready-assembled and can also not be opened or taken apart.",
"Furthermore, the concentric webs 34 and 35 engage with projection 29 of the sealing material 28 and form the labyrinth seal, with the pressure of the seals against the corresponding components being maintained owing to the locking of the locking catches 33 by gripping behind the collar 27 .",
"In the region of connection 41 , where part of the nebulising device exits the body 1 , 2 , a seal occurs between the soft resilient plastic 40 and the webs of the second locking part 2 and a projection 44 surrounding a recess in the first locking part 1 for receiving the connection 41 , such that a sufficient seal is also provided here.",
"In the assembled state, the body 1 , 2 forms a flow channel from connection 10 via connecting piece 11 to the second connection 31 which consists of connecting piece 32 , whereby air flows around the nebulising device 3 along flow-around channels 42 , 43 .",
"The direction of flow or the airflow during the inhalation phase is shown by means of arrows in FIGS. 6 a and b , and the direction of flow or the airflow during the exhalation phase is shown by means of arrows in FIGS. 6 c and d .",
"It is thereby apparent that the direction of flow into the connecting piece 11 and out of the connecting piece 32 is the same and that the membrane 37 and/or the plane in which the membrane 37 lies is arranged perpendicular to this direction of flow or to the central axis of the respective connecting piece 11 , 12 or 31 .",
"In the shown embodiment, this results in a fluid contained in the fluid container 14 being nebulised through the openings of the membrane into the nebulisation chamber 38 in the direction of flow, i.e. parallel thereto.",
"The deposition of fluid on the surfaces of the flow channel or in the subsequent tubes is consequently reduced and the efficiency of the system is increased.",
"This design furthermore allows a bias flow to flow from the air supply line 101 into the air exhaust line 102 via the bypass 13 without passing the nebulising device 3 and in particular the nebulisation chamber 38 , and thus this bias flow does not flush any aerosol (nebulised fluid) generated by the nebulising device 3 into the air exhaust line 102 outside of an inhalation cycle and/or exhalation cycle, as a result of which the efficiency of the system is further increased (see FIGS. 6 e and f ).",
"A unit that is stable against tilting is furthermore formed by the three connecting pieces 11 , 12 and 32 and the integral connection of the fluid container 14 to the body 1 , 2 , said tilt-stable unit being of benefit for the flow behaviour of the preferably liquid fluid out of the fluid container 14 into the fluid chamber 24 and up to the membrane 37 .",
"A uniform and consistent supply of the fluid is furthermore facilitated by the design of the tapered portion 23 and in particular the incline of the wall 25 , and thus even if the nebuliser shown in FIG. 4 is rotated about the central axis of the connecting piece 32 by 45° in one of the two directions, the presence of the liquid on the membrane 37 can still be reliably ensured.",
"The cross-sectional area of the flow-around channel 42 and 43 is thereby designed such that it is not significantly smaller than and is not significantly larger (the latter so as not to create an unnecessarily large dead volume that must be displaced during exhalation by the patient in the case of assisted respiration) than the smallest cross-sectional area in the lines of the ventilation device that lead to the patient 104 (lines 101 and 103 ).",
"The lines leading to the patient 103 can be composed of a so-called catheter mount (double swivel connector) and an endotracheal tube.",
"This prevents an increased flow resistance as well as an increased dead volume, which can both have a negative effect on the functionality of the ventilation device.",
"Furthermore, a tightness is achieved owing to the sealing material 28 and the insert mould 40 of the frame 39 , which can also withstand a pressure of up to 100 mbar.",
"Owing to the use of the membrane with the minute openings, a pressure loss in the system when the fluid container 14 is open is also ruled out.",
"A flow out of the flow channel and into the fluid container 14 is not possible through the minute openings.",
"The nebulising device 3 can furthermore be coupled to the control of the ventilation device 100 via the connection 41 so as to trigger the nebulising device 3 only in the inhalation cycle.",
"That is to say only when the patient 104 inhales, be it assisted or forced by the ventilation device 100 , is the membrane vibrated so that nebulisation of the fluid F in the fluid container 14 occurs.",
"The efficiency can thereby be increased even further.",
"As was explained with reference to the first embodiment, the air supply line 101 and the air exhaust line 102 in the shown nebuliser are each formed by a separate tube, with the tubes being coupled to the connecting pieces 11 and 12 , respectively.",
"In the second and alternative embodiment as shown in FIG. 7 , the first connection 10 comprises only one connecting piece 45 , into which a corresponding connecting piece 105 of a first line 101 , 102 of the ventilation device 100 can be inserted.",
"It is also apparent from FIG. 7 that the second connection 31 comprises a connecting piece 32 having dimensions which are substantially identical to the connecting piece 105 so that the nebuliser of the present invention can be coupled into existing tube systems without any problems and can also only be assembled with the intended orientation.",
"The lines 101 (air supply/air exhaust), 102 (air exhaust/air supply) are hereby formed in a common tube in the form of a coaxial tube, with the air supply line 101 being formed by a tube having a smaller diameter that is arranged in a tube 102 having a larger diameter and is held concentrically by means of a holder 107 .",
"The air exhaust line is formed by the clearance between the inner tube and the outer wall of the outer tube 101 .",
"The design can, however, also be reversed, as indicated above.",
"The front face 106 of the inner tube 101 that is directed towards the nebuliser ends at a distance ahead of the membrane 37 and the nebulisation chamber 38 such that the bypass 13 (shown by means of arrows in FIG. 7 ) is formed in the clearance between the front face 106 and the nebulising device 3 .",
"The embodiment according to FIG. 7 does not otherwise significantly differ from the embodiment in FIGS. 1 to 6 , and thus no further explanation will be provided and reference is merely made to the embodiment as described above.",
"It is obvious that the present invention is not limited to the described embodiments but that various modifications may be carried out.",
"For example, instead of the coaxial tube of FIG. 7 , a tube may also be provided with a partition so as to form the two lines 101 , 102 .",
"A third variant is a system consisting of two tubes (air supply and air exhaust) that are inseparably connected to a Y-piece.",
"The installation situation of the aerosol generating means in this case also corresponds to FIG. 7 .",
"Instead of arranging the membrane 37 vertically, it is also conceivable to arrange it perpendicular to the direction of flow at a certain gradient that may deviate by up to 45° from the vertical.",
"It is mainly important that the nebulising device in the form of the membrane lies in the flow path and that air passes around it.",
"According to the invention, the fluid container is designed differently, with the fluid container not necessarily having to accommodate the fluid itself, but may rather have appropriate devices so as to accommodate a container directly containing the fluid, or the fluid container may itself be designed such that it can be coupled and uncoupled via an interface.",
"For example, the tapered portion 121 in FIG. 8 could be sealed facing away from the membrane and provided with a hollow needle 122 which, upon coupling of the cylindrical portion 120 , opens a valve 123 that may consist of a ball 126 and a device which urges the ball 126 against a valve seat, for example a spring 125 that rests upon a fixed bearing 124 in the cylindrical portion 120 , which can also be referred to herein as an ampoule, at its end facing away from the valve seat, as a result of which the fluid can flow all at once or gradually into the fluid chamber 24 or the tapered part 121 .",
"The valve can thereby be automatically opened, for example directly upon placement of the cylindrical part 120 on the tapered part 121 , for example by means of a screw thread 127 , as soon as a substantially sealing connection between these elements has been established (see the schematic representation in FIG. 8 ).",
"The provision of a spike 128 is also conceivable, via which an ampoule 129 , which contains the fluid, is pierced.",
"The latter is schematically shown in FIG. 9 , whereby the spike pierces the bottom 130 of the ampoule 129 and folds it back so that fluid can flow into the fluid chamber 24 .",
"The spike is configured hollow for this purpose.",
"Furthermore, the use of a different nebulising device to the one shown is, in principle, also conceivable, for example nozzle nebulisers could also be used provided that the direction of nebulisation is substantially in, i.e. parallel to, the direction of flow between connections 10 and 31 .",
"It is furthermore also conceivable to arrange the nebuliser in the line 101 and to design the connection of lines 101 , 102 and 103 via a Y-piece.",
"However, efficiency is then reduced since the bias flow would always transport aerosol into the air exhaust line 102 unless a triggering of the nebulising device 3 in accordance with the inhalation cycle is provided so that during the bias flow, nebulisation does not occur without inhalation.",
"It would also be conceivable, in principle, to arrange the nebuliser after a Y-piece, i.e. the nebuliser such as shown in FIG. 7 could be directly connected to a Y-piece, i.e. between the y-piece and the line 103 (catheter mount and endotracheal tube) as well as the lines 101 , 102 that are coupled to the Y-piece.",
"However, in particular the integration of the Y-piece and nebuliser, as is described in the first embodiment, is particularly preferred.",
"Finally, the following active ingredient classes or substances can be nebulised by the nebuliser of the present invention, however this list is not exhaustive: The active compounds include, for example, substances selected from the group consisting of anti-inflammatory compounds, glucocorticoids, anti-allergy medicaments, antioxidants, vitamins, leukotriene antagonists, anti-infective agents, antibiotics, antifungicides, antiviral agents, mucolytic agents, decongestants, antiseptics, cytostatic agents, immunomodulators, vaccines, wound-healing agents, local anaesthetics, oligonucleotides, peptides, proteins and plant extracts.",
"Examples of possibly useful anti-inflammatory compounds are glucocorticoids and non-steroidal anti-inflammatory agents, such as betamethasone, beclomethasone, budesonide, ciclesonide, dexamethasone, desoxymethasone, fluoconolone acetonide, flucinonide, flunisolide, fluticasone, icomethasone, rofleponide, triamcinolone acetonide, fluorcortin butyl, hydrocortisone, hydroxycortisone-17-butyrate, prednicarbate, 6-methylprednisolone aceponate, mometasone furoate, dehydroepiandrosterone sulphate (DHEAS), elastane, prostaglandin, leukotrine, bradykinin antagonists, non-steroidal anti-inflammatory drugs (NSAIDs), such as ibuprofen, including all pharmaceutically acceptable salts, esters, isomers, stereoisomers, diastereomers, epimers, solvates or other hydrates thereof, prodrugs, derivatives or any other chemical or physical forms of effective compounds, which comprise the corresponding effective residues.",
"Examples of anti-infective agents, the class or therapeutic category of which is understood herein as including compounds that are effective against bacterial, fungal and viral infections, i.e. including the classes of microbicides, antibiotics, fungicides, antiseptics and anti-viral agents, are penicillins, including benzylpenicillins (penicillin G sodium, clemizone penicillin, benzathine penicillin G), phenoxypenicillins (penicillin V, propicillin), amino-benzylpenicillins (ampicillin, amoxicillin, bacampicillin), acylaminopenicillins (azlocillin, mezlocillin, piperacillin, apalcillin), carboxypenicillins (carbenicillin, ticarcillin, temocillin), isoxazolylpenicillins (oxacillin, cloxacillin, dicloxacillin, flucloxacillin), and amiidine penicillins (mecillinam);",
"cephalosporins, including cefazolins (cefazolin, cefazedone);",
"cefuroximes (cerufoxime, cefamdole, cefotiam), cefoxitins (cefoxitin, cefotetan, latamoxef, flomoxef), cefotaximes (cefotaxime, ceftriaxone, ceftizoxime, cefmenoxime), ceftazidimes (ceftazidime, cefpirome, cefepime), cefalexins (cefalexin, cefaclor, cefadroxil, cefradine, loracarbef, cefprozil) and cefiximes (cefixime, cefpodoxime proxetil, cefuroxime axetil, cefetamet pivoxil, cefotiam hexetil), loracarbef, cefepime, clavulanic acid/amoxicillin, ceftobiprole;",
"synergists, including beta-lactamase inhibitors, such as clavulanic acid, sulbactam and tazobactam;",
"carbapenems, including imipenem, cilastin, meropenem, doripenem, tebipenem, ertapenem, ritipenam and biapenem;",
"monobactams, including aztreonam;",
"aminoglycosides such as apramycin, gentamicin, amikacin, isepamicin, arbekacin, tobramycin, netilmicin, spectinomycin, streptomycin, capreomycin, neomycin, paromoycin and kanamycin;",
"macrolides, including erythromycin, clarithromycin, roxithromycin, azithromycin, dithromycin, josamycin, spiramycin and telithromycin;",
"gyrase inhibitors or fluroquinolones, including ciprofloxacin, gatifloxacin, norfloacin, ofloxycin, levofloxacin, perfloxacin, lomefloxacin, garenoxacin, clinafloxacin, sitafloxacin, prulifloxacin, olamufloxacin, caderofloxacin, gemifloxacin, balofloxacin, trovafloxacin and moxifloxacin;",
"tetracyclines, including tetracycline, oxytetracycline, rolitetracycline, minocycline, doxycycline, tigecycline and aminocycline;",
"glycopeptides, including vacomycin, teicoplanin, ristocetin, avoparcin, oritavancin, ramoplanin and peptide 4;",
"polypeptides, including plectasin, dalbavancin, daptomycin, oritavancin, ramoplanin, dalbavancin, telavancin, bacitracin, tyrothricin, neomycin, kanamycin, mupirocin, paromomycin, polymyxin B and colistin;",
"sulfonamides, including sulfadiazine, sulfamethoxazole, sulfalene, co-trimoxazole, co-trimetrol, co-trimoxazine, co-tetraxazine;",
"azoles, including clotrimazole, oxiconazole, miconazole, ketoconazole, itraconazole, fluconazole, metronidazole, tinidazole, bifonazole, ravuconazole, posaconazole, voriconazole and ornidazole and other anti-fungicides including flucytosine, griseofluvine, tonoftal, naftifine, terbinafine, amorolfine, ciclopiroxolamine, echinocandin, such as micafungin, caspofungin, anidulafungin;",
"nitrofurans, including nitrofurantoin and nitrofuranzone;",
"polyenes, including amphotericin B, natamycin, nystatin, flucocytosine;",
"other antibiotics, including tithromycin, lincomycin, clindamycin, oxazolindiones (linzezolids), ranbezolid, streptogramin A+B, pristinamycin aA+B, virginiamycin A+B, dalfopristin/quinupristin (synercid), chloramphenicol, ethambutol, pyrazinamide, terizidone, dapsone, prothionamide, fosfomycin, fucidic acid, rifampicin, isoniazid, cycloserine, terizidone, ansamycin, lysostaphin, iclaprim, mirocin B17, clerocidin, filgrastim and pentamidine;",
"antiviral agents, including aziclovir, ganciclovir, birivudin, valaciclovir, zidovudine, didanosine, thiacytidine, stavudine, lamivudine, zalcitabine, ribavirin, nevirapirine, delaviridine, trifluridine, ritonavir, saquinavir, indinavir, foscarnet, amantadine, podophyllotoxin, vidarabine, tromantadine and proteinase inhibitors;",
"antiseptics, including acridine derivatives, iodine povidone, benzoates, rivanol, chlorhexidine, quaternary ammonium compounds, cetrimides, biphenylol, chlorophene and octenidine;",
"plant extracts or components, such as plant extracts of camomile, hamamelis, Echinacea, calendula, thyme, papain, pelargonium, pine trees, essential oils, myrtol, pinene, limonene, cineole, thymol, menthol, camphor, tannin, alpha-hederin, bisabolol, lycopodine, vitapherole;",
"wound-healing compounds, including dexpanthenol, allantoin, vitamins, hyaluronic acid, alpha-antitrypsin, inorganic and organic zinc salts/compounds, bismuth salts and selenium salts;",
"interferons (alpha, beta, gamma), tumour necrosis factors, cytokines, interleukins;",
"immunomodulators, including methotrexate, azathioprine, cyclosporine, tacrolismus, sirolismus, rapamycin, mofetil, mofetil-mycophenolate;",
"cytostatic agents and metastasis inhibitors;",
"alkylating agents, such as nimustine, melphanalan, carmustine, lomustine, cyclophosphosphamide, ifosfamide, trofosamide, chlorambucil, busulfan, treosulfan, prednimustine, thiotepa;",
"anti-metabolites, for example cytarabine, fluorouracil, methotrexate, mercaptopurine, thioguanine;",
"alkaloids such as vinblastine, vincristine, vindesine;",
"antibiotics such as, for example, alcarubicin, bleomycin, dactinomycin, daunorubicin, doxorubicin, epirubicin, idarubicin, mitomycin, plicamycin;",
"complexes of elements of the transition groups (for example, Ti, Zr, V, Nb, Ta, Mo, W, Pt) such as carboplatin, cis-platin and metallocene compounds such as, for example, titanocene dichloride;",
"amsacrine, dacarbazine, estramustine, etoposide, beraprost, hydroxycarbamide, mitoxanthrone, procarbazine, temiposide;",
"paclitaxel, iressa, zactima, poly-ADP-ribose-polymerase (PRAP) enzyme inhibitors, banoxantrone, gemcitabine, pemetrexed, bevacizumab, ranibizumab.",
"Examples of potentially useful mucolytic agents are DNase, P2Y2-agonists (denufosol), medicaments that affect the penetration of chlorine and sodium, such as, for example, N-(3,5-diamino-6-chloropyrazine-2-carbonyl)-N′-{4-[4-(2,3-dihydroxypropoxy)-phenyl]butyl}guanidine-methane sulfonate (PARION 552-02) heparinoids, guaifenesin, acetylcysteine, carbocysteine, ambroxol, bromhexine, tyloxapol, lecithins, myrtol and recombinant surfactant proteins.",
"Examples of potentially useful vasoconstrictors and decongestants that may be useful for reducing swelling of the mucous membrane are phenylephrine, naphazoline, tramazoline, tetryzoline, oxymetazoline, fenoxazoline, xylometazoline, epinephrine, isoprenaline, hexoprenaline and ephedrine.",
"Examples of potentially useful local anaesthetics include benzocaine, tetracaine, procaine, lidocaine and bupivacaine.",
"Examples of potentially useful anti-allergy agents include the aforementioned glucocorticoids, cromolyn sodium, nedocromil, cetrizine, loratidine, montelukast, roflumilast, ziluton, omalizumab, heparinoids and other antihistamines, including azelastine, cetirizine, desloratadine, ebastine, fexofenadine, levocetirizine, loratadine.",
"Antisense oligonucleotides are short, synthetic strands of DNA (or analogues) which are complementary or opposite to the target sequence (DNA, RNA) and which are designed such that they stop a biological process such as transcription, translation or splicing.",
"The inhibition of gene expression hereby caused makes oligonucleotides useful for the treatment of many illnesses, depending on their composition, and numerous compounds are currently being clinically tested, such as, for example, ALN-RSV01 for the treatment of respiratory syncytial virus, AVE-7279 for the treatment of asthma and allergies, TPI-ASM8 for the treatment of allergic asthma and 1018-ISS for the treatment of cancer.",
"Examples of potentially useful peptides and proteins include amino acids, such as, for example, L-arginine, L-lysine, antibodies to toxins produced by microorganisms, antimicrobial peptides such as cecropins, defensins, thionins and cathelicidins.",
"For each of these and other explicitly mentioned examples of medicinal substances that are potentially useful for carrying out the invention, the compound names specified herein should be understood as also including any pharmaceutically acceptable salts, solvates or other hydrates, prodrugs, isomers or any other chemical or physical forms of the relevant compounds which contain the corresponding active residues."
] |
RELATED APPLICATIONS
The subject application is a U.S. National Stage application that claims the priority of International Application No. PCT/IE2006/000061, filed on 02 Jun. 2006.
TECHNICAL FIELD
This invention relates to forklift trucks, and in particular to forklift trucks designed to be carried on another vehicle of the type generally known as “truck mounted forklifts”.
BACKGROUND ART
Forklift trucks designed to be carried on the rear of a vehicle are well known. Such forklift trucks are usually stowed by securing the forks of the forklift truck to the body of the vehicle and then elevating the body of the forklift truck relative to the forks so that the forklift truck body is lifted off the ground for travel.
U.S. Pat. No. 5,482,141 describes a forklift truck of this type in which the forklift truck has an overhead chassis structure which can be converted between a working configuration and a stowage configuration. In the stowage configuration the hinged overhead chassis closes by folding and the forklift truck body length is reduced for storage and travel.
Such forklift trucks provide the advantage that the shorter body length makes the transport vehicle more stable during travel, but this is achieved by having to make the overhead chassis structure of the truck adjustable, at increased expense and with the possibility of reduced overall strength and integrity.
DISCLOSURE OF THE INVENTION
The invention provides a forklift truck comprising a truck body, a fork mechanism adapted to engage a load at one end of the body, and at least one wheel at an opposite end of the body, said at least one wheel being mounted on the body for translational movement relative to the body between a working position and a storage position.
In contrast to systems which propose folding the entire chassis the present invention achieves a reduction in truck length by retracting a rear wheel mounted at an end opposite to the forks of the truck. When the forklift truck is designed to be carried on the rear of another vehicle using the forks to mount the truck to that vehicle, the tractable wheel will normally be the rearmost protruding element of the combination. Retraction of that wheel does not significantly alter the balance of the truck but it does reduce the chance of damage to the wheel by a following or passing vehicle or when reversing.
This reduces the rear projection which in turn minimises tail swing and reduces the overall length of the transport vehicle.
Preferably, the at least one wheel is mounted on a moveable mounting member and the forklift truck further comprises retraction means for translationally moving said moveable mounting member relative to the body between said working and storage positions.
In a preferred embodiment the truck also includes a rigid chassis, wherein said retraction means is mounted on said rigid chassis for translationally moving said moveable mounting member relative to said rigid chassis.
The use of a retractable wheel on a rigid chassis demonstrates a different approach to the collapsible or foldable overhead chassis of the prior art.
Preferably, the moveable mounting member comprises a mounting plate which is slideable within a guide from a working position to a storage position.
In a preferred embodiment, the wheel is connected to said mounting plate by means of an arm to which the wheel is rotatably connected at the wheel hub, and wherein said arm is mounted by a swivel mounting to said mounting plate thereby enabling said wheel to be steered relative to the plate.
The truck preferably also includes a hub motor mounted between said arm and said hub for driving the wheel.
Preferably, said wheel is provided with a steering mechanism for rotating the plane of the wheel relative to the body and furthermore, said wheel is preferably mounted on the body with sufficient freedom to be rotated by the steering mechanism when the wheel is in its storage position by substantially 90 degrees from a normal straight-ahead position. By enabling the retraction movement to occur in combination with the rotation of the steering through 90 degrees, the wheel's rearward projection can be reduced even further.
It is particularly preferred, in this option, to rotate the steering in that direction which most reduces the extent of rearward projection. Thus where a motor or a mounting arm is mounted on one side of the wheel (causing a protrusion on that side) the wheel is preferably steered through 90 degrees to conceal that protrusion from projecting rearwardly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further illustrated with reference to the following description of embodiments thereof, given by way of example only with reference to the accompanying drawings, in which:
FIG. 1 is a side elevation of a forklift truck according to the invention;
FIG. 2 is a side elevation of the truck of FIG. 1 when attached to a heavy goods vehicle;
FIG. 3 is a cross sectional plan view of the truck of FIG. 1 with the wheel extended;
FIG. 4 is a cross sectional plan view of the truck of FIG. 2 when mounted on a heavy goods vehicle, with the wheel retracted; and
FIGS. 5-7 are perspective views of a detail of the truck of FIGS. 1-4 with the rear wheel progressively extended from a storage position to a working position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a side elevation of a forklift truck, indicated generally at 10 , having a chassis 12 , a driver cab 14 , a pair of front wheels 16 (the nearest of which can be seen in FIG. 1 ) at a front end of the forklift truck 10 , and a single rear wheel 18 at a rear end 19 of the forklift truck 10 . The driver cab is offset on one side of the front-to-rear centre line of the chassis and is situated at the side from which the view of FIG. 1 is taken. A telescopic boom 13 carrying a set of forks 15 is offset on the other side of the centre line (behind the cab in the view of FIG. 1 ). The forks are adapted to manipulate a load at the front end 17 of the forklift truck. This general arrangement of chassis, offset cab and offset telescopic boom is well known in the field of truck mounted forklifts.
As shown in FIG. 2 , the forklift truck 10 is adapted to be coupled to and carried by a heavy goods vehicle 20 . This is achieved by inserting the forks (not shown) into a receiving compartment of the heavy goods vehicle 20 and locking them in place, then activating the control to lower the forks which raises the forklift truck 10 body relative both to the forks and to the heavy goods vehicle until it reaches the position shown in FIG. 2 .
In order to decrease the rear projection (which is very important in most markets), the length 22 between the rearmost point 24 of the heavy goods vehicle 20 and the rearmost point 26 of the forklift truck 10 , the rear wheel 18 is extendable between a transit position and a working position.
FIG. 1 shows the rear wheel 18 in its working position (with the retracted position shown in dotted outline), while FIG. 2 shows the rear wheel 18 in its retracted position (with the working position shown in dotted outline).
FIG. 3 is a plan cross sectional view of the U-shaped chassis 12 and wheels 16 , 18 of the truck 10 . The rear wheel 18 is shown in its working position (and in dotted outline with reference numeral 18 ′ in its transit position). The centre of gravity 28 of the truck is shown along with an inner triangle 30 connecting the centres of the three wheels when rear wheel 18 ′ is in its transit configuration, and an outer triangle 32 connecting the centres of the wheel when rear wheel 18 is in its working position. This demonstrates that the “triangle of stability” is increased when the rear wheel is in its working position. The greater the distance the centre of gravity is from the edge of the stability triangle (L-L 1 ) the more stable the forklift is during operation. The larger the stability triangle the more stable the forklift is during operation.
FIG. 4 is cross sectional plan view of the truck when mounted on a heavy goods vehicle as shown in FIG. 2 , and FIG. 4 again shows the extent of rear projection 22 when the rear wheel 18 ′ is in its transit configuration. As will be further described below, the mechanism for retracting the wheel can be combined with a steering mechanism to turn the wheel through 90 degrees and thus move the rearmost point of projection even further forward.
FIGS. 5 , 6 and 7 provide a cutaway perspective view of the rear wheel along with its steering mechanism and the mechanism for retracting and extending the wheel between the transit and working positions.
The mechanism of FIGS. 5-7 provides an additional advantage to the general concept of retraction shown in FIGS. 1-4 . Whereas the wheel in FIGS. 1-4 is simply shown as being retracted without any rotation, the mechanism shown in FIGS. 5-7 actually allows the wheel not only to be retracted but also to be rotated by 90 degrees so that the radial plane of the wheel is parallel to the back of the forklift truck. Because the rear wheel is prevented from protruding outwards along the common longitudinal axis of the heavy goods vehicle and forklift truck, the overall length is decreased further.
FIG. 5 shows the wheel retracted and rotated into its transit position. FIG. 6 shows the wheel extended outward to the working position but still rotated parallel to the back of the forklift truck. FIG. 7 shows the wheel in its working position, after it has been rotated so that the radial plane of the wheel is parallel to the direction of normal movement of the truck when steering straight ahead.
As best seen in FIG. 7 , the wheel 18 is carried on an arm 36 which mounts the hub 37 of the wheel. A hydraulic motor (not visible) is integral with the hub and a hydraulic feed to that motor provides the driving mechanism for the wheel. The arm 36 terminates at its top end at a top plate 38 which is rotatable about a vertical axis by means of a hydraulic linkage 40 (see FIGS. 5 and 6 ). Hydraulic linkage 40 provides the steering mechanism for rotating the wheel 18 relative to the chassis 12 . This hydraulic linkage is functionally linked to the steering wheel in the driver's cab.
The top plate 38 of arm 36 is rotatably mounted on an orbital mounting plate 42 , so actuation of the hydraulic linkage 40 causes top plate 38 and orbital mounting plate 42 to rotate relative to one another. Orbital mounting plate 42 is prevented from rotation relative to the chassis by being mounted on a sliding plate 44 . Sliding plate 44 is slideably received between a pair of horizontal plates 46 , 48 which in turn are mounted on the chassis structure. Thus, plate 44 can slide back and forth to move the wheel between the retracted position shown in FIG. 5 and the working position shown in FIGS. 6 and 7 . Once the wheel is in the position shown in FIG. 6 , the hydraulic steering linkage 40 rotates the wheel about its vertical axis to the position shown in FIG. 7 .
A hydraulic retraction arm 50 controls this back and forth sliding movement. Hydraulic retraction arm 50 provides a linkage between a mounting point 52 connected to the chassis structure at one end, and the orbital mounting plate 42 and sliding plate 44 at the other end. A control (not shown) in the driver's cab actuates the hydraulic retraction arm 50 to retract or extend sliding plate 44 (and hence the wheel) between the positions of FIG. 5 and FIG. 6 .
The embodiment described above can be varied or modified as appropriate without departing from the scope of the claimed invention, including, in particular, by providing more than one rear wheel, provided that the rearmost wheel or wheels is retractable from a working position to a storage position in which the overall length of the truck is decreased. | A forklift truck ( 10 ) comprising a truck body, a fork mechanism at one end of the body, and at least one wheel ( 18 ) at an opposite end of the body, said at least one wheel ( 18 ) being mounted on the body for translational movement relative to the body between a working position and a storage position. | Provide a concise summary of the essential information conveyed in the given context. | [
"RELATED APPLICATIONS The subject application is a U.S. National Stage application that claims the priority of International Application No. PCT/IE2006/000061, filed on 02 Jun. 2006.",
"TECHNICAL FIELD This invention relates to forklift trucks, and in particular to forklift trucks designed to be carried on another vehicle of the type generally known as “truck mounted forklifts.”",
"BACKGROUND ART Forklift trucks designed to be carried on the rear of a vehicle are well known.",
"Such forklift trucks are usually stowed by securing the forks of the forklift truck to the body of the vehicle and then elevating the body of the forklift truck relative to the forks so that the forklift truck body is lifted off the ground for travel.",
"U.S. Pat. No. 5,482,141 describes a forklift truck of this type in which the forklift truck has an overhead chassis structure which can be converted between a working configuration and a stowage configuration.",
"In the stowage configuration the hinged overhead chassis closes by folding and the forklift truck body length is reduced for storage and travel.",
"Such forklift trucks provide the advantage that the shorter body length makes the transport vehicle more stable during travel, but this is achieved by having to make the overhead chassis structure of the truck adjustable, at increased expense and with the possibility of reduced overall strength and integrity.",
"DISCLOSURE OF THE INVENTION The invention provides a forklift truck comprising a truck body, a fork mechanism adapted to engage a load at one end of the body, and at least one wheel at an opposite end of the body, said at least one wheel being mounted on the body for translational movement relative to the body between a working position and a storage position.",
"In contrast to systems which propose folding the entire chassis the present invention achieves a reduction in truck length by retracting a rear wheel mounted at an end opposite to the forks of the truck.",
"When the forklift truck is designed to be carried on the rear of another vehicle using the forks to mount the truck to that vehicle, the tractable wheel will normally be the rearmost protruding element of the combination.",
"Retraction of that wheel does not significantly alter the balance of the truck but it does reduce the chance of damage to the wheel by a following or passing vehicle or when reversing.",
"This reduces the rear projection which in turn minimises tail swing and reduces the overall length of the transport vehicle.",
"Preferably, the at least one wheel is mounted on a moveable mounting member and the forklift truck further comprises retraction means for translationally moving said moveable mounting member relative to the body between said working and storage positions.",
"In a preferred embodiment the truck also includes a rigid chassis, wherein said retraction means is mounted on said rigid chassis for translationally moving said moveable mounting member relative to said rigid chassis.",
"The use of a retractable wheel on a rigid chassis demonstrates a different approach to the collapsible or foldable overhead chassis of the prior art.",
"Preferably, the moveable mounting member comprises a mounting plate which is slideable within a guide from a working position to a storage position.",
"In a preferred embodiment, the wheel is connected to said mounting plate by means of an arm to which the wheel is rotatably connected at the wheel hub, and wherein said arm is mounted by a swivel mounting to said mounting plate thereby enabling said wheel to be steered relative to the plate.",
"The truck preferably also includes a hub motor mounted between said arm and said hub for driving the wheel.",
"Preferably, said wheel is provided with a steering mechanism for rotating the plane of the wheel relative to the body and furthermore, said wheel is preferably mounted on the body with sufficient freedom to be rotated by the steering mechanism when the wheel is in its storage position by substantially 90 degrees from a normal straight-ahead position.",
"By enabling the retraction movement to occur in combination with the rotation of the steering through 90 degrees, the wheel's rearward projection can be reduced even further.",
"It is particularly preferred, in this option, to rotate the steering in that direction which most reduces the extent of rearward projection.",
"Thus where a motor or a mounting arm is mounted on one side of the wheel (causing a protrusion on that side) the wheel is preferably steered through 90 degrees to conceal that protrusion from projecting rearwardly.",
"BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be further illustrated with reference to the following description of embodiments thereof, given by way of example only with reference to the accompanying drawings, in which: FIG. 1 is a side elevation of a forklift truck according to the invention;",
"FIG. 2 is a side elevation of the truck of FIG. 1 when attached to a heavy goods vehicle;",
"FIG. 3 is a cross sectional plan view of the truck of FIG. 1 with the wheel extended;",
"FIG. 4 is a cross sectional plan view of the truck of FIG. 2 when mounted on a heavy goods vehicle, with the wheel retracted;",
"and FIGS. 5-7 are perspective views of a detail of the truck of FIGS. 1-4 with the rear wheel progressively extended from a storage position to a working position.",
"DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS FIG. 1 is a side elevation of a forklift truck, indicated generally at 10 , having a chassis 12 , a driver cab 14 , a pair of front wheels 16 (the nearest of which can be seen in FIG. 1 ) at a front end of the forklift truck 10 , and a single rear wheel 18 at a rear end 19 of the forklift truck 10 .",
"The driver cab is offset on one side of the front-to-rear centre line of the chassis and is situated at the side from which the view of FIG. 1 is taken.",
"A telescopic boom 13 carrying a set of forks 15 is offset on the other side of the centre line (behind the cab in the view of FIG. 1 ).",
"The forks are adapted to manipulate a load at the front end 17 of the forklift truck.",
"This general arrangement of chassis, offset cab and offset telescopic boom is well known in the field of truck mounted forklifts.",
"As shown in FIG. 2 , the forklift truck 10 is adapted to be coupled to and carried by a heavy goods vehicle 20 .",
"This is achieved by inserting the forks (not shown) into a receiving compartment of the heavy goods vehicle 20 and locking them in place, then activating the control to lower the forks which raises the forklift truck 10 body relative both to the forks and to the heavy goods vehicle until it reaches the position shown in FIG. 2 .",
"In order to decrease the rear projection (which is very important in most markets), the length 22 between the rearmost point 24 of the heavy goods vehicle 20 and the rearmost point 26 of the forklift truck 10 , the rear wheel 18 is extendable between a transit position and a working position.",
"FIG. 1 shows the rear wheel 18 in its working position (with the retracted position shown in dotted outline), while FIG. 2 shows the rear wheel 18 in its retracted position (with the working position shown in dotted outline).",
"FIG. 3 is a plan cross sectional view of the U-shaped chassis 12 and wheels 16 , 18 of the truck 10 .",
"The rear wheel 18 is shown in its working position (and in dotted outline with reference numeral 18 ′ in its transit position).",
"The centre of gravity 28 of the truck is shown along with an inner triangle 30 connecting the centres of the three wheels when rear wheel 18 ′ is in its transit configuration, and an outer triangle 32 connecting the centres of the wheel when rear wheel 18 is in its working position.",
"This demonstrates that the “triangle of stability”",
"is increased when the rear wheel is in its working position.",
"The greater the distance the centre of gravity is from the edge of the stability triangle (L-L 1 ) the more stable the forklift is during operation.",
"The larger the stability triangle the more stable the forklift is during operation.",
"FIG. 4 is cross sectional plan view of the truck when mounted on a heavy goods vehicle as shown in FIG. 2 , and FIG. 4 again shows the extent of rear projection 22 when the rear wheel 18 ′ is in its transit configuration.",
"As will be further described below, the mechanism for retracting the wheel can be combined with a steering mechanism to turn the wheel through 90 degrees and thus move the rearmost point of projection even further forward.",
"FIGS. 5 , 6 and 7 provide a cutaway perspective view of the rear wheel along with its steering mechanism and the mechanism for retracting and extending the wheel between the transit and working positions.",
"The mechanism of FIGS. 5-7 provides an additional advantage to the general concept of retraction shown in FIGS. 1-4 .",
"Whereas the wheel in FIGS. 1-4 is simply shown as being retracted without any rotation, the mechanism shown in FIGS. 5-7 actually allows the wheel not only to be retracted but also to be rotated by 90 degrees so that the radial plane of the wheel is parallel to the back of the forklift truck.",
"Because the rear wheel is prevented from protruding outwards along the common longitudinal axis of the heavy goods vehicle and forklift truck, the overall length is decreased further.",
"FIG. 5 shows the wheel retracted and rotated into its transit position.",
"FIG. 6 shows the wheel extended outward to the working position but still rotated parallel to the back of the forklift truck.",
"FIG. 7 shows the wheel in its working position, after it has been rotated so that the radial plane of the wheel is parallel to the direction of normal movement of the truck when steering straight ahead.",
"As best seen in FIG. 7 , the wheel 18 is carried on an arm 36 which mounts the hub 37 of the wheel.",
"A hydraulic motor (not visible) is integral with the hub and a hydraulic feed to that motor provides the driving mechanism for the wheel.",
"The arm 36 terminates at its top end at a top plate 38 which is rotatable about a vertical axis by means of a hydraulic linkage 40 (see FIGS. 5 and 6 ).",
"Hydraulic linkage 40 provides the steering mechanism for rotating the wheel 18 relative to the chassis 12 .",
"This hydraulic linkage is functionally linked to the steering wheel in the driver's cab.",
"The top plate 38 of arm 36 is rotatably mounted on an orbital mounting plate 42 , so actuation of the hydraulic linkage 40 causes top plate 38 and orbital mounting plate 42 to rotate relative to one another.",
"Orbital mounting plate 42 is prevented from rotation relative to the chassis by being mounted on a sliding plate 44 .",
"Sliding plate 44 is slideably received between a pair of horizontal plates 46 , 48 which in turn are mounted on the chassis structure.",
"Thus, plate 44 can slide back and forth to move the wheel between the retracted position shown in FIG. 5 and the working position shown in FIGS. 6 and 7 .",
"Once the wheel is in the position shown in FIG. 6 , the hydraulic steering linkage 40 rotates the wheel about its vertical axis to the position shown in FIG. 7 .",
"A hydraulic retraction arm 50 controls this back and forth sliding movement.",
"Hydraulic retraction arm 50 provides a linkage between a mounting point 52 connected to the chassis structure at one end, and the orbital mounting plate 42 and sliding plate 44 at the other end.",
"A control (not shown) in the driver's cab actuates the hydraulic retraction arm 50 to retract or extend sliding plate 44 (and hence the wheel) between the positions of FIG. 5 and FIG. 6 .",
"The embodiment described above can be varied or modified as appropriate without departing from the scope of the claimed invention, including, in particular, by providing more than one rear wheel, provided that the rearmost wheel or wheels is retractable from a working position to a storage position in which the overall length of the truck is decreased."
] |
FIELD OF INVENTION
[0001] The present invention relates to a process for manufacture of high iron hydraulic cement clinker using down draft sintering technique.
BACKGROUND OF THE INVENTION
[0002] High iron cement clinker is a non-portland type of cement clinker which contains iron (Fe 2 O 3 ) to the extent of 40% and above as major chemical constituent. The cement made from high iron cement clinker possesses clearly and high binding strength on hydration. This type of high iron hydraulic cement is usable as a substitute to Portland cement in construction activities, a special cement in sulphate resistance constructions, a metallurgical cement or binder in briquetting, pelletisation and sintering of iron ore, iron oxide and metal containing fines for iron making and a hydraulic mineral binder for absorbing water soluble metals in treatment and stabilization of hazardous toxic solid wastes.
[0003] Portland and aluminous cements are known cementitious systems in which calcium silicates and calcium aluminates respectively are the major cement mineral phases. Iron (Fe 2 O 3 ) content in these cements are very low and ranges 2 to 6% in Portland cement and up to 15% (maximum) in aluminous cements. Iron and iron bearing mineral phases existing in these cementitious systems are quite insignificant in respect to quantity and cement property. Chemically and mineralogically the high iron cement is quite different from the Portland and aluminous cements. Iron (Fe 2 O 3 ) in high iron cement is beyond the limit of the above two cements. Mainly, the calcium-iron and calcium-alumina-iron type of ferric phases are the major mineral constituents of high iron cement clinker responsible for developing hydraulic property and strength of the cement. Hydraulic property and development of strength of high iron cement largely depend on the mineral structure and degree of solid solution of different ferrite phase, crystallinity and presence of different calcium silicate and other mineral phases. In high iron cement clinker, the formation of different ferrite mineral phases mainly depend on the chemical parameters of calcium, alumina and iron; sintering and cooling conditions. Comparatively, ferrite mineral phases of high iron cement clinker form at much lower temperature than the calcium silicates of the Portland cement clinkers. In respect to hydraulic property and strength, the performance of high iron cement is also better than the Portland cement. Lime and iron bearing raw materials are the main source for manufacture of high iron cement. Owing to the many advantageous qualities like cost effectiveness, energy efficiency and better performance of high iron cement than the Portland cement, the development of suitable processes in production of high iron cement clinker in the present context has been given more attention
[0004] At present, iron rich solid wastes are abundantly available in different metallurgical, chemical and mining industries. Accumulation of these wastes without proper use is a significant problem in respect of the environmental pollution caused. Thus, use of these types of waste materials may find a suitable value-added application in making high iron cements. Although some research activities have been carried out in past in this area but technological development in production of high iron cement has not been made significant progress.
[0005] References is made to the following disclosures:
[0006] 1. Kimenko Z. G; Tikhonov, V. A. Bobik, G. L; Petrovskaya, N. L. : Dmitrievskii, V. S.; Ozerov, V. M. (USSR). Visn L'Viv. Politekh. Inst. 1975, 95, 98-100 (Ukraine). Production of high iron cement for sintering iron ore concentrate (Chemical Ab.: 1975, 85 : 1294451 g).
[0007] 2. Tikhonov, V. A; Klimenko, Z. G: Berezhnenko, E. T., Zhavoronkova, E. V. (L'Viv. Politckh, Inst. L'Vov, USSR). Tr-Mezhdunar. Kongr Khim. Tsem., 6 th 1974 (Pub. 1976), 3, 154-6 (Russ). Edited by Boldyrev, A. S.; Stroiizdat: Moscow, USSR Special highly ferruginous cement (Chemical Abs.: 1977, 86 : 110385n).
[0008] 3. Mehta, P. K. (Univ. of California). High iron oxide hydraulic cement. U.S. Pat. No. 4,036,657 (CL 106-89, C04B7/02), 19 Jul. 1977, Appl. 598, 411. 23 Jul. 1975 (Chemical Abs.: 1977, 87 : 121920e).
[0009] 4. Buraev, M. L.; Tuzyak, V e; Shpinova, L. G. (L'Viv. Politekh. Inst., L'Vov, USSR). Synthesis of alumina-iron oxide cement from red slime. Kompleskn Ispol'. Miner. Syr'ya, 1984 (2) 72-75 (Russ) (Chemical Abs.: 1985, 102 : 50050h).
[0010] 5. Feng. Xiuji, Zhu, Yufeng (Wuhan Inst. Build Mater. Wuhan, Peop. Rep. China). Research on an early strength cement containing high content of iron. Congr. Int. Quim. Cemento [An] 8 th 1986, 2, 285-92 (Eng) (Chemical Abs.: 1988, 109 . 78641y).
[0011] 6. Huo, Xingong; Zhen, Yinchum; Liu, Zhencai; Wang, Baoan; Wang, Suqing; Ruan, Doutian (Benxi Steel Co.) Faming Zhuanli Shenqing Gongkai Shoumingashu. Production of ferrite cement using highly activated slag from reolving furnace steel smelting. CN 87, 100, 826 (CI. C04B7/153), 16 Dec. 1997 Appl. 13 Feb. 1987 (Chemical Abs. 1989, 110. 43938u).
[0012] wherein efforts have been made to develop iron rich hydraulic cement clinker using the raw materials like iron ore, red slime, steel melting slag by adopting conventional cement kilns and by smelting in steel smelting converters.
[0013] The drawbacks of the earlier processes are the limitations in the use of various types of iron rich raw materials, deterioration of refractory life due to the formation of low temperature iron rich liquid phase, difficulty in maintaining proper reducing and oxidizing atmosphere and faster cooling conditions to achieve desired iron rich hydraulic cement mineral phases, involvement of more process steps to make clinker by steel smelting converter, energy intensive of grinding of fused and melted iron rich clinker particles, etc.
OBJECT OF THE INVENTION
[0014] The main object of the invention is to provide a process for manufacture of high iron hydraulic cement clinker using down draft sintering technique which obviates the drawbacks as detailed above.
[0015] Another object of the invention is to maintain the flexibility in the process for utilization of wide varieties of raw materials, fines, solid wastes ect. containing lime and iron.
[0016] Still another object of the invention is to use coke, coal, char and carbon containing solid wastes as the source of fuel in the process.
[0017] Yet another object of the invention is to maintain easier raw material processing and sintering steps in the process to eliminate the use of retractories and high temperature melting operations.
[0018] Yet another object of the invention is provide an eco-friendly process and to use simpler plant machineries for commercial production in batch and continuous scale
[0019] Yet another object of the invention is to maintain high productivity and low energy consumption in manufacture of high iron cements consisting of 40% iron (Fe 2 O 3 ) and above.
SUMMARY OF THE INVENTION
[0020] Accordingly, the present invention provides a process for manufacture of high iron hydraulic cement clinker using down draft sintering technique which comprises preparing a homogenous raw mixture of raw materials selected from limestone, lime, lime sludge, lime bearing solid wastes, iron ore, slime red mud, ferruginuous bauxite, laterite, clay, iron oxide containing metallurgical and chemical wastes, slag, coke breeze, coal char, carbonaceous sludge, carbon bearing solid wastes and any mixture thereof, pelletising the resultant homogenized raw mixture in the presence of water to prepare granulated particles, sintering and cooling the pelletised granulated particles by down draft sintering technique to convert into clinker, grinding the clinker particles with and without gypsum to make high iron hydraulic cements and binders for different applications.
[0021] In one embodiment of the invention, the homogeneous raw mixture is prepared in semi-wet or dry form by blending or grinding depending the particle fineness.
[0022] In an embodiment of the invention, the chemical ratio of CaO/(Al 2 O 3 +Fe 2 O 3 ), SiO 2 /(Al 2 O 3 +Fe 2 O 3 ) and (Al 2 O 3 +Fe 2 O 3 ) in the homogenized raw mixture is between 1.3 to 2.5, 0.2 to 0.5 and 0.25 to 0.8 respectively.
[0023] In an embodiment of the invention, the particle fineness of the homogenized raw mixture is below 150 mesh (100 micron) size.
[0024] In yet another embodiment of the invention, the content of solid carbon ranges 4 to 12% in the homogenized mixture as feed to generate in-situ heat for sintering.
[0025] In still another embodiment of the invention, pelletization of the homogenized mixture is done in the in presence of water to make granulated particles below 15 mm sizes consisting of 8 to 15% water.
[0026] In still another embodiment of the invention, sintering of the granulated particles is done at a temperature in the range of 1050 to 1450° C. to convert into clinker by down draft sintering, maintaining an operating condition of 300 to 600 mm bed height of the granulated particle, 200 to 800 mm water gauge (WG) air suction pressure below the bed, and 15 to 20 mm vertical sintering speed from top to bottom of the bed.
[0027] In still another embodiment of the invention, depending on the granulated particle size, the product obtained is cooled between 200 to 1000° C. and 400 to 600° C.
[0028] In still another embodiment of the present both sintering and cooling operation in cement clinker formation is within the bed itself and is done in a period of 15 to 30 minutes.
[0029] In still another embodiment of the present invention, the sintering hearth is free of refractory lining and attached with scrubbers for cleaning of hot gas carrying dust particles to control pollution during sintering operation.
[0030] In still another embodiment of the present invention, the clinkerised lumpy aggregates are crushed for size reduction and then ground with or without gypsum and other additives to make cements and binders for different applications.
[0031] In another embodiment of the invention, a mineralizing agent selected from sulphate, fluorine, chlorine bearing minerals and chemical wastes is added to the raw mixture.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The process details of the present invention are as follows:
[0033] Limestone, lime, lime sludge, lime bearing solid wastes, iron ore, slime red mud, ferruginuous bauxite, laterite, clay, iron oxide containing metallurgical and chemical wastes, slag, coke breeze, coal char, carbonaceous sludge, carbon bearing solid wastes are the different types of raw materials suitable for use in manufacture of high iron cement clinkers.
[0034] Sulphate, fluorinc, chlorine bearing minerals and chemical waster are also usable as mineralizing agent in the process. Iron is a major constituent of the high iron cement of which iron content is beyond the limit of Portland and aluminous cement. Norms for chemical parameters in designing the raw mix for high iron cement is also different than the Portland and aluminous cements. Based on the content of CaO, Fe 2 O 3 , Al 2 O 3 , SiO 2 , carbon etc. of various materials and additives, it is mixed in different properties accordingly to maintain the essential chemical parameters such as 1.3 to 2.5 of CaO (Al 2 O 3 +Fe 2 O 3 ), 0.2 to 0.5 of SiO 2 (Al 2 O 3 +Fe 2 O 3 ), 0.25 to 0.8 of Al 2 O 3 +Fe 2 O 3 , 4 to 12% of carbon and with or without it mineralizing agent in preparation of high iron cement raw mixtures. Depending on the particle fineness, moisture content and nature of materials, the raw mixture may be prepared in dry or semi dry from the blending or by grinding for complete homogenization. Particle fineness of the homogenized raw mixture is maintained preferable below 100 micron size. The homogenized raw mixture is then subjected to make pelletised particles of below 15 mm size granules by the pelletisation technique in the presence of water. Pelletisation condition is maintained in such a manner that the pelletised particles retain less than 15% water and green strength for handling in sintering operation. Sintering of the pelletised particles is carried out by the down draft sintering system to convert into cement clinkers. Principles of Down Draft Sintering (DDS) system is commercially known in iron and steel industries for agglomeration of iron ore fines for blast furnace use in making iron. The granulated material of the cement raw mix is charged into the sintering hearth which is like as pot consisting of grate bars at the bottom. The charge material rests on a false hearth (50 mm thick) layer over the grate bar in form of a bed ranging 300 to 600 mm thickness. Top of the charge material bed in the sintering hearth is ignited by using burners or pre-burnt coal or coke to create heat front. Air suction pressure between 100 to 1000 mm WG is maintained below the grate bars to move the heat front 15 to 20 mm per minute from top to bottom of the bed Drying calcinations, sintering and then cooling of the material in formation of clinker takes place on a static bed. Presence of solid carbon within the charge material generates in-situ heat ranging 1000 to 1500° C. or higher temperature in the bed. Conversion of charge bed into cement clinker takes 15 to 30 minutes time depending on the height and permeability of the charge bed, air suction pressure, sintering temperature etc. Clinkersied product discharged from the sinter pot is crushed to below 10 mm sizes to store or to use in grinding to make cement.
[0035] Based on the raw mix composition and presence of sulphate chloride, fluorite bearing additive, the high iron cement clinker produced by the above method contains C 2 F, C 4 AF, C 6 AF 2 and C 6 A 2 F mineral structures of ferrite compounds, di- and tri-calcium silicate, and calcium sulphoaluminate (C 4 A 3 S), calcium tluoroaluminate (C 11 A-CaF 2 ), calcium chloroaluminate (C 11 A 7 ClCl 2 ), calcium sulphoaluminogerrite (C 2 A x F 1-x Sa), [where x varies between 0.1 to 0.8 and n varies. 0.05 to 0.5] as the assemblage of different cement mineral phase [C—CaO, F—Fe 2 O 3 , A—Al 2 O 3 , S—SO 4 ]. Ferrite phases ranging 30 to 70% in association with dicalcium silicate silicate or tricalcium as the primary mineral constituents occur in the high iron cement clinker Other minerals like. C 4 AS, CuA—CaF 2 , C 11 A—CaCl 2 , and calcium sulpho aluminoferrite also exist in different proportions with the ferrite phase depending the nature of additives and fluxes.
[0036] Sintering and cooling operation of down draft sintering (DDS) methods is very fast than the other existing cement clinkerization system, which promotes to maintain micro-crystallinity of different cement mineral phases and phases degree of solid solution of ferrite mineral in the clinker. High hydraulic strength of cement is related to the composition and crystallinity of various cement mineral phases. Particularly the high iron cement clinkers made in the present process mainly acicular to tabular shape ferrite mineral phrases of below 10 micron sizes and dicalcium and tricalcuim silicate crystals of below 40 micron sizes and solid solution of C 6 AF 2 and C 6 A 2 F ferrite mineral structures. Due to the special features of mineralogical and microstructural characteristics in the strength of microstructural characteristics in the high iron cement clinker consisting of 40% iron and above help to achieve hydraulic strength as high as 120 MPa in the cement after 28 days of curing Further, the formulation of high iron cement clinker is mostly by solid state reaction of particles with minimum fusion which helps to retain spongy and porous character for easier grinding to cement fineness
[0037] Laboratory scale down draft sintering (DDS) system consisting of rectangular box type sintering hearth of size (300×300) mm 2 cross section area and 500 mm height of capacity of feed 50 to 60 kg of granulated raw mix per batch has been adapted in conducting the experiments at different bed height, suction pressure, sintering and cooling rate On various compositions to optimize the process for commercial production of high iron cement clinker.
[0038] The following examples air, given by way of illustration and therefore should not be construed to limit the scope of the present invention.
EXAMPLES 1
[0039] Dry powdery material of acetylene plant lime sludge [63.25% CaO], blast furnace (B.F.) dust [46.70% Fe 2 O 3 ] 7.24% SiO 2 and 30.17% carbon] and additives are mixed to make 50 kg raw material mixtures e in which the weight ratio of lime sludge and B.F. dust is 2:1 The blended materials are pulverized in a ball mill for homogenization and to maintain below 150 mesh (BSS) particle fineness. The homogenized raw mixtures consists of 1.96, 0.21 and 0.31 as the chemical ratio of CaO/(Al 2 O 3 +Fe 2 O 3 ), SiO 2 /(Al 2 O 3 +Fe 2 O 3 ) and Al 2 O 3 +Fe 2 O 3 respectively. The homogenized raw mixture is then pelletised in presence of water by a disc granulator to make below 15 mm size granules consisting of 10% water. Bulk density of the green granulated particle is 1250 kg/m 3 , 50 kg of the green granulated material is charged into a sintering hearth of (300 mm×300 mm) cross-section and 500 mm height like a box to make 450 mm thick bed in a laboratory set up DDS unit. Top of the bed is ignited by burning charcoal on it and 350 mm water gauge (WG) air suction pressure is applied below the charge bed to complete the sintering and cooling operation in 30 minutes to prepare iron cement clinker. Solid carbon present in the pelletised granules generate in situ heat for clinker formation at 1375° C. temperature. 30 kg of iron rich clinker is produced from 50 kg of charge material.
[0040] The clinker consist of 59.70% Al 2 O 3 and 25 5% Al 2 O 3 +Fe 2 O 3 as major chemical constituent and 52% iron bearing ferrite compounds and 40% tricalcium silicate as the major mineral phase. The clinker is ground to make cements with and without gypsum. The cement prepared without gypsum possesses 45 to 160 minute of setting time, and 420, 560, 710 kg cm 2 respectively the compressive strength (1:3 cement and sand mortar ratio) at 3, 7 and 28 days of curing. The cement prepared with 4% gypsum, shows 85 to 210 minute setting time and compressive strength of 430, 576, 750 kg,/cm 2 respectively of 1:3 cement and sand mortar cube at 3, 7 and 28 days of curing. Effect of gypsum As a set retarder is very negligible on strength development of the cement. Expansion of the cements is within the limit as per Portland cement. This type of high iron cement is suitable for metallurgical and constructional use.
EXAMPLE 2
[0041] Dry powdery materials or acetylene plant lime, Basic Oxygen Furnace (BOF) dust [76.80% Fe 2 O 3 , 3.60% SiO 2 , 2.85% Al 2 O 3 , 11.08% CaO, 0.15 TiO 2 , 0 78% (Na 2 O+K 2 O), clay (50.59% SiO 2 , 20.82% Al 2 O 3 , 14.20% Fe 2 O 3 , 1.65% TiO 2 ) and coke breeze [68% fixed carbon, 29% ash, 3% volatile] are used in different weight percentages to prepare 50 kg raw mixture consisting of 7% solid carbon and 1.48, 0.27, 0.3 as the chemical ratio of CaO/(Al 2 O 3 +Fe 2 O 3 ), SiO 2 /(Al 2 O 3 +Fe 2 O 3 ) and Al 2 O 3 +Fe 2 O 3 respectively. Granulated pellets of below 15 mm sizes of the ground mixture are prepared with 12% water by the disc granulator. 50 kg of the granulated pellets is used to make clinker by the laboratory set up DDS system maintaining 400 mm heal height and applying 250 mm WG air suction pressure to complete the sintering and cooling in 28 minutes. Coke breezer present in the granulated pellets generates in situ heat and clinker formation has taken place at 1420° C. temperature 34 kg of clinker has been obtained from 50 kg of feed.
[0042] The clinker contains 53% CaO and 33% Fe 2 O 3 . Mineralogically the clinker consists of acicular pattern of iron rich ferrite minerals of C 6 AF 2 , C 4 AF and crystals of tricalcium silicate (C 3 S) and dicalcium silicate (C 2 S) of below 40 micron sizes. Cement prepared from this type of clinker shows 120 to 240 minute setting time and compressive strength of 1:3 cement and mortar at 1, 3, 7, 28 days of curing 180, 430, 610 and 780 kg/cm 2 respectively. The use of gypsum as set retarder in the cement shows less significant effect in respect to setting time and strength. This type of cements is suitable for metallurgical use as well as in building constrictions.
EXAMPLE 3
[0043] Calcined lime (88% CaO, 4.50% SiO 2 , 1.80 MgO), iron ore slime (93% Fe 2 O 3 , 1.12% SiO 2 , 2.17% Al 2 O 3 ), lateritic bauxite (38% Fe 2 O 3 , 41.5% Al 2 O 3 , 3.8% SiO 2 , 1.8% TiO 2 ), char fines (88% fixed carbon), fluorite and gypsum are mixed in the weight percentage of 48, 22, 16, 102 and 2 respectively to make 50 kg of raw material mixture. It is then ground in the hall mill to a particle fineness of below 150 mesh (BSS sieve) size. Chemical ratio of CaO (Al 2 O 3 +Fe 2 O 3 ) and Al 2 O 3 +Fe 2 O 3 of the raw material mixture is in the order of 1.42, 0.2 and 0.35 respectively. The powdery mixture is granulated with 15% water to make below 12 mm, size granules. Then 50 kg of granulated material is used to make clinker by the down draft sintering (DDS) technique at 1400° C. using the 460 mm bed height of the material.
[0044] The resultant clinker contains 56% CaO and 34% Fe 2 O 3 as the major constituent. Different mineral phases of the clinker are C 6 AF 3 , C 4 AF, calcium silicates (C 3 S, C 2 S), C 11 A 7 CaF 2 ) calcium sulpho aluminate (C 4 A 3 S), calcium sulpho alumino ferrite etc. The clinker exhibits very fine crystalline structure of different mineral phases. Cement prepared with addition of 10% gypsum shows faster setting (less than 60 minutes) and very high compressive strength in the order of 510, 700 kg/cm 2 in 3, 7 and 28 days of curing. Use of gypsum has got very positive effect inn this type of iron rich cement.
[0045] It is inferred that the manufacture of high iron cement clinkers for different applications using various types of raw materials in the present process is quite flexible. Rapid sintering and cooling conditions of the process is a special feature to achieve fine crystalline structure, high temperature solid solutions of ferrite and other mineral phases in the high iron cement clinker and high hydraulic strength of the cement. In addition to the clinker chemistry and mineralogy, the development of high hydraulic, strength of the high iron cement is also related to the cement particle size and content of gypsum as set retarder,
[0046] The main advantages of the presence invention are:
[0047] 1. Use of wide varieties of raw materials, industrial and mining solid wastes, fines, etc. rich in lime and iron, and various types of fluxing materials.
[0048] 2. Scope for utilization of solid carbon bearing materials like coal, coke, char, waste fines as main source of fuel.
[0049] 3. Flexibility in raw mix design in manufacture of iron rich cements for various uses.
[0050] 4. High thermal efficiency in clinker formation due the presence of in situ carbon within the particle.
[0051] 5. Rapid sintering and cooling rate of the sintering system, promotes high degree of solid solution in iron mineral phases and micro-crystallinity in the clinker to achieve better cement property.
[0052] 6. Minimization of pollution as the sintering system consists of both dry and scrubber for cleaning of gas, and dust
[0053] 7. High productivity of the sintering system due to low retention time
[0054] 8. Cost effective as the sintering system is free of refractory materials. | The present invention describes a process for manufacture of high iron hydraulic cement clinker in production of cement and cementation binder for application in construction activity andin metallurgical industry for sintering of iron ore fines and making cold bonded briquettes and pellets. The process is cost effective and flexible for utilization of wide varieties of raw material consisting of lime and iron in production of high iron cements for different application. | Identify and summarize the most critical features from the given passage. | [
"FIELD OF INVENTION [0001] The present invention relates to a process for manufacture of high iron hydraulic cement clinker using down draft sintering technique.",
"BACKGROUND OF THE INVENTION [0002] High iron cement clinker is a non-portland type of cement clinker which contains iron (Fe 2 O 3 ) to the extent of 40% and above as major chemical constituent.",
"The cement made from high iron cement clinker possesses clearly and high binding strength on hydration.",
"This type of high iron hydraulic cement is usable as a substitute to Portland cement in construction activities, a special cement in sulphate resistance constructions, a metallurgical cement or binder in briquetting, pelletisation and sintering of iron ore, iron oxide and metal containing fines for iron making and a hydraulic mineral binder for absorbing water soluble metals in treatment and stabilization of hazardous toxic solid wastes.",
"[0003] Portland and aluminous cements are known cementitious systems in which calcium silicates and calcium aluminates respectively are the major cement mineral phases.",
"Iron (Fe 2 O 3 ) content in these cements are very low and ranges 2 to 6% in Portland cement and up to 15% (maximum) in aluminous cements.",
"Iron and iron bearing mineral phases existing in these cementitious systems are quite insignificant in respect to quantity and cement property.",
"Chemically and mineralogically the high iron cement is quite different from the Portland and aluminous cements.",
"Iron (Fe 2 O 3 ) in high iron cement is beyond the limit of the above two cements.",
"Mainly, the calcium-iron and calcium-alumina-iron type of ferric phases are the major mineral constituents of high iron cement clinker responsible for developing hydraulic property and strength of the cement.",
"Hydraulic property and development of strength of high iron cement largely depend on the mineral structure and degree of solid solution of different ferrite phase, crystallinity and presence of different calcium silicate and other mineral phases.",
"In high iron cement clinker, the formation of different ferrite mineral phases mainly depend on the chemical parameters of calcium, alumina and iron;",
"sintering and cooling conditions.",
"Comparatively, ferrite mineral phases of high iron cement clinker form at much lower temperature than the calcium silicates of the Portland cement clinkers.",
"In respect to hydraulic property and strength, the performance of high iron cement is also better than the Portland cement.",
"Lime and iron bearing raw materials are the main source for manufacture of high iron cement.",
"Owing to the many advantageous qualities like cost effectiveness, energy efficiency and better performance of high iron cement than the Portland cement, the development of suitable processes in production of high iron cement clinker in the present context has been given more attention [0004] At present, iron rich solid wastes are abundantly available in different metallurgical, chemical and mining industries.",
"Accumulation of these wastes without proper use is a significant problem in respect of the environmental pollution caused.",
"Thus, use of these types of waste materials may find a suitable value-added application in making high iron cements.",
"Although some research activities have been carried out in past in this area but technological development in production of high iron cement has not been made significant progress.",
"[0005] References is made to the following disclosures: [0006] 1.",
"Kimenko Z. G;",
"Tikhonov, V. A. Bobik, G. L;",
"Petrovskaya, N. L. : Dmitrievskii, V. S.;",
"Ozerov, V. M. (USSR).",
"Visn L'Viv.",
"Politekh.",
"Inst.",
"1975, 95, 98-100 (Ukraine).",
"Production of high iron cement for sintering iron ore concentrate (Chemical Ab.",
": 1975, 85 : 1294451 g).",
"[0007] 2.",
"Tikhonov, V. A;",
"Klimenko, Z. G: Berezhnenko, E. T., Zhavoronkova, E. V. (L'Viv.",
"Politckh, Inst.",
"L'Vov, USSR).",
"Tr-Mezhdunar.",
"Kongr Khim.",
"Tsem.",
", 6 th 1974 (Pub.",
"1976), 3, 154-6 (Russ).",
"Edited by Boldyrev, A. S.;",
"Stroiizdat: Moscow, USSR Special highly ferruginous cement (Chemical Abs.",
": 1977, 86 : 110385n).",
"[0008] 3.",
"Mehta, P. K. (Univ.",
"of California).",
"High iron oxide hydraulic cement.",
"U.S. Pat. No. 4,036,657 (CL 106-89, C04B7/02), 19 Jul. 1977, Appl.",
"598, 411.",
"23 Jul. 1975 (Chemical Abs.",
": 1977, 87 : 121920e).",
"[0009] 4.",
"Buraev, M. L.;",
"Tuzyak, V e;",
"Shpinova, L. G. (L'Viv.",
"Politekh.",
"Inst.",
", L'Vov, USSR).",
"Synthesis of alumina-iron oxide cement from red slime.",
"Kompleskn Ispol'.",
"Miner.",
"Syr'ya, 1984 (2) 72-75 (Russ) (Chemical Abs.",
": 1985, 102 : 50050h).",
"[0010] 5.",
"Feng.",
"Xiuji, Zhu, Yufeng (Wuhan Inst.",
"Build Mater.",
"Wuhan, Peop.",
"Rep.",
"China).",
"Research on an early strength cement containing high content of iron.",
"Congr.",
"Int.",
"Quim.",
"Cemento [An] 8 th 1986, 2, 285-92 (Eng) (Chemical Abs.",
": 1988, 109 .",
"78641y).",
"[0011] 6.",
"Huo, Xingong;",
"Zhen, Yinchum;",
"Liu, Zhencai;",
"Wang, Baoan;",
"Wang, Suqing;",
"Ruan, Doutian (Benxi Steel Co.) Faming Zhuanli Shenqing Gongkai Shoumingashu.",
"Production of ferrite cement using highly activated slag from reolving furnace steel smelting.",
"CN 87, 100, 826 (CI.",
"C04B7/153), 16 Dec. 1997 Appl.",
"13 Feb. 1987 (Chemical Abs.",
"1989, 110.",
"43938u).",
"[0012] wherein efforts have been made to develop iron rich hydraulic cement clinker using the raw materials like iron ore, red slime, steel melting slag by adopting conventional cement kilns and by smelting in steel smelting converters.",
"[0013] The drawbacks of the earlier processes are the limitations in the use of various types of iron rich raw materials, deterioration of refractory life due to the formation of low temperature iron rich liquid phase, difficulty in maintaining proper reducing and oxidizing atmosphere and faster cooling conditions to achieve desired iron rich hydraulic cement mineral phases, involvement of more process steps to make clinker by steel smelting converter, energy intensive of grinding of fused and melted iron rich clinker particles, etc.",
"OBJECT OF THE INVENTION [0014] The main object of the invention is to provide a process for manufacture of high iron hydraulic cement clinker using down draft sintering technique which obviates the drawbacks as detailed above.",
"[0015] Another object of the invention is to maintain the flexibility in the process for utilization of wide varieties of raw materials, fines, solid wastes ect.",
"containing lime and iron.",
"[0016] Still another object of the invention is to use coke, coal, char and carbon containing solid wastes as the source of fuel in the process.",
"[0017] Yet another object of the invention is to maintain easier raw material processing and sintering steps in the process to eliminate the use of retractories and high temperature melting operations.",
"[0018] Yet another object of the invention is provide an eco-friendly process and to use simpler plant machineries for commercial production in batch and continuous scale [0019] Yet another object of the invention is to maintain high productivity and low energy consumption in manufacture of high iron cements consisting of 40% iron (Fe 2 O 3 ) and above.",
"SUMMARY OF THE INVENTION [0020] Accordingly, the present invention provides a process for manufacture of high iron hydraulic cement clinker using down draft sintering technique which comprises preparing a homogenous raw mixture of raw materials selected from limestone, lime, lime sludge, lime bearing solid wastes, iron ore, slime red mud, ferruginuous bauxite, laterite, clay, iron oxide containing metallurgical and chemical wastes, slag, coke breeze, coal char, carbonaceous sludge, carbon bearing solid wastes and any mixture thereof, pelletising the resultant homogenized raw mixture in the presence of water to prepare granulated particles, sintering and cooling the pelletised granulated particles by down draft sintering technique to convert into clinker, grinding the clinker particles with and without gypsum to make high iron hydraulic cements and binders for different applications.",
"[0021] In one embodiment of the invention, the homogeneous raw mixture is prepared in semi-wet or dry form by blending or grinding depending the particle fineness.",
"[0022] In an embodiment of the invention, the chemical ratio of CaO/(Al 2 O 3 +Fe 2 O 3 ), SiO 2 /(Al 2 O 3 +Fe 2 O 3 ) and (Al 2 O 3 +Fe 2 O 3 ) in the homogenized raw mixture is between 1.3 to 2.5, 0.2 to 0.5 and 0.25 to 0.8 respectively.",
"[0023] In an embodiment of the invention, the particle fineness of the homogenized raw mixture is below 150 mesh (100 micron) size.",
"[0024] In yet another embodiment of the invention, the content of solid carbon ranges 4 to 12% in the homogenized mixture as feed to generate in-situ heat for sintering.",
"[0025] In still another embodiment of the invention, pelletization of the homogenized mixture is done in the in presence of water to make granulated particles below 15 mm sizes consisting of 8 to 15% water.",
"[0026] In still another embodiment of the invention, sintering of the granulated particles is done at a temperature in the range of 1050 to 1450° C. to convert into clinker by down draft sintering, maintaining an operating condition of 300 to 600 mm bed height of the granulated particle, 200 to 800 mm water gauge (WG) air suction pressure below the bed, and 15 to 20 mm vertical sintering speed from top to bottom of the bed.",
"[0027] In still another embodiment of the invention, depending on the granulated particle size, the product obtained is cooled between 200 to 1000° C. and 400 to 600° C. [0028] In still another embodiment of the present both sintering and cooling operation in cement clinker formation is within the bed itself and is done in a period of 15 to 30 minutes.",
"[0029] In still another embodiment of the present invention, the sintering hearth is free of refractory lining and attached with scrubbers for cleaning of hot gas carrying dust particles to control pollution during sintering operation.",
"[0030] In still another embodiment of the present invention, the clinkerised lumpy aggregates are crushed for size reduction and then ground with or without gypsum and other additives to make cements and binders for different applications.",
"[0031] In another embodiment of the invention, a mineralizing agent selected from sulphate, fluorine, chlorine bearing minerals and chemical wastes is added to the raw mixture.",
"DETAILED DESCRIPTION OF THE INVENTION [0032] The process details of the present invention are as follows: [0033] Limestone, lime, lime sludge, lime bearing solid wastes, iron ore, slime red mud, ferruginuous bauxite, laterite, clay, iron oxide containing metallurgical and chemical wastes, slag, coke breeze, coal char, carbonaceous sludge, carbon bearing solid wastes are the different types of raw materials suitable for use in manufacture of high iron cement clinkers.",
"[0034] Sulphate, fluorinc, chlorine bearing minerals and chemical waster are also usable as mineralizing agent in the process.",
"Iron is a major constituent of the high iron cement of which iron content is beyond the limit of Portland and aluminous cement.",
"Norms for chemical parameters in designing the raw mix for high iron cement is also different than the Portland and aluminous cements.",
"Based on the content of CaO, Fe 2 O 3 , Al 2 O 3 , SiO 2 , carbon etc.",
"of various materials and additives, it is mixed in different properties accordingly to maintain the essential chemical parameters such as 1.3 to 2.5 of CaO (Al 2 O 3 +Fe 2 O 3 ), 0.2 to 0.5 of SiO 2 (Al 2 O 3 +Fe 2 O 3 ), 0.25 to 0.8 of Al 2 O 3 +Fe 2 O 3 , 4 to 12% of carbon and with or without it mineralizing agent in preparation of high iron cement raw mixtures.",
"Depending on the particle fineness, moisture content and nature of materials, the raw mixture may be prepared in dry or semi dry from the blending or by grinding for complete homogenization.",
"Particle fineness of the homogenized raw mixture is maintained preferable below 100 micron size.",
"The homogenized raw mixture is then subjected to make pelletised particles of below 15 mm size granules by the pelletisation technique in the presence of water.",
"Pelletisation condition is maintained in such a manner that the pelletised particles retain less than 15% water and green strength for handling in sintering operation.",
"Sintering of the pelletised particles is carried out by the down draft sintering system to convert into cement clinkers.",
"Principles of Down Draft Sintering (DDS) system is commercially known in iron and steel industries for agglomeration of iron ore fines for blast furnace use in making iron.",
"The granulated material of the cement raw mix is charged into the sintering hearth which is like as pot consisting of grate bars at the bottom.",
"The charge material rests on a false hearth (50 mm thick) layer over the grate bar in form of a bed ranging 300 to 600 mm thickness.",
"Top of the charge material bed in the sintering hearth is ignited by using burners or pre-burnt coal or coke to create heat front.",
"Air suction pressure between 100 to 1000 mm WG is maintained below the grate bars to move the heat front 15 to 20 mm per minute from top to bottom of the bed Drying calcinations, sintering and then cooling of the material in formation of clinker takes place on a static bed.",
"Presence of solid carbon within the charge material generates in-situ heat ranging 1000 to 1500° C. or higher temperature in the bed.",
"Conversion of charge bed into cement clinker takes 15 to 30 minutes time depending on the height and permeability of the charge bed, air suction pressure, sintering temperature etc.",
"Clinkersied product discharged from the sinter pot is crushed to below 10 mm sizes to store or to use in grinding to make cement.",
"[0035] Based on the raw mix composition and presence of sulphate chloride, fluorite bearing additive, the high iron cement clinker produced by the above method contains C 2 F, C 4 AF, C 6 AF 2 and C 6 A 2 F mineral structures of ferrite compounds, di- and tri-calcium silicate, and calcium sulphoaluminate (C 4 A 3 S), calcium tluoroaluminate (C 11 A-CaF 2 ), calcium chloroaluminate (C 11 A 7 ClCl 2 ), calcium sulphoaluminogerrite (C 2 A x F 1-x Sa), [where x varies between 0.1 to 0.8 and n varies.",
"0.05 to 0.5] as the assemblage of different cement mineral phase [C—CaO, F—Fe 2 O 3 , A—Al 2 O 3 , S—SO 4 ].",
"Ferrite phases ranging 30 to 70% in association with dicalcium silicate silicate or tricalcium as the primary mineral constituents occur in the high iron cement clinker Other minerals like.",
"C 4 AS, CuA—CaF 2 , C 11 A—CaCl 2 , and calcium sulpho aluminoferrite also exist in different proportions with the ferrite phase depending the nature of additives and fluxes.",
"[0036] Sintering and cooling operation of down draft sintering (DDS) methods is very fast than the other existing cement clinkerization system, which promotes to maintain micro-crystallinity of different cement mineral phases and phases degree of solid solution of ferrite mineral in the clinker.",
"High hydraulic strength of cement is related to the composition and crystallinity of various cement mineral phases.",
"Particularly the high iron cement clinkers made in the present process mainly acicular to tabular shape ferrite mineral phrases of below 10 micron sizes and dicalcium and tricalcuim silicate crystals of below 40 micron sizes and solid solution of C 6 AF 2 and C 6 A 2 F ferrite mineral structures.",
"Due to the special features of mineralogical and microstructural characteristics in the strength of microstructural characteristics in the high iron cement clinker consisting of 40% iron and above help to achieve hydraulic strength as high as 120 MPa in the cement after 28 days of curing Further, the formulation of high iron cement clinker is mostly by solid state reaction of particles with minimum fusion which helps to retain spongy and porous character for easier grinding to cement fineness [0037] Laboratory scale down draft sintering (DDS) system consisting of rectangular box type sintering hearth of size (300×300) mm 2 cross section area and 500 mm height of capacity of feed 50 to 60 kg of granulated raw mix per batch has been adapted in conducting the experiments at different bed height, suction pressure, sintering and cooling rate On various compositions to optimize the process for commercial production of high iron cement clinker.",
"[0038] The following examples air, given by way of illustration and therefore should not be construed to limit the scope of the present invention.",
"EXAMPLES 1 [0039] Dry powdery material of acetylene plant lime sludge [63.25% CaO], blast furnace (B.F.) dust [46.70% Fe 2 O 3 ] 7.24% SiO 2 and 30.17% carbon] and additives are mixed to make 50 kg raw material mixtures e in which the weight ratio of lime sludge and B.F. dust is 2:1 The blended materials are pulverized in a ball mill for homogenization and to maintain below 150 mesh (BSS) particle fineness.",
"The homogenized raw mixtures consists of 1.96, 0.21 and 0.31 as the chemical ratio of CaO/(Al 2 O 3 +Fe 2 O 3 ), SiO 2 /(Al 2 O 3 +Fe 2 O 3 ) and Al 2 O 3 +Fe 2 O 3 respectively.",
"The homogenized raw mixture is then pelletised in presence of water by a disc granulator to make below 15 mm size granules consisting of 10% water.",
"Bulk density of the green granulated particle is 1250 kg/m 3 , 50 kg of the green granulated material is charged into a sintering hearth of (300 mm×300 mm) cross-section and 500 mm height like a box to make 450 mm thick bed in a laboratory set up DDS unit.",
"Top of the bed is ignited by burning charcoal on it and 350 mm water gauge (WG) air suction pressure is applied below the charge bed to complete the sintering and cooling operation in 30 minutes to prepare iron cement clinker.",
"Solid carbon present in the pelletised granules generate in situ heat for clinker formation at 1375° C. temperature.",
"30 kg of iron rich clinker is produced from 50 kg of charge material.",
"[0040] The clinker consist of 59.70% Al 2 O 3 and 25 5% Al 2 O 3 +Fe 2 O 3 as major chemical constituent and 52% iron bearing ferrite compounds and 40% tricalcium silicate as the major mineral phase.",
"The clinker is ground to make cements with and without gypsum.",
"The cement prepared without gypsum possesses 45 to 160 minute of setting time, and 420, 560, 710 kg cm 2 respectively the compressive strength (1:3 cement and sand mortar ratio) at 3, 7 and 28 days of curing.",
"The cement prepared with 4% gypsum, shows 85 to 210 minute setting time and compressive strength of 430, 576, 750 kg,/cm 2 respectively of 1:3 cement and sand mortar cube at 3, 7 and 28 days of curing.",
"Effect of gypsum As a set retarder is very negligible on strength development of the cement.",
"Expansion of the cements is within the limit as per Portland cement.",
"This type of high iron cement is suitable for metallurgical and constructional use.",
"EXAMPLE 2 [0041] Dry powdery materials or acetylene plant lime, Basic Oxygen Furnace (BOF) dust [76.80% Fe 2 O 3 , 3.60% SiO 2 , 2.85% Al 2 O 3 , 11.08% CaO, 0.15 TiO 2 , 0 78% (Na 2 O+K 2 O), clay (50.59% SiO 2 , 20.82% Al 2 O 3 , 14.20% Fe 2 O 3 , 1.65% TiO 2 ) and coke breeze [68% fixed carbon, 29% ash, 3% volatile] are used in different weight percentages to prepare 50 kg raw mixture consisting of 7% solid carbon and 1.48, 0.27, 0.3 as the chemical ratio of CaO/(Al 2 O 3 +Fe 2 O 3 ), SiO 2 /(Al 2 O 3 +Fe 2 O 3 ) and Al 2 O 3 +Fe 2 O 3 respectively.",
"Granulated pellets of below 15 mm sizes of the ground mixture are prepared with 12% water by the disc granulator.",
"50 kg of the granulated pellets is used to make clinker by the laboratory set up DDS system maintaining 400 mm heal height and applying 250 mm WG air suction pressure to complete the sintering and cooling in 28 minutes.",
"Coke breezer present in the granulated pellets generates in situ heat and clinker formation has taken place at 1420° C. temperature 34 kg of clinker has been obtained from 50 kg of feed.",
"[0042] The clinker contains 53% CaO and 33% Fe 2 O 3 .",
"Mineralogically the clinker consists of acicular pattern of iron rich ferrite minerals of C 6 AF 2 , C 4 AF and crystals of tricalcium silicate (C 3 S) and dicalcium silicate (C 2 S) of below 40 micron sizes.",
"Cement prepared from this type of clinker shows 120 to 240 minute setting time and compressive strength of 1:3 cement and mortar at 1, 3, 7, 28 days of curing 180, 430, 610 and 780 kg/cm 2 respectively.",
"The use of gypsum as set retarder in the cement shows less significant effect in respect to setting time and strength.",
"This type of cements is suitable for metallurgical use as well as in building constrictions.",
"EXAMPLE 3 [0043] Calcined lime (88% CaO, 4.50% SiO 2 , 1.80 MgO), iron ore slime (93% Fe 2 O 3 , 1.12% SiO 2 , 2.17% Al 2 O 3 ), lateritic bauxite (38% Fe 2 O 3 , 41.5% Al 2 O 3 , 3.8% SiO 2 , 1.8% TiO 2 ), char fines (88% fixed carbon), fluorite and gypsum are mixed in the weight percentage of 48, 22, 16, 102 and 2 respectively to make 50 kg of raw material mixture.",
"It is then ground in the hall mill to a particle fineness of below 150 mesh (BSS sieve) size.",
"Chemical ratio of CaO (Al 2 O 3 +Fe 2 O 3 ) and Al 2 O 3 +Fe 2 O 3 of the raw material mixture is in the order of 1.42, 0.2 and 0.35 respectively.",
"The powdery mixture is granulated with 15% water to make below 12 mm, size granules.",
"Then 50 kg of granulated material is used to make clinker by the down draft sintering (DDS) technique at 1400° C. using the 460 mm bed height of the material.",
"[0044] The resultant clinker contains 56% CaO and 34% Fe 2 O 3 as the major constituent.",
"Different mineral phases of the clinker are C 6 AF 3 , C 4 AF, calcium silicates (C 3 S, C 2 S), C 11 A 7 CaF 2 ) calcium sulpho aluminate (C 4 A 3 S), calcium sulpho alumino ferrite etc.",
"The clinker exhibits very fine crystalline structure of different mineral phases.",
"Cement prepared with addition of 10% gypsum shows faster setting (less than 60 minutes) and very high compressive strength in the order of 510, 700 kg/cm 2 in 3, 7 and 28 days of curing.",
"Use of gypsum has got very positive effect inn this type of iron rich cement.",
"[0045] It is inferred that the manufacture of high iron cement clinkers for different applications using various types of raw materials in the present process is quite flexible.",
"Rapid sintering and cooling conditions of the process is a special feature to achieve fine crystalline structure, high temperature solid solutions of ferrite and other mineral phases in the high iron cement clinker and high hydraulic strength of the cement.",
"In addition to the clinker chemistry and mineralogy, the development of high hydraulic, strength of the high iron cement is also related to the cement particle size and content of gypsum as set retarder, [0046] The main advantages of the presence invention are: [0047] 1.",
"Use of wide varieties of raw materials, industrial and mining solid wastes, fines, etc.",
"rich in lime and iron, and various types of fluxing materials.",
"[0048] 2.",
"Scope for utilization of solid carbon bearing materials like coal, coke, char, waste fines as main source of fuel.",
"[0049] 3.",
"Flexibility in raw mix design in manufacture of iron rich cements for various uses.",
"[0050] 4.",
"High thermal efficiency in clinker formation due the presence of in situ carbon within the particle.",
"[0051] 5.",
"Rapid sintering and cooling rate of the sintering system, promotes high degree of solid solution in iron mineral phases and micro-crystallinity in the clinker to achieve better cement property.",
"[0052] 6.",
"Minimization of pollution as the sintering system consists of both dry and scrubber for cleaning of gas, and dust [0053] 7.",
"High productivity of the sintering system due to low retention time [0054] 8.",
"Cost effective as the sintering system is free of refractory materials."
] |
FIELD OF THE INVENTION
The invention relates to a computer-based management system for a service contracting business which quickly and easily generates written contract proposals, invoices and reports on profitability. The invention also relates to a service business management system that is readily transportable, permitting business to be effectively conducted from virtually any location.
BACKGROUND OF THE INVENTION
Written contracts help protect both contractors and their clients by reducing misunderstandings, clarifying terms and setting mutually agreed upon prices.
Service contractors, such as those involved in any form of the many property maintenance, repair and building trades, are faced with certain problems. They can greatly benefit from the advantages of having written contracts with their clients, however, the nature of these businesses creates logistical problems. Most service contractors need to view a job site or property at a remote location in order to prepare a contract proposal. They also tend to work in the field or have employees who work in the field. In a typical day many contractors will work at a number of locations—at an office, in the field, from a vehicle, and at home. Thus organizing and managing a service business involves challenges often not associated with other businesses.
Computers are an effective tool to help organize information and manage a business. Most businesses use them; however, most service contracting businesses only realize a fraction of the potential benefit because of limited availability of software programs written specifically for them and the mismatch between common computer systems—desktop PCs or larger computers—and the mobile nature of their work.
Some of the conventional methods that service contracting people use to conduct business are:
giving verbal quotes and invoices;
submitting nothing other than a price written on a business card;
preparing hand written contract proposals and invoices; and
viewing a job or completing work in the field, returning to the office to use a computer system to generate a contract proposal, change order, or invoice, and then mailing, faxing or delivering the documents to the client.
Some of the drawbacks of these common practices are as follows: verbal contracts or prices written on business cards result in no documentation or historical records. If there are any problems or misunderstandings, the contracts may be unenforceable. Hand written paper work is often poorly organized and difficult to read. Any changes to original copies are cumbersome at best. When any of these methods are used, job estimates are often largely guess work, or based on rule of thumb generalizations that may or may not be based on sound management and accounting practices. In order to be successful, businesses using these methods often use only seasoned individuals with years of work experience for bidding.
Better organized service businesses often have a computer system in a central office. Some of the disadvantages with this arrangement are the time delays that occur due to the distance between work sites and the office, and the lack of access to important information while in the field or away from the office for any reason. For example, it typically takes several days to a week for a mailed contract proposal to reach a client after the initial visit to review work to be done. Furthermore, most service businesses use a word processor or spreadsheet computer program to generate contract proposals and invoices. These are very inefficient systems in this context because critical information is either not captured at all, or stored in many separate files making it difficult to extract and utilize it in a meaningful way.
Conventional methods for conducting business away from an office include using standard brief cases and perhaps file boxes to transport written documents or records. More recently business people have employed a laptop or notebook computer, a carrying case and possibly even some related organizers or gadgets for their vehicles.
U.S. Pat. No. 5,570,291 is a system for quickly estimating and ordering the custom manufacture of an item wherein a remote computer with general customer and delivery data, is linked to a central computer with a database of product details for creating price estimates, which in turn is linked to a third computer at a manufacturing plant for accessing scheduling and delivery data as well as immediate order placement. This system is geared towards the manufacture of a product.
U.S. Pat. No. 5,317,503 is an apparatus designed for calculating the repair cost of a damaged car. It is specifically designed for insurance applications.
Tree Management Systems, Inc. of Bloomington, Indiana, provides a tree service industry system for both a hand held computing device and standard desktop computers. The desktop system allows the operator to organize client and job information, generate invoices and itemized proposals, schedule work, track employee and inventory data, and generate reports for receivables, jobs and sales. The portable hand held system is limited only to maintaining customer information and generating proposals.
Contractor's Management Systems of Langdon, N.H., provides a system for the plumbing, HVAC and electrical industries that includes general ledger, financial statements, check writing, point of sale processing, bar coding, inventory tracking, and service scheduling as well as estimating and establishing set prices for common tasks. The system apparently requires an operator to factor in an overhead margin and a profit margin on top of labor costs and materials costs to determine prices for specific tasks to be included in a “price book”. Reference is also made to generating estimates by creating and combining several assemblies of parts. Thus, it appears that this system is geared towards setting standard prices that will repeatedly be charged for specific tasks such as changing a hot water heater or installing a bath tub. There is also reference to comparing actual hours and materials to “defined” hours and materials in order to examine a task for profitability. It appears that this is an attempt to check that the average amount of actual time and materials used in a specific task over time is commensurate with the time and materials allocated when the price for that task was set. There is a reference to a portable system, but the capabilities are apparently limited to generating proposals and invoices.
The Roofer's Database of Garland, Tex., provides a software program for the roofing industry that organizes customer and job information, generates proposals and invoices, tracks employees, suppliers, sales leads and sales performance. Reference is made to “job costing” for job estimates where the operator inputs “profit and overhead percentages” in addition to labor and materials. It also refers to measuring productivity by tracking the history of “squares” (of direct material) bid versus “squares” (of direct materials) used.
Evergreen Technology of Seattle, Wash., provides a system specifically for the painting and wall covering industry that includes labor rate calculation, bidding, invoicing, work scheduling and employee motivation. In the labor rate calculation, overhead is based on monthly expenses. Depreciation for equipment or other capitalized expenses doesn't appear to be accounted for. Profit is a flat percentage markup on an operator's “desired profit”, and there are no guidelines for establishing what an appropriate profit percentage should be. Time and materials are used to generate itemized prices in an estimate worksheet, but actual proposals don't have itemized prices or a job discount, and an operator doesn't have the ability to use discretion to override a price that the system calculates. There are job cost reports that compare actual to estimated labor, materials, overhead and profit for a job.
What is desired, therefore, is a computer-based system specifically designed to help service contracting people in a variety of industries quickly and easily generate written contract proposals with itemized prices that are competitive yet profitable. Furthermore, the operator should be able to use discretion as needed to override any particular price that the system calculates or to offer a job discount as desired to reflect the efficiencies that a contractor can realize when executing larger jobs or multiple jobs in a single location, and to encourage clients to accept more services. Since the most significant cost driver in many service businesses is labor, the emphasis for pricing, profitability and any comparisons is summarized by consistently referring to labor rates that, after being adjusted for direct materials expenses, specifically incorporate all other business expenses and a justifiable profit.
The benchmark or minimum labor rate is calculated using generally accepted job cost accounting methods that properly incorporate depreciation expenses and profit. Profit, as forecasted in a proposal price, should conform to the common job cost accounting concepts of return on investment or return on equity compared to alternative potential investments. Thus, an estimated profit can justifiably be set by comparing an expected rate of return to returns of Treasury Bills and the stock market as is common in economic theory, instead of randomly choosing a “profit markup” on any particular job.
The system also organizes information so that it is easily accessible and can provide meaningful performance feedback including survey responses from clients so that managers can make informed decisions about how to improve the business. The system generates work orders, invoices and profit reports based on only the accepted portions of an itemized proposal.
A system with all of the above capabilities would further benefit service contracting people if the whole system was completely portable.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a computer-based service business management system that organizes and stores important information and allows it to be quickly and easily accessed and utilized.
It is another object of this invention to provide a system that quickly and easily generates written contract proposals and invoices.
It is another object of this invention to provide a system that will quickly and easily calculate and display a minimum labor rate charge that will cover estimates of business costs and allow for a profit.
It is another object of this invention to provide a system that will calculate and display estimates of competitive yet profitable prices for a contract proposal by incorporating a user's estimates of time and materials to complete the job, and will automatically apply a calculated minimum labor rate charge.
It is another object of this invention to provide a system that will calculate and display estimates of competitive yet profitable prices for a contract proposal by incorporating a user's measurements of an area to be worked on, and automatically applying historical average usage rates or industry standardized usage rates for direct labor time and direct materials used per unit of area, and then automatically apply a calculated minimum labor rate charge.
It is another object of this invention to provide a system that quickly and easily generates written contract proposals with itemized prices.
It is another object of this invention to provide a system that will calculate and display an estimate of a maximum job discount that can be offered based on the difference between a sum of itemized prices included within the contract proposal and a calculated minimum job price based upon a minimum labor rate charge.
It is another object of this invention to provide a system that will calculate and display an estimate of a maximum job discount that can be offered based on the difference between a sum of itemized prices included within the contract proposal and a calculated minimum job price that incorporates estimates of time and materials to complete the job, based on a users measurement of area to be worked on, and automatically applies a calculated minimum labor rate charge.
It is another object of this invention to provide a system that quickly and easily generates written contract proposals with itemized prices and a job discount that is offered if a contract is accepted in full.
It is another object of this invention to provide a system that quickly and easily generates work orders and invoices based on accepted contracts or only the accepted portions of itemized contract proposals.
It is another object of this invention to provide a system that helps manage a business by generating reports that calculate estimates of job profit and compare bidding estimates to actual results based on labor rates. These reports can be used to track the effectiveness of managers, sales people and employees, as well as general business performance. These reports also provide regular feedback so that informed adjustments and improvements can be made in performance.
It is another object of this invention to provide a system that organizes client lists and utilizes client feedback to quickly and easily generate lists of references for presentation to potential new clients.
It is another object of this invention to provide a system that can quickly and easily summarize outstanding receivables.
These and other objects of the invention are achieved by provision of a micro processor, an input device for entering job costing data and job parameter information, an output device such as a printer to generate contract proposals and/or management reports.
A display device is preferably also provided to display the minimum labor rate calculated by a program executed on the microprocessor from the job costing data. Memory is preferably also provided to store at least the minimum labor rate for use in generating management reports.
In one embodiment, the program calculates minimum job price which is displayed, prompting entry of a contract price. In another embodiment, the program calculates a maximum job discount which is displayed, prompting entry of a labor rate and determination of a price.
Management reports generated by the system include comparison of minimum to actual labor rate and actual to contract labor rate. Survey results may be reviewed on a crew by crew basis, and references may be retrieved on a customer basis.
Additionally, it is an object of this invention to provide a complete computer-based service business management system and materials commonly used by service contracting people to conduct business in an arrangement that can be readily transported, and quickly and easily utilized from virtually any location. This combination of materials and information that can be transported in a usable arrangement is considered to be more than a mobile office and might therefore be referred to as a “mobile business management system”.
This additional object and other objects of the invention are achieved by provision of the previously listed items for the computer-based service business management system as well as:
a carrying case
power supply components such as batteries, battery chargers, power cords, a power converter, power adapters, or a power surge protector
other materials and equipment commonly used by service contracting people to conduct business such as pens, pencils, calculators, reference materials, marketing materials, a stapler, paper clips, binders or business cards.
The principal information processor for the mobile business management system may be integral to the mobile system, as would be the case if a common portable computer is used by itself, or it may be located apart from the mobile system, as would be the case if a central computer is remotely accessed by the mobile system. Remote access might be accomplished by telecommunications or wireless communications.
As used to describe the invention, “service contracting people” and “service contractors” include, but are not limited to, service contracting business owners, managers, sales people, forepersons, trades people, their employees and subcontractors.
Also as used to describe the invention, “service contracting businesses” and “service contractors” include, but are not limited to, businesses related to:
awnings/canopies
building/remodeling
carpentry
carpet installation/cleaning
chimney cleaning
closet remodeling/closet organizers
decorating
drywall/sheetrocking
electrical services
excavating
fencing
fire/burglar alarms
flooring
furniture restoration
glass repair/replacement
handyman services
home health care
house/office cleaning
HVAC
insulation
interior plantscapes
irrigation systems
kitchen remodeling
landscaping
locksmith
masonry
moving
painting
paving
pet restraining systems
plumbing
pressure washing
roofing/siding
sandblasting
tiling
tree service
upholstering
water/damage restoration
waterproofing
welding
window cleaning
window replacements
window treatments
Without limitation, some examples of service contracting people using a mobile business management system are:
a sales person presenting an on site contract proposal directly to the client during the initial visit to review work to be done, resulting in a signed contract on the spot;
a job foreperson creating a change order sheet in the field to be immediately signed by the client, providing the necessary documentation that will help minimize misunderstandings;
a repair person creating an invoice for on site work just completed and presenting it directly to the client, resulting in reduced office work, reduced time delays and improved cash flow for the business; and
a manager generating and printing reports at home in the evening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram depicting an embodiment of the service business management system of the present invention as a mobile system including a carrying case for transport.
FIG. 2 is a block diagram generally depicting the flow of information to and from the service business management system of FIG. 1 .
FIG. 3 is a block diagram detailing the flow of information in FIG. 2 .
FIG. 4 is a flow diagram detailing the setup block in FIG. 3 .
FIG. 5 is a flow diagram detailing the contract proposal block in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a diagram representing a mobile service business management system in accordance with the invention. The service business management system 10 includes an input device such as a keyboard 12 or a voice recognition system, display device such as a monitor 14 , and an output device such as a printer 16 . FIG. 1 depicts the system 10 in a mobile embodiment as a portable computer 18 in a carrying case 20 that can transport the system components in an arrangement such that they can quickly and easily be utilized from within the case 20 when the case 20 is in an open position with minimal connecting or repositioning. In FIG. 1, the printer 16 is shown engaged in a printing process, with a paper feeder 22 feeding paper, and a printed sheet of paper 24 exiting the printer 16 . Power supplies for the computer 18 and the printer 16 can be rechargeable batteries that are integral to either unit, connection to an available AC outlet or plugging into a vehicle cigarette lighter via a DC to AC power converter. A separate pouch or gusset 26 as part of the case 20 can contain power cords, adapters, power converters or power surge protectors as needed. Holders 28 and 30 can organize paper, letterhead, pens, pencils, a calculator, a stapler and the like. Thus, the mobile system 10 in FIG. 1 can be transported by carrying handles 32 and 34 to any number of locations such as job sites, vehicles, an operator's home or office and then quickly and easily utilized to conduct business.
It is to be understood that FIG. 1 depicts a mobile embodiment of the invention and that the service business management system 10 in other embodiments may include, but are not limited to, a standard desktop PC and office printer, a LAN or other installation of multiple interconnected computers, hand held or pen computers, or network computers and the like.
FIG. 2 is a block diagram generally depicting information flows relating to the service business management system 10 . A particular service business might use a single system 10 , or a plurality of systems as represented in FIG. 2 . An owner or manager 50 would typically be a system operator as well as other managers, sales people or forepersons. Operators 50 utilize the system 10 to gather, store and present information to and from a plurality of clients 52 and a plurality of work crews 54 . The system 10 helps to organize the business and provide feedback that can be used to improve service quality and profitability.
FIG. 3 is a block diagram detailing the interactions in FIG. 2 . It is understood that as represented in the diagram the system 10 may be a single system operated by a single person or a number of people, or a number of systems operated by a number of people, and that the business may employ one or a number of work crews 54 to provide services for one or a number of clients 52 . The following discussion refers to a typical example of a preferred embodiment of the invention.
In FIG. 3, a manager 50 sets up the system 10 at block 60 by inputting information that will be used when generating contract proposals 64 and other reports. FIG. 4 details the setup block 60 . In FIG. 4, the system operator 50 inputs job costing data at block 100 that the system 10 utilizes to calculate a minimum labor rate charge at block 102 . An example of job costing data input at block 100 would be:
an average of direct labor wages for employees on work crews (AW)
annual direct labor hours (DLH)
the workman's compensation insurance rate for the business expressed as a percentage of wages(WCIR)
estimated annual overhead expenses for the business (OE)
equity investment in the business (El)
expected return on equity investment expressed as an annualized percentage rate of return (ROE)
An example of the calculation performed by the system 10 to determine the minimum labor rate (MLR) at block 102 would be: MLR = AW + ( AW * WCIR ) + OE DLH + ( EI * ROE ) DLH
Overhead expenses should include appropriate depreciation expenses for equipment and other business expenses that are capitalized. In this example, profit is expressed as the equity investment in the business multiplied by the expected return on equity investment. Equity investment is commonly defined in accounting references as total business assets including working capital, minus outstanding debt including capitalized leases. Expected return on equity investment for a particular service business can be related to the long term return on the publicly traded stock of companies in the same industry or similar industries. Upward adjustments are typically made in the expected rate of return to allow for a controlling ownership interest or a small business that is inherently more risky than a larger publicly traded company. Thus, it is not unusual for a small business owner to expect an annual return on the equity investment in the range of twenty to thirty percent.
The minimum labor rate, as calculated above, is displayed by the system 10 for use by managers, sales people and other employees. Because several of the numbers used are forecasted estimates for the current or coming time period, deriving these numbers can prompt managers and other employees to focus on general business issues and goals. Furthermore, as time progresses or the business changes, managers and employees can review previous estimates and come up with new estimates based on new or updated information. Again, this can prompt discussion of important issues.
At block 104 , the operator 50 inputs a list of the materials and their unit prices commonly used by the work crews to provide services to clients. These will typically be direct materials that are considered part of a specific job, such as paint products for a painting contractor or fabric for a window treatment business.
At block 106 , the system operator 50 inputs a list of any commonly used subcontractors and their known charges or rates. For example, a driveway paving contractor may often use a particular excavating company when a large piece of excavating equipment is needed for a job. The system operator 50 may input the name and phone number of the excavator, the model of the machine, the hourly or daily rate for the machine and an operator, and any transport fee to have the machine delivered and removed from the job.
At block 108 , the operator 50 inputs any other common direct costs associated with the business. For example, a kitchen remodeling contractor might include a town permit fee and the charge rate, such as $10 for every $1,000 of estimated job cost.
At block 110 , the operator 50 inputs, as needed or desired, historical or industry standards for labor production rates and materials usage rates per unit of work area. In some service industries, these rates are measurable and consistent enough that a measurement of an area to be worked on, such as the square footage of a new black top driveway, can be used to calculate estimates for direct labor time and direct materials.
Referring back to FIG. 3, the system 10 stores the setup information from block 60 , as well as all other information inputted into the system in database 62 for use and recall as required. It is understood that as represented in FIG. 3, the database 62 may be located in the same place as the rest of the system 10 —as would be the case in embodiments of the invention including a self contained portable computer or a single desktop PC—or the database 62 may be located separately from a system 10 —as would be the case if a mobile system 10 or several mobile systems are used by sales people in the field and a central computer is remotely accessed by the mobile systems via telecommunications or wireless communications. Similarly, a network computer that has limited processing or storage capabilities may be used together with a portable printer as a mobile system 10 and the internet may be utilized to access an internet site that is in effect the database 62 , or may be connected to the database 62 .
Now that the system 10 has been set up at block 60 , it is ready to start generating printed contract proposals at block 64 . FIG. 5 is a flow diagram detailing the contract proposal block 64 . In FIG. 5, a system operator 50 first looks up the client/job site at block 200 by searching the client/job site database 202 , which is a part of the system database 62 . If the client/job site data is found, the operator 50 proceeds to block 206 . If the client/job site data is not found, the operator 50 creates a new account at block 204 by inputting the appropriate information. Once the client/job site account is either located or created, the operator 50 can start creating the contract proposal. At block 206 , the operator 50 inputs a work description for one line item or work item of the proposal. If needed, the operator 50 can incorporate any of the materials inputted during the setup procedure 60 by viewing the materials database 208 which is a part of the system database 62 shown in FIG. 3 . The operator 50 includes any materials in the work description by viewing the materials list and selecting any appropriate records. If a material is not found in the materials list, the operator 50 can easily add it to the database 208 in FIG. 5 .
Once the line item work description at block 206 is completed, the operator 50 inputs at block 210 either estimates of time and materials needed to complete the work or a measurement of the work area as described in block 206 . Specifically, the operator 50 either inputs estimates of direct labor time and direct materials amounts, or a measurement of the work area to which the system 10 applies the labor production rates and materials usage rates input at block 110 in FIG. 4 in order to calculate the estimates of direct labor time and direct materials amounts needed to complete the work description. To include direct materials or other direct costs, the operator 50 or the system 10 can access the materials database 208 and the other cost database 212 in FIG. 5, which are part of the system database 62 as inputted in the system setup at block 60 in FIG. 3 . The operator 50 also inputs at block 210 in FIG. 5 a labor rate that can vary depending on the type and difficulty of work, the crew that will most likely be doing the work, and other considerations. The labor rate inputted for any single line item will typically be greater than the minimum labor rate calculated by the system 10 at block 102 in FIG. 4 . This is done to allow for general operating inefficiencies that are common when contractors execute relatively small jobs, compared to general operating efficiencies that are common when contractors execute relatively large jobs.
The system computes and displays two prices at block 214 of FIG. 5 for the work item described in block 206 . One price is a minimum line item price that is calculated by multiplying the direct labor time estimate from block 210 by the minimum labor rate calculated from the data in the job costing database 216 which was inputted at block 100 in FIG. 4, and then adding the costs for the direct materials and other direct from block 210 in FIG. 5 .
The second price displayed for the work line item is calculated by using the same time and materials estimates from block 210 , then multiplying the direct labor time estimate by the labor rate inputted at block 210 .
At block 218 , the operator 50 considers both prices calculated and displayed by the system 10 at block 214 , and then inputs a price for the contract proposal work line item that is preferably at or near the higher price related to the higher labor rate inputted at block 210 .
As shown in FIG. 5, the line item description, costing and pricing procedures are repeated for each additional work line item to be included in the contract proposal until all line items are completed.
At block 220 , the system 10 calculates and displays a maximum job discount that can be offered to the client if the whole contract proposal including all line items entered at block 206 is accepted. Specifically, the system 10 calculates the maximum job discount by summing the itemized proposal prices inputted at block 218 , then subtracting a sum of the minimum line item prices calculated at block 214 which are based on the minimum labor rate calculated from the job costing data stored at database 216 . Thus, the maximum job discount summarizes the difference between the minimum labor rate and higher labor rates incorporated in the proposal line item prices.
At block 222 , the operator 50 considers the maximum job discount displayed at block 220 , and then uses discretion to input an actual job discount for the contract proposal, if any. Typically, to come up with an actual job discount, the operator 50 also considers such things as the type of work, the desirability of working for the client, the size of the job, and the potential efficiencies of doing the whole job. By including line item prices and a job discount for the contract proposal, a sales person can propose additional work without increasing the possibility of no acceptances, while the discount encourages a client to sign up for the whole job.
Finally, at block 224 the operator 50 has completed all the inputs the system 10 needs to generate the printed proposal. Referring again to FIG. 3, the system 10 prints the contract proposal 64 to be reviewed by the client 52 . An operator 50 can also use the system 10 to generate a list of references 66 for the client 52 . Specifics regarding the generation of the list of references 66 will be detailed later in the discussion of FIG. 3 .
If the client 52 wants to proceed with any of the work, an acceptance 68 is indicated, typically a copy of the proposal with accepted line items initialed and the clients signature indicating acceptance of the initialed work descriptions as well as other terms and conditions included in the contract. Upon receiving the acceptance 68 , the operator 50 inputs markers into the system 10 to identify accepted line items of the contract proposal 64 . The operator 50 then uses the system 10 to print out a work order 70 for the work crew 54 , and the job can be included in the scheduling function 72 as the manager 50 coordinates work to be done by the work crews 54 . Also, upon acceptance 68 , the client 52 can now be included in the client list 74 which is generated by the system 10 and includes all patrons for whom work has been performed or is scheduled to be performed by the business.
The work order 70 includes information related to the accepted work items from block 68 presented in a way that helps the work crews 54 execute the job in a concise, efficient and organized manner. Typically, the first page of the work order 70 includes a job summary that includes client and job site information, job price, the sales person who bid the job, the date of the bid, and summaries of estimates from block 210 in FIG. 5 of time, materials and other costs for all accepted line items. Thus, the manager 50 can quickly and easily assess the scope of the job no matter which employee actually bid the job or when it was bid. Furthermore, the work crew 54 will have a concise shopping list of materials and other items that will likely be needed to start and complete the job.
The remainder of the work order 70 includes a break down of information for each line item accepted at block 68 . Specifically, for each accepted line item, the work order 70 would include the work description and direct materials input at block 206 in FIG. 5, the line item price input an block 218 , and the estimates of direct labor time, direct materials amounts and other direct costs and specifications which were input or calculated at block 210 . If there was a job discount (JD) input at block 222 and the whole job was accepted, then the price for each line item on the work order 70 is adjusted to reflect the job discount as follows: the line item or work item price (WIP) at block 218 of FIG. 5; minus a price adjustment (PA), which is calculated as: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) )
Thus, the work crew 54 in FIG. 3 has complete written specifications to autonomously perform work as accepted by the client 52 , allowing managers and sales people the freedom to concentrate on other activities to further the business rather than spending significant amounts of time supervising work crews.
The work order 70 is also preferably designed to be a job worksheet. As the work crew 54 is executing work items, they are instructed to record the names of employees performing each work item as well as the actuals 76 for time, materials and other direct costs used to complete each work item. This process helps work crew members focus on the estimated time and materials from block 210 in FIG. 5 as their specific goals for executing each line item as described at block 206 . As the work crew 54 is completing work items and filling in the actuals 76 , they are also getting immediate feedback on their work performance by comparing the actuals 76 to the estimates detailed in the work order 70 .
When the job is completed, the operator 50 inputs the actuals 76 for each work item as well as the date the job was completed into the system 10 . Now the system 10 can be used to generate an invoice 78 and preferably a survey to be presented to the client 52 . Typically, the survey requests the client 52 to rate general satisfaction with the work done, specify anything that was particularly liked or disliked, and give permission to use their name and phone number as a reference.
When the job is completed, any corresponding balance due from the client 52 can be included in a receivables report 80 generated by the system 10 which tallies all outstanding receivables at any given time for the manager 50 .
The operator 50 can also use the system 10 to generate a job profit report 82 for the manager 50 and possibly other employees. The job profit report 82 includes a job summary for reviewing the whole job, and details for each of the completed work items. The job summary preferably identifies the client and job site, the sales person, the bid date, the date completed, and includes an estimate of actual profit for the whole job, the estimated actual job profit as a percentage of the job price, comparisons of the actual labor rate for the whole job to the minimum labor rate calculated in block 102 in FIG. 4 and the labor rate at which the job was bid, and comparisons of estimates from block 210 in FIG. 5 to the actuals at block 76 in FIG. 3 .
The estimate of actual profit for the whole job (AJP) is calculated by the system 10 as follows: for all accepted work items at block 68 of FIG. 3 —the sum of the work item prices (WIP) at block 218 of FIG. 5; minus any job discount (JD) at block 222 of FIG. 5; minus a sum of the actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC); minus actuals at block 76 of FIG. 3 for the sum of direct labor times multiplied by average direct labor wages at block 100 of FIG. 4 (ADLC); minus actuals at block 76 of FIG. 3 for the sum of direct labor times multiplied by average direct labor wages and the workman's compensation insurance rate at block 100 of FIG. 4 (AWCI); minus actuals at block 76 of FIG. 3 for the sum of direct labor times multiplied by annual overhead expenses at block 100 of FIG. 4 and then divided by annual direct labor time at block 100 of FIG. 4 (AOE):
AJP=ΣWIP−JD−ΣADMC−ADLC−AWCI−AOE
The estimated actual job profit as a percentage of job price (AJP %) is calculated by the system 10 as the estimated actual profit for the whole job (AJP) as described above divided by: the sum of the work item prices (WIP) at block 218 of FIG. 5 for all accepted work items at block 68 of FIG. 3, minus any job discount (JD) at block 222 of FIG. 5 : AJP % = AJP ( ∑ WIP - JD )
The actual labor rate for the whole job (AJLR) is calculated by the system 10 as follows: for all accepted work items at block 68 of FIG. 3 —the sum of the work item prices (WIP) at block 218 of FIG. 5; minus any job discount (JD) at block 222 of FIG. 5; minus a sum of the actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC); divided by a sum of the actuals at block 76 of FIG. 3 for direct labor time (ADLT): AJLR = ( ∑ WIP - JD - ∑ ADMC ) ∑ ADLT
The labor rate at which the job was bid (BJLR) is calculated by the system 10 as follows: for all accepted work items at block 68 of FIG. 3 —the sum of the work item prices (WIP) at block 218 of FIG. 5; minus any job discount (JD) at block 222 of FIG. 5; minus a sum of the estimates at block 210 of FIG. 5 for direct materials costs and other direct costs (EDMC); divided by the sum of the estimates at block 210 of FIG. 5 for direct labor time (EDLT): BJLR = ( ∑ WIP - JD - ∑ EDMC ) ∑ EDLT
For each of the completed work items, the job profit report 82 in FIG. 3 preferably includes an estimate of actual profit, the estimated actual profit as a percentage of the work item price, comparisons of the actual labor rate to the labor rate at which the work item was bid, and comparisons of estimates at block 210 of FIG. 5 to the actuals at block 76 of FIG. 3 for the work item.
The estimate of actual profit for the work item (WIAP) is calculated by the system 10 as follows: for the work item—the price (WIP) at block 218 of FIG. 5; minus a price adjustment (PA) if there was a job discount (JD) input at block 222 and the whole job was accepted, as follows: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) ;
minus actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC); minus actuals at block 76 of FIG. 3 for direct labor time multiplied by average direct labor wages at block 100 of FIG. 4 (ADLC); minus actuals at block 76 of FIG. 3 for direct labor time multiplied by average direct labor wages and the workman's compensation insurance rate at block 100 of FIG. 4 (AWCI); minus actuals at block 76 of FIG. 3 for direct labor time multiplied by annual overhead expenses at block 100 of FIG. 4 and then divided by annual direct labor time at block 100 of FIG. 4 (AOE):
WIAP=WIP−PA−ADMC−ADLC−AWCI−AOE
The estimated actual profit for the work item as a percentage of the work item price (WIAP %) is calculated by the system 10 as the estimate of actual profit for the work item (WIAP) as described above divided by the work item price (WIP) at block 218 of FIG. 5, minus a price adjustment (PA) if there was a job discount input at block 222 (JD) and the whole job was accepted: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) WIAP % = WIAP ( WIP - PA )
The actual labor rate for the work item (WIALR) is calculated by the system 10 as follows: for the work item—the price (WIP) at block 218 of FIG. 5; minus a price adjustment (PA) if there was a job discount input at block 222 (JD) and the whole job was accepted: PA = JD * ( WIP ( Σ ( WIP excluding JD ) ) ) ;
minus actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC); divided by actuals at block 76 of FIG. 3 for direct labor time (ADLT): WIALR = ( WIP - PA - ADMC ) ADLT
The labor rate at which the work item was bid (WIBLR) is calculated by the system 10 as follows: for the work item—the price (WIP) at block 218 of FIG. 5 ; minus a price adjustment (PA) if there was a job discount input at block 222 (JD) and the whole job was accepted: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) ;
minus estimates at block 210 of FIG. 5 for direct materials costs and other direct costs (EDMC); divided by the estimate at block 210 of FIG. 5 for direct labor time (EDLT): WIBLR = ( WIP - PA - EDMC ) EDLT
The job profit report 82 in FIG. 3 can be used by the manager 50 for summarized feedback on business and employee performance compared to budget forecasts and goals. As jobs are completed, job profit reports 82 provide continual feedback, allowing the manger 50 to quickly identify both problems and successes, communicate any issues to employees and initiate changes that will improve service quality and profitability. Thus, the system 10 facilitates the communication loop or information cycle—set performance standards and goals, execute work, measure performance, compare performance to goals, improve performance—that is common in management theory and is often utilized in large well organized businesses. The system 10 allows smaller contracting businesses to easily employ these practices giving them the opportunity for continuous improvement and growth.
Additional feedback is realized when a survey response 84 is returned by the client 52 and the operator 50 inputs the data into the system 10 . The system 10 can then identify clients 52 that are satisfied with the work and have given permission to use them as references to generate a list of references 66 . The system 10 can also sort the list of references 66 by locality, such as zip code. Thus, when a contract proposal 64 is generated by the system 10 , an appropriate list of local references 66 can also be presented to the client 52 which can help increase the chances of initiating an acceptance 68 .
Survey responses 84 together with job profit reports 82 provide the manager 50 with a wealth of information with which to make informed management decisions and employee reviews 86 . For employee reviews 86 , the manager 50 can provide concise measurements of performance with specific details of successes and shortcomings. | The invention provides a micro processor, an input device for entering job costing data and job parameter information, an output device such as a printer to generate contract proposals and/or management reports. A display device is preferably also provided to display the minimum labor rate calculated by a program executed on the microprocessor from the job costing data. Memory is preferably also provided to store at least the minimum labor rate for use in generating management reports. | Summarize the information, clearly outlining the challenges and proposed solutions. | [
"FIELD OF THE INVENTION The invention relates to a computer-based management system for a service contracting business which quickly and easily generates written contract proposals, invoices and reports on profitability.",
"The invention also relates to a service business management system that is readily transportable, permitting business to be effectively conducted from virtually any location.",
"BACKGROUND OF THE INVENTION Written contracts help protect both contractors and their clients by reducing misunderstandings, clarifying terms and setting mutually agreed upon prices.",
"Service contractors, such as those involved in any form of the many property maintenance, repair and building trades, are faced with certain problems.",
"They can greatly benefit from the advantages of having written contracts with their clients, however, the nature of these businesses creates logistical problems.",
"Most service contractors need to view a job site or property at a remote location in order to prepare a contract proposal.",
"They also tend to work in the field or have employees who work in the field.",
"In a typical day many contractors will work at a number of locations—at an office, in the field, from a vehicle, and at home.",
"Thus organizing and managing a service business involves challenges often not associated with other businesses.",
"Computers are an effective tool to help organize information and manage a business.",
"Most businesses use them;",
"however, most service contracting businesses only realize a fraction of the potential benefit because of limited availability of software programs written specifically for them and the mismatch between common computer systems—desktop PCs or larger computers—and the mobile nature of their work.",
"Some of the conventional methods that service contracting people use to conduct business are: giving verbal quotes and invoices;",
"submitting nothing other than a price written on a business card;",
"preparing hand written contract proposals and invoices;",
"and viewing a job or completing work in the field, returning to the office to use a computer system to generate a contract proposal, change order, or invoice, and then mailing, faxing or delivering the documents to the client.",
"Some of the drawbacks of these common practices are as follows: verbal contracts or prices written on business cards result in no documentation or historical records.",
"If there are any problems or misunderstandings, the contracts may be unenforceable.",
"Hand written paper work is often poorly organized and difficult to read.",
"Any changes to original copies are cumbersome at best.",
"When any of these methods are used, job estimates are often largely guess work, or based on rule of thumb generalizations that may or may not be based on sound management and accounting practices.",
"In order to be successful, businesses using these methods often use only seasoned individuals with years of work experience for bidding.",
"Better organized service businesses often have a computer system in a central office.",
"Some of the disadvantages with this arrangement are the time delays that occur due to the distance between work sites and the office, and the lack of access to important information while in the field or away from the office for any reason.",
"For example, it typically takes several days to a week for a mailed contract proposal to reach a client after the initial visit to review work to be done.",
"Furthermore, most service businesses use a word processor or spreadsheet computer program to generate contract proposals and invoices.",
"These are very inefficient systems in this context because critical information is either not captured at all, or stored in many separate files making it difficult to extract and utilize it in a meaningful way.",
"Conventional methods for conducting business away from an office include using standard brief cases and perhaps file boxes to transport written documents or records.",
"More recently business people have employed a laptop or notebook computer, a carrying case and possibly even some related organizers or gadgets for their vehicles.",
"U.S. Pat. No. 5,570,291 is a system for quickly estimating and ordering the custom manufacture of an item wherein a remote computer with general customer and delivery data, is linked to a central computer with a database of product details for creating price estimates, which in turn is linked to a third computer at a manufacturing plant for accessing scheduling and delivery data as well as immediate order placement.",
"This system is geared towards the manufacture of a product.",
"U.S. Pat. No. 5,317,503 is an apparatus designed for calculating the repair cost of a damaged car.",
"It is specifically designed for insurance applications.",
"Tree Management Systems, Inc. of Bloomington, Indiana, provides a tree service industry system for both a hand held computing device and standard desktop computers.",
"The desktop system allows the operator to organize client and job information, generate invoices and itemized proposals, schedule work, track employee and inventory data, and generate reports for receivables, jobs and sales.",
"The portable hand held system is limited only to maintaining customer information and generating proposals.",
"Contractor's Management Systems of Langdon, N.H., provides a system for the plumbing, HVAC and electrical industries that includes general ledger, financial statements, check writing, point of sale processing, bar coding, inventory tracking, and service scheduling as well as estimating and establishing set prices for common tasks.",
"The system apparently requires an operator to factor in an overhead margin and a profit margin on top of labor costs and materials costs to determine prices for specific tasks to be included in a “price book.”",
"Reference is also made to generating estimates by creating and combining several assemblies of parts.",
"Thus, it appears that this system is geared towards setting standard prices that will repeatedly be charged for specific tasks such as changing a hot water heater or installing a bath tub.",
"There is also reference to comparing actual hours and materials to “defined”",
"hours and materials in order to examine a task for profitability.",
"It appears that this is an attempt to check that the average amount of actual time and materials used in a specific task over time is commensurate with the time and materials allocated when the price for that task was set.",
"There is a reference to a portable system, but the capabilities are apparently limited to generating proposals and invoices.",
"The Roofer's Database of Garland, Tex.",
", provides a software program for the roofing industry that organizes customer and job information, generates proposals and invoices, tracks employees, suppliers, sales leads and sales performance.",
"Reference is made to “job costing”",
"for job estimates where the operator inputs “profit and overhead percentages”",
"in addition to labor and materials.",
"It also refers to measuring productivity by tracking the history of “squares”",
"(of direct material) bid versus “squares”",
"(of direct materials) used.",
"Evergreen Technology of Seattle, Wash.",
", provides a system specifically for the painting and wall covering industry that includes labor rate calculation, bidding, invoicing, work scheduling and employee motivation.",
"In the labor rate calculation, overhead is based on monthly expenses.",
"Depreciation for equipment or other capitalized expenses doesn't appear to be accounted for.",
"Profit is a flat percentage markup on an operator's “desired profit”, and there are no guidelines for establishing what an appropriate profit percentage should be.",
"Time and materials are used to generate itemized prices in an estimate worksheet, but actual proposals don't have itemized prices or a job discount, and an operator doesn't have the ability to use discretion to override a price that the system calculates.",
"There are job cost reports that compare actual to estimated labor, materials, overhead and profit for a job.",
"What is desired, therefore, is a computer-based system specifically designed to help service contracting people in a variety of industries quickly and easily generate written contract proposals with itemized prices that are competitive yet profitable.",
"Furthermore, the operator should be able to use discretion as needed to override any particular price that the system calculates or to offer a job discount as desired to reflect the efficiencies that a contractor can realize when executing larger jobs or multiple jobs in a single location, and to encourage clients to accept more services.",
"Since the most significant cost driver in many service businesses is labor, the emphasis for pricing, profitability and any comparisons is summarized by consistently referring to labor rates that, after being adjusted for direct materials expenses, specifically incorporate all other business expenses and a justifiable profit.",
"The benchmark or minimum labor rate is calculated using generally accepted job cost accounting methods that properly incorporate depreciation expenses and profit.",
"Profit, as forecasted in a proposal price, should conform to the common job cost accounting concepts of return on investment or return on equity compared to alternative potential investments.",
"Thus, an estimated profit can justifiably be set by comparing an expected rate of return to returns of Treasury Bills and the stock market as is common in economic theory, instead of randomly choosing a “profit markup”",
"on any particular job.",
"The system also organizes information so that it is easily accessible and can provide meaningful performance feedback including survey responses from clients so that managers can make informed decisions about how to improve the business.",
"The system generates work orders, invoices and profit reports based on only the accepted portions of an itemized proposal.",
"A system with all of the above capabilities would further benefit service contracting people if the whole system was completely portable.",
"SUMMARY OF THE INVENTION Accordingly, it is an object of this invention to provide a computer-based service business management system that organizes and stores important information and allows it to be quickly and easily accessed and utilized.",
"It is another object of this invention to provide a system that quickly and easily generates written contract proposals and invoices.",
"It is another object of this invention to provide a system that will quickly and easily calculate and display a minimum labor rate charge that will cover estimates of business costs and allow for a profit.",
"It is another object of this invention to provide a system that will calculate and display estimates of competitive yet profitable prices for a contract proposal by incorporating a user's estimates of time and materials to complete the job, and will automatically apply a calculated minimum labor rate charge.",
"It is another object of this invention to provide a system that will calculate and display estimates of competitive yet profitable prices for a contract proposal by incorporating a user's measurements of an area to be worked on, and automatically applying historical average usage rates or industry standardized usage rates for direct labor time and direct materials used per unit of area, and then automatically apply a calculated minimum labor rate charge.",
"It is another object of this invention to provide a system that quickly and easily generates written contract proposals with itemized prices.",
"It is another object of this invention to provide a system that will calculate and display an estimate of a maximum job discount that can be offered based on the difference between a sum of itemized prices included within the contract proposal and a calculated minimum job price based upon a minimum labor rate charge.",
"It is another object of this invention to provide a system that will calculate and display an estimate of a maximum job discount that can be offered based on the difference between a sum of itemized prices included within the contract proposal and a calculated minimum job price that incorporates estimates of time and materials to complete the job, based on a users measurement of area to be worked on, and automatically applies a calculated minimum labor rate charge.",
"It is another object of this invention to provide a system that quickly and easily generates written contract proposals with itemized prices and a job discount that is offered if a contract is accepted in full.",
"It is another object of this invention to provide a system that quickly and easily generates work orders and invoices based on accepted contracts or only the accepted portions of itemized contract proposals.",
"It is another object of this invention to provide a system that helps manage a business by generating reports that calculate estimates of job profit and compare bidding estimates to actual results based on labor rates.",
"These reports can be used to track the effectiveness of managers, sales people and employees, as well as general business performance.",
"These reports also provide regular feedback so that informed adjustments and improvements can be made in performance.",
"It is another object of this invention to provide a system that organizes client lists and utilizes client feedback to quickly and easily generate lists of references for presentation to potential new clients.",
"It is another object of this invention to provide a system that can quickly and easily summarize outstanding receivables.",
"These and other objects of the invention are achieved by provision of a micro processor, an input device for entering job costing data and job parameter information, an output device such as a printer to generate contract proposals and/or management reports.",
"A display device is preferably also provided to display the minimum labor rate calculated by a program executed on the microprocessor from the job costing data.",
"Memory is preferably also provided to store at least the minimum labor rate for use in generating management reports.",
"In one embodiment, the program calculates minimum job price which is displayed, prompting entry of a contract price.",
"In another embodiment, the program calculates a maximum job discount which is displayed, prompting entry of a labor rate and determination of a price.",
"Management reports generated by the system include comparison of minimum to actual labor rate and actual to contract labor rate.",
"Survey results may be reviewed on a crew by crew basis, and references may be retrieved on a customer basis.",
"Additionally, it is an object of this invention to provide a complete computer-based service business management system and materials commonly used by service contracting people to conduct business in an arrangement that can be readily transported, and quickly and easily utilized from virtually any location.",
"This combination of materials and information that can be transported in a usable arrangement is considered to be more than a mobile office and might therefore be referred to as a “mobile business management system.”",
"This additional object and other objects of the invention are achieved by provision of the previously listed items for the computer-based service business management system as well as: a carrying case power supply components such as batteries, battery chargers, power cords, a power converter, power adapters, or a power surge protector other materials and equipment commonly used by service contracting people to conduct business such as pens, pencils, calculators, reference materials, marketing materials, a stapler, paper clips, binders or business cards.",
"The principal information processor for the mobile business management system may be integral to the mobile system, as would be the case if a common portable computer is used by itself, or it may be located apart from the mobile system, as would be the case if a central computer is remotely accessed by the mobile system.",
"Remote access might be accomplished by telecommunications or wireless communications.",
"As used to describe the invention, “service contracting people”",
"and “service contractors”",
"include, but are not limited to, service contracting business owners, managers, sales people, forepersons, trades people, their employees and subcontractors.",
"Also as used to describe the invention, “service contracting businesses”",
"and “service contractors”",
"include, but are not limited to, businesses related to: awnings/canopies building/remodeling carpentry carpet installation/cleaning chimney cleaning closet remodeling/closet organizers decorating drywall/sheetrocking electrical services excavating fencing fire/burglar alarms flooring furniture restoration glass repair/replacement handyman services home health care house/office cleaning HVAC insulation interior plantscapes irrigation systems kitchen remodeling landscaping locksmith masonry moving painting paving pet restraining systems plumbing pressure washing roofing/siding sandblasting tiling tree service upholstering water/damage restoration waterproofing welding window cleaning window replacements window treatments Without limitation, some examples of service contracting people using a mobile business management system are: a sales person presenting an on site contract proposal directly to the client during the initial visit to review work to be done, resulting in a signed contract on the spot;",
"a job foreperson creating a change order sheet in the field to be immediately signed by the client, providing the necessary documentation that will help minimize misunderstandings;",
"a repair person creating an invoice for on site work just completed and presenting it directly to the client, resulting in reduced office work, reduced time delays and improved cash flow for the business;",
"and a manager generating and printing reports at home in the evening.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagram depicting an embodiment of the service business management system of the present invention as a mobile system including a carrying case for transport.",
"FIG. 2 is a block diagram generally depicting the flow of information to and from the service business management system of FIG. 1 .",
"FIG. 3 is a block diagram detailing the flow of information in FIG. 2 .",
"FIG. 4 is a flow diagram detailing the setup block in FIG. 3 .",
"FIG. 5 is a flow diagram detailing the contract proposal block in FIG. 3 .",
"DETAILED DESCRIPTION OF THE INVENTION FIG. 1 is a diagram representing a mobile service business management system in accordance with the invention.",
"The service business management system 10 includes an input device such as a keyboard 12 or a voice recognition system, display device such as a monitor 14 , and an output device such as a printer 16 .",
"FIG. 1 depicts the system 10 in a mobile embodiment as a portable computer 18 in a carrying case 20 that can transport the system components in an arrangement such that they can quickly and easily be utilized from within the case 20 when the case 20 is in an open position with minimal connecting or repositioning.",
"In FIG. 1, the printer 16 is shown engaged in a printing process, with a paper feeder 22 feeding paper, and a printed sheet of paper 24 exiting the printer 16 .",
"Power supplies for the computer 18 and the printer 16 can be rechargeable batteries that are integral to either unit, connection to an available AC outlet or plugging into a vehicle cigarette lighter via a DC to AC power converter.",
"A separate pouch or gusset 26 as part of the case 20 can contain power cords, adapters, power converters or power surge protectors as needed.",
"Holders 28 and 30 can organize paper, letterhead, pens, pencils, a calculator, a stapler and the like.",
"Thus, the mobile system 10 in FIG. 1 can be transported by carrying handles 32 and 34 to any number of locations such as job sites, vehicles, an operator's home or office and then quickly and easily utilized to conduct business.",
"It is to be understood that FIG. 1 depicts a mobile embodiment of the invention and that the service business management system 10 in other embodiments may include, but are not limited to, a standard desktop PC and office printer, a LAN or other installation of multiple interconnected computers, hand held or pen computers, or network computers and the like.",
"FIG. 2 is a block diagram generally depicting information flows relating to the service business management system 10 .",
"A particular service business might use a single system 10 , or a plurality of systems as represented in FIG. 2 .",
"An owner or manager 50 would typically be a system operator as well as other managers, sales people or forepersons.",
"Operators 50 utilize the system 10 to gather, store and present information to and from a plurality of clients 52 and a plurality of work crews 54 .",
"The system 10 helps to organize the business and provide feedback that can be used to improve service quality and profitability.",
"FIG. 3 is a block diagram detailing the interactions in FIG. 2 .",
"It is understood that as represented in the diagram the system 10 may be a single system operated by a single person or a number of people, or a number of systems operated by a number of people, and that the business may employ one or a number of work crews 54 to provide services for one or a number of clients 52 .",
"The following discussion refers to a typical example of a preferred embodiment of the invention.",
"In FIG. 3, a manager 50 sets up the system 10 at block 60 by inputting information that will be used when generating contract proposals 64 and other reports.",
"FIG. 4 details the setup block 60 .",
"In FIG. 4, the system operator 50 inputs job costing data at block 100 that the system 10 utilizes to calculate a minimum labor rate charge at block 102 .",
"An example of job costing data input at block 100 would be: an average of direct labor wages for employees on work crews (AW) annual direct labor hours (DLH) the workman's compensation insurance rate for the business expressed as a percentage of wages(WCIR) estimated annual overhead expenses for the business (OE) equity investment in the business (El) expected return on equity investment expressed as an annualized percentage rate of return (ROE) An example of the calculation performed by the system 10 to determine the minimum labor rate (MLR) at block 102 would be: MLR = AW + ( AW * WCIR ) + OE DLH + ( EI * ROE ) DLH Overhead expenses should include appropriate depreciation expenses for equipment and other business expenses that are capitalized.",
"In this example, profit is expressed as the equity investment in the business multiplied by the expected return on equity investment.",
"Equity investment is commonly defined in accounting references as total business assets including working capital, minus outstanding debt including capitalized leases.",
"Expected return on equity investment for a particular service business can be related to the long term return on the publicly traded stock of companies in the same industry or similar industries.",
"Upward adjustments are typically made in the expected rate of return to allow for a controlling ownership interest or a small business that is inherently more risky than a larger publicly traded company.",
"Thus, it is not unusual for a small business owner to expect an annual return on the equity investment in the range of twenty to thirty percent.",
"The minimum labor rate, as calculated above, is displayed by the system 10 for use by managers, sales people and other employees.",
"Because several of the numbers used are forecasted estimates for the current or coming time period, deriving these numbers can prompt managers and other employees to focus on general business issues and goals.",
"Furthermore, as time progresses or the business changes, managers and employees can review previous estimates and come up with new estimates based on new or updated information.",
"Again, this can prompt discussion of important issues.",
"At block 104 , the operator 50 inputs a list of the materials and their unit prices commonly used by the work crews to provide services to clients.",
"These will typically be direct materials that are considered part of a specific job, such as paint products for a painting contractor or fabric for a window treatment business.",
"At block 106 , the system operator 50 inputs a list of any commonly used subcontractors and their known charges or rates.",
"For example, a driveway paving contractor may often use a particular excavating company when a large piece of excavating equipment is needed for a job.",
"The system operator 50 may input the name and phone number of the excavator, the model of the machine, the hourly or daily rate for the machine and an operator, and any transport fee to have the machine delivered and removed from the job.",
"At block 108 , the operator 50 inputs any other common direct costs associated with the business.",
"For example, a kitchen remodeling contractor might include a town permit fee and the charge rate, such as $10 for every $1,000 of estimated job cost.",
"At block 110 , the operator 50 inputs, as needed or desired, historical or industry standards for labor production rates and materials usage rates per unit of work area.",
"In some service industries, these rates are measurable and consistent enough that a measurement of an area to be worked on, such as the square footage of a new black top driveway, can be used to calculate estimates for direct labor time and direct materials.",
"Referring back to FIG. 3, the system 10 stores the setup information from block 60 , as well as all other information inputted into the system in database 62 for use and recall as required.",
"It is understood that as represented in FIG. 3, the database 62 may be located in the same place as the rest of the system 10 —as would be the case in embodiments of the invention including a self contained portable computer or a single desktop PC—or the database 62 may be located separately from a system 10 —as would be the case if a mobile system 10 or several mobile systems are used by sales people in the field and a central computer is remotely accessed by the mobile systems via telecommunications or wireless communications.",
"Similarly, a network computer that has limited processing or storage capabilities may be used together with a portable printer as a mobile system 10 and the internet may be utilized to access an internet site that is in effect the database 62 , or may be connected to the database 62 .",
"Now that the system 10 has been set up at block 60 , it is ready to start generating printed contract proposals at block 64 .",
"FIG. 5 is a flow diagram detailing the contract proposal block 64 .",
"In FIG. 5, a system operator 50 first looks up the client/job site at block 200 by searching the client/job site database 202 , which is a part of the system database 62 .",
"If the client/job site data is found, the operator 50 proceeds to block 206 .",
"If the client/job site data is not found, the operator 50 creates a new account at block 204 by inputting the appropriate information.",
"Once the client/job site account is either located or created, the operator 50 can start creating the contract proposal.",
"At block 206 , the operator 50 inputs a work description for one line item or work item of the proposal.",
"If needed, the operator 50 can incorporate any of the materials inputted during the setup procedure 60 by viewing the materials database 208 which is a part of the system database 62 shown in FIG. 3 .",
"The operator 50 includes any materials in the work description by viewing the materials list and selecting any appropriate records.",
"If a material is not found in the materials list, the operator 50 can easily add it to the database 208 in FIG. 5 .",
"Once the line item work description at block 206 is completed, the operator 50 inputs at block 210 either estimates of time and materials needed to complete the work or a measurement of the work area as described in block 206 .",
"Specifically, the operator 50 either inputs estimates of direct labor time and direct materials amounts, or a measurement of the work area to which the system 10 applies the labor production rates and materials usage rates input at block 110 in FIG. 4 in order to calculate the estimates of direct labor time and direct materials amounts needed to complete the work description.",
"To include direct materials or other direct costs, the operator 50 or the system 10 can access the materials database 208 and the other cost database 212 in FIG. 5, which are part of the system database 62 as inputted in the system setup at block 60 in FIG. 3 .",
"The operator 50 also inputs at block 210 in FIG. 5 a labor rate that can vary depending on the type and difficulty of work, the crew that will most likely be doing the work, and other considerations.",
"The labor rate inputted for any single line item will typically be greater than the minimum labor rate calculated by the system 10 at block 102 in FIG. 4 .",
"This is done to allow for general operating inefficiencies that are common when contractors execute relatively small jobs, compared to general operating efficiencies that are common when contractors execute relatively large jobs.",
"The system computes and displays two prices at block 214 of FIG. 5 for the work item described in block 206 .",
"One price is a minimum line item price that is calculated by multiplying the direct labor time estimate from block 210 by the minimum labor rate calculated from the data in the job costing database 216 which was inputted at block 100 in FIG. 4, and then adding the costs for the direct materials and other direct from block 210 in FIG. 5 .",
"The second price displayed for the work line item is calculated by using the same time and materials estimates from block 210 , then multiplying the direct labor time estimate by the labor rate inputted at block 210 .",
"At block 218 , the operator 50 considers both prices calculated and displayed by the system 10 at block 214 , and then inputs a price for the contract proposal work line item that is preferably at or near the higher price related to the higher labor rate inputted at block 210 .",
"As shown in FIG. 5, the line item description, costing and pricing procedures are repeated for each additional work line item to be included in the contract proposal until all line items are completed.",
"At block 220 , the system 10 calculates and displays a maximum job discount that can be offered to the client if the whole contract proposal including all line items entered at block 206 is accepted.",
"Specifically, the system 10 calculates the maximum job discount by summing the itemized proposal prices inputted at block 218 , then subtracting a sum of the minimum line item prices calculated at block 214 which are based on the minimum labor rate calculated from the job costing data stored at database 216 .",
"Thus, the maximum job discount summarizes the difference between the minimum labor rate and higher labor rates incorporated in the proposal line item prices.",
"At block 222 , the operator 50 considers the maximum job discount displayed at block 220 , and then uses discretion to input an actual job discount for the contract proposal, if any.",
"Typically, to come up with an actual job discount, the operator 50 also considers such things as the type of work, the desirability of working for the client, the size of the job, and the potential efficiencies of doing the whole job.",
"By including line item prices and a job discount for the contract proposal, a sales person can propose additional work without increasing the possibility of no acceptances, while the discount encourages a client to sign up for the whole job.",
"Finally, at block 224 the operator 50 has completed all the inputs the system 10 needs to generate the printed proposal.",
"Referring again to FIG. 3, the system 10 prints the contract proposal 64 to be reviewed by the client 52 .",
"An operator 50 can also use the system 10 to generate a list of references 66 for the client 52 .",
"Specifics regarding the generation of the list of references 66 will be detailed later in the discussion of FIG. 3 .",
"If the client 52 wants to proceed with any of the work, an acceptance 68 is indicated, typically a copy of the proposal with accepted line items initialed and the clients signature indicating acceptance of the initialed work descriptions as well as other terms and conditions included in the contract.",
"Upon receiving the acceptance 68 , the operator 50 inputs markers into the system 10 to identify accepted line items of the contract proposal 64 .",
"The operator 50 then uses the system 10 to print out a work order 70 for the work crew 54 , and the job can be included in the scheduling function 72 as the manager 50 coordinates work to be done by the work crews 54 .",
"Also, upon acceptance 68 , the client 52 can now be included in the client list 74 which is generated by the system 10 and includes all patrons for whom work has been performed or is scheduled to be performed by the business.",
"The work order 70 includes information related to the accepted work items from block 68 presented in a way that helps the work crews 54 execute the job in a concise, efficient and organized manner.",
"Typically, the first page of the work order 70 includes a job summary that includes client and job site information, job price, the sales person who bid the job, the date of the bid, and summaries of estimates from block 210 in FIG. 5 of time, materials and other costs for all accepted line items.",
"Thus, the manager 50 can quickly and easily assess the scope of the job no matter which employee actually bid the job or when it was bid.",
"Furthermore, the work crew 54 will have a concise shopping list of materials and other items that will likely be needed to start and complete the job.",
"The remainder of the work order 70 includes a break down of information for each line item accepted at block 68 .",
"Specifically, for each accepted line item, the work order 70 would include the work description and direct materials input at block 206 in FIG. 5, the line item price input an block 218 , and the estimates of direct labor time, direct materials amounts and other direct costs and specifications which were input or calculated at block 210 .",
"If there was a job discount (JD) input at block 222 and the whole job was accepted, then the price for each line item on the work order 70 is adjusted to reflect the job discount as follows: the line item or work item price (WIP) at block 218 of FIG. 5;",
"minus a price adjustment (PA), which is calculated as: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) Thus, the work crew 54 in FIG. 3 has complete written specifications to autonomously perform work as accepted by the client 52 , allowing managers and sales people the freedom to concentrate on other activities to further the business rather than spending significant amounts of time supervising work crews.",
"The work order 70 is also preferably designed to be a job worksheet.",
"As the work crew 54 is executing work items, they are instructed to record the names of employees performing each work item as well as the actuals 76 for time, materials and other direct costs used to complete each work item.",
"This process helps work crew members focus on the estimated time and materials from block 210 in FIG. 5 as their specific goals for executing each line item as described at block 206 .",
"As the work crew 54 is completing work items and filling in the actuals 76 , they are also getting immediate feedback on their work performance by comparing the actuals 76 to the estimates detailed in the work order 70 .",
"When the job is completed, the operator 50 inputs the actuals 76 for each work item as well as the date the job was completed into the system 10 .",
"Now the system 10 can be used to generate an invoice 78 and preferably a survey to be presented to the client 52 .",
"Typically, the survey requests the client 52 to rate general satisfaction with the work done, specify anything that was particularly liked or disliked, and give permission to use their name and phone number as a reference.",
"When the job is completed, any corresponding balance due from the client 52 can be included in a receivables report 80 generated by the system 10 which tallies all outstanding receivables at any given time for the manager 50 .",
"The operator 50 can also use the system 10 to generate a job profit report 82 for the manager 50 and possibly other employees.",
"The job profit report 82 includes a job summary for reviewing the whole job, and details for each of the completed work items.",
"The job summary preferably identifies the client and job site, the sales person, the bid date, the date completed, and includes an estimate of actual profit for the whole job, the estimated actual job profit as a percentage of the job price, comparisons of the actual labor rate for the whole job to the minimum labor rate calculated in block 102 in FIG. 4 and the labor rate at which the job was bid, and comparisons of estimates from block 210 in FIG. 5 to the actuals at block 76 in FIG. 3 .",
"The estimate of actual profit for the whole job (AJP) is calculated by the system 10 as follows: for all accepted work items at block 68 of FIG. 3 —the sum of the work item prices (WIP) at block 218 of FIG. 5;",
"minus any job discount (JD) at block 222 of FIG. 5;",
"minus a sum of the actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC);",
"minus actuals at block 76 of FIG. 3 for the sum of direct labor times multiplied by average direct labor wages at block 100 of FIG. 4 (ADLC);",
"minus actuals at block 76 of FIG. 3 for the sum of direct labor times multiplied by average direct labor wages and the workman's compensation insurance rate at block 100 of FIG. 4 (AWCI);",
"minus actuals at block 76 of FIG. 3 for the sum of direct labor times multiplied by annual overhead expenses at block 100 of FIG. 4 and then divided by annual direct labor time at block 100 of FIG. 4 (AOE): AJP=ΣWIP−JD−ΣADMC−ADLC−AWCI−AOE The estimated actual job profit as a percentage of job price (AJP %) is calculated by the system 10 as the estimated actual profit for the whole job (AJP) as described above divided by: the sum of the work item prices (WIP) at block 218 of FIG. 5 for all accepted work items at block 68 of FIG. 3, minus any job discount (JD) at block 222 of FIG. 5 : AJP % = AJP ( ∑ WIP - JD ) The actual labor rate for the whole job (AJLR) is calculated by the system 10 as follows: for all accepted work items at block 68 of FIG. 3 —the sum of the work item prices (WIP) at block 218 of FIG. 5;",
"minus any job discount (JD) at block 222 of FIG. 5;",
"minus a sum of the actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC);",
"divided by a sum of the actuals at block 76 of FIG. 3 for direct labor time (ADLT): AJLR = ( ∑ WIP - JD - ∑ ADMC ) ∑ ADLT The labor rate at which the job was bid (BJLR) is calculated by the system 10 as follows: for all accepted work items at block 68 of FIG. 3 —the sum of the work item prices (WIP) at block 218 of FIG. 5;",
"minus any job discount (JD) at block 222 of FIG. 5;",
"minus a sum of the estimates at block 210 of FIG. 5 for direct materials costs and other direct costs (EDMC);",
"divided by the sum of the estimates at block 210 of FIG. 5 for direct labor time (EDLT): BJLR = ( ∑ WIP - JD - ∑ EDMC ) ∑ EDLT For each of the completed work items, the job profit report 82 in FIG. 3 preferably includes an estimate of actual profit, the estimated actual profit as a percentage of the work item price, comparisons of the actual labor rate to the labor rate at which the work item was bid, and comparisons of estimates at block 210 of FIG. 5 to the actuals at block 76 of FIG. 3 for the work item.",
"The estimate of actual profit for the work item (WIAP) is calculated by the system 10 as follows: for the work item—the price (WIP) at block 218 of FIG. 5;",
"minus a price adjustment (PA) if there was a job discount (JD) input at block 222 and the whole job was accepted, as follows: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) ;",
"minus actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC);",
"minus actuals at block 76 of FIG. 3 for direct labor time multiplied by average direct labor wages at block 100 of FIG. 4 (ADLC);",
"minus actuals at block 76 of FIG. 3 for direct labor time multiplied by average direct labor wages and the workman's compensation insurance rate at block 100 of FIG. 4 (AWCI);",
"minus actuals at block 76 of FIG. 3 for direct labor time multiplied by annual overhead expenses at block 100 of FIG. 4 and then divided by annual direct labor time at block 100 of FIG. 4 (AOE): WIAP=WIP−PA−ADMC−ADLC−AWCI−AOE The estimated actual profit for the work item as a percentage of the work item price (WIAP %) is calculated by the system 10 as the estimate of actual profit for the work item (WIAP) as described above divided by the work item price (WIP) at block 218 of FIG. 5, minus a price adjustment (PA) if there was a job discount input at block 222 (JD) and the whole job was accepted: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) WIAP % = WIAP ( WIP - PA ) The actual labor rate for the work item (WIALR) is calculated by the system 10 as follows: for the work item—the price (WIP) at block 218 of FIG. 5;",
"minus a price adjustment (PA) if there was a job discount input at block 222 (JD) and the whole job was accepted: PA = JD * ( WIP ( Σ ( WIP excluding JD ) ) ) ;",
"minus actuals at block 76 of FIG. 3 for direct materials costs and other direct costs (ADMC);",
"divided by actuals at block 76 of FIG. 3 for direct labor time (ADLT): WIALR = ( WIP - PA - ADMC ) ADLT The labor rate at which the work item was bid (WIBLR) is calculated by the system 10 as follows: for the work item—the price (WIP) at block 218 of FIG. 5 ;",
"minus a price adjustment (PA) if there was a job discount input at block 222 (JD) and the whole job was accepted: PA = JD * ( WIP ( ∑ ( WIP excluding JD ) ) ) ;",
"minus estimates at block 210 of FIG. 5 for direct materials costs and other direct costs (EDMC);",
"divided by the estimate at block 210 of FIG. 5 for direct labor time (EDLT): WIBLR = ( WIP - PA - EDMC ) EDLT The job profit report 82 in FIG. 3 can be used by the manager 50 for summarized feedback on business and employee performance compared to budget forecasts and goals.",
"As jobs are completed, job profit reports 82 provide continual feedback, allowing the manger 50 to quickly identify both problems and successes, communicate any issues to employees and initiate changes that will improve service quality and profitability.",
"Thus, the system 10 facilitates the communication loop or information cycle—set performance standards and goals, execute work, measure performance, compare performance to goals, improve performance—that is common in management theory and is often utilized in large well organized businesses.",
"The system 10 allows smaller contracting businesses to easily employ these practices giving them the opportunity for continuous improvement and growth.",
"Additional feedback is realized when a survey response 84 is returned by the client 52 and the operator 50 inputs the data into the system 10 .",
"The system 10 can then identify clients 52 that are satisfied with the work and have given permission to use them as references to generate a list of references 66 .",
"The system 10 can also sort the list of references 66 by locality, such as zip code.",
"Thus, when a contract proposal 64 is generated by the system 10 , an appropriate list of local references 66 can also be presented to the client 52 which can help increase the chances of initiating an acceptance 68 .",
"Survey responses 84 together with job profit reports 82 provide the manager 50 with a wealth of information with which to make informed management decisions and employee reviews 86 .",
"For employee reviews 86 , the manager 50 can provide concise measurements of performance with specific details of successes and shortcomings."
] |
FIELD OF THE INVENTION
The present invention is generally related to headphones, and more particularly is related to headphones that may be folded.
BACKGROUND OF THE INVENTION
Technology has enabled a decrease in size of many categories of audio devices including, but not limited to, Compact Disc (CD) and Moving Pictures Experts Group-audio layer 3 (MP3) players, thereby making portability of such devices both feasible and desirable. It is equally desirable that headphones utilized in association with these audio devices be small for ease of portability.
Currently, headphones incorporate different combinations of pivot points, extensions, and beam and hinge configurations to allow for folding. Certain foldable headphones contain a central pivot point located on a headband at a point corresponding to a top portion of the head of a user. This configuration typically uses an additional pivot point at each earpiece, or the earpieces are mounted on slideable extensions. An example of headphones that have a central pivot point with an additional pivot point at each earpiece is provided by U.S. Pat. No. 6,385,325, issued May 7, 2002, to Koji Nageno (herinafter “Nageno”). Generally, Nageno provides “collapsible” headphones having earpieces that fold inward towards the headband, while the headband folds in on itself. Unfortunately, the earpieces of Nageno are not protected from damage that may be provided by exterior elements and/or conditions.
Another example of foldable headphones is provided by U.S. Pat. No. 4,409,442, issued Oct. 11, 1983, to Tomohiko Kamimura (hereinafter “Kamimura”). Generally, Kamimura provides foldable headphones that contain a central pivot point and slideable extensions. In addition, Kamimura provides earpieces that are fully retracted on extensions, towards the headband, and the headband is folded in on itself.
Foldable headphones may also have a beam and hinge configuration. An example of such headphones is provided by U.S. Pat. No. 4,609,786, issued Sep. 2, 1986, to Hideo Omoto (herinafter “Omoto”). Generally, Omoto provides earpieces that roll inside the headband in a coiled fashion. Unfortunately, once again, the earpieces of Omoto are not protected from exterior elements and/or conditions. Variations of these configurations suffer similar disadvantages, specifically, unprotected earpieces, minimal foldability, or both.
Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide a foldable headphone unit and method for folding the headphone unit. Briefly described, one embodiment of the invention, among others, can be implemented as follows. The foldable headphone unit has a first extendable sidepiece and a second extendable sidepiece, both rotatably attached to a top member. The first extendable sidepiece is attached to a first earpiece, and the second extendable sidepiece is attached to a second earpiece. Each earpiece has an open portion that fits against the ear of the user. The first and second extendable sidepieces may be extended, thereby allowing the first and second earpieces to pivot, resulting in the open portions of the first and second earpieces being directly opposed, and allowing the first and second earpieces and the first and second extendable sidepieces to fold upward toward the top member.
The present invention can also be viewed as providing methods for folding a foldable headphone unit. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: extending first and second sidepieces; rotating a first yoke assembly towards an inner portion of the first sidepiece; rotating a second yoke assembly toward an inner portion of the second sidepiece; and pivoting the first and second earpieces, resulting in opposed positioning of the open portions of the earpieces.
Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a front view of a headphone unit in a folded configuration, in accordance with a first exemplary embodiment of the invention.
FIG. 2 is an illustration of the headphone unit of FIG. 1 in an unfolded configuration.
FIG. 3 is an illustration of the headphone unit of FIG. 1 in accordance with a second exemplary embodiment of the invention, where the headphone unit is in an unfolded configuration.
DETAILED DESCRIPTION
FIG. 1 is a front view of a headphone unit 100 in a folded configuration, in accordance with a first exemplary embodiment of the invention. As is shown by FIG. 1 , a first end of a top member 101 is rotatably coupled to a first end of a first upper-side member 103 A via a first connecting pin 105 A. Specifically, when the headphone unit 100 is being folded, the first connecting pin 105 A and the top member 101 allow the first upper-side member 103 A to rotate inward towards a lower surface of the top member 101 . When the headphone unit 100 is being unfolded for use, the first connecting pin 105 A and the top member 101 allow the upper-side member 103 A to rotate outward, away from the lower surface of the top member 101 , to form the generally arcuate shape defined by the headphone unit 100 , but prevent further outward rotation.
Similarly, a second end of the top member 101 is rotatably coupled to a first end of a second upper-side member 103 B via a second connecting pin 105 B. Rotation of the second upper-side member 103 B is similar to the rotation of the first upper-side member 103 A previously described. One of ordinary skill in the art will appreciate that the connecting pins 105 A, 105 B may be replaced by any other device that provides rotation capability between the top member 101 and the upper-side members 103 A, 103 B. The connecting pins may be replaced by, as an example, but not limited to, ball and joint mechanisms.
A first end of a generally arcuate first extension band 107 A is fixedly coupled internal to the first upper-side member 103 A at an approximate midpoint of the first upper-side member 103 A. Similarly, a first end of a generally arcuate second extension band 107 B is fixedly coupled to the second upper-side member 103 B. One of ordinary skill in the art will appreciate that coupling between the upper-side member 103 A, 103 B and the extension band 107 A, 107 B may be achieved by any method or apparatus providing a fixed coupling, internal or external, between the upper-side member 103 A, 103 B and the extension band 107 A, 107 B. The coupling may be achieved by, as an example, but not limited to, welding, bonding, or bolting the upper-side member 103 A, 103 B to the extension band 107 A, 107 B.
A second end of the first extension band 107 A passes through a slot in a first end of a first lower-side member 109 A, and is slideably coupled internally to the first lower-side member 109 A, the coupling forming a frictional fit between the first lower-side member 109 A and the first extension band 107 A. Similarly, a second extension band 107 B is slideably coupled to a second lower-side member 109 B. The lower-side members 109 A, 109 B may be extended away from the upper-side members 103 A, 103 B, or retracted towards the upper-side members 103 A, 103 B along the slideably coupled extension bands 107 A, 107 B. Further, the frictional fit holds the lower-side members 109 A, 109 B in an extended or retracted position as required by the user for folding or use of the headphone unit 100 . One of ordinary skill in the art will appreciate that the slideable coupling between the extension bands 107 A, 107 B and the lower-side members 109 A, 109 B may be made internally or externally to the lower-side members 109 A, 109 B, and may be achieved by any method, including, but not limited to, opposing frictional surfaces, or a detent arrangement.
Alternatively, in accordance with a second exemplary embodiment of the headphone unit 200 shown in FIG. 3 , a first end of a generally arcuate extension band 207 A, 207 B is slideably coupled internally to an upper-side member 203 A, 203 B, and a second end of the extension band 207 A, 207 B is fixedly coupled to a lower-side member 209 A, 209 B. In this second exemplary embodiment, the top member 101 and the upper-side members 203 A, 203 B may be extended away from the lower-side members 209 A, 209 B, or be retracted towards the lower-side members 209 A, 209 B along the slideably coupled extension bands 207 A, 207 B. One of ordinary skill in the art will appreciate that the above-described methods of providing fixed coupling and slideable coupling between the extension bands 207 A, 207 B, the upper-side members 203 A, 203 B, and the lower-side members 209 A, 209 B apply similarly to this second exemplary embodiment of the invention. FIG. 3 is further described below.
Returning to FIG. 1 , the top member 101 , upper-side members 103 A, 103 B, extension bands 107 A, 107 B, and lower-side members 109 A, 109 B may be made of a resilient material, for example, but not limited to, plastic, and define a generally arcuate shape.
A second end of the first lower-side member 109 A is rotatably coupled to a first end of a first yoke assembly 111 A via a third connecting pin 105 C. Specifically, when the headphone unit 100 is being folded, the third connecting pin 105 C and the first lower-side member 109 A allow the first yoke assembly 111 A to rotate upward towards an inner surface of the first lower-side member 109 A. When the headphone unit 100 is being unfolded for use, the third connecting pin 105 C and the first lower-side member 109 A allow the first yoke assembly 111 A to rotate downward, away from the inner surface of the first lower-side member 109 A, to form the generally arcuate shape defined by the headphone unit 100 , but prevent further outward rotation. Similarly, a second end of a second lower-side member 109 B is rotatably coupled to a first end of a second yoke assembly 111 B via a fourth connecting pin 105 D. One of ordinary skill in the art will appreciate that the connecting pins 105 C, 105 D may be replaced by any other device that provides rotation capability between the lower-side members 109 A, 109 B and the yoke assemblies 111 A, 111 B. The connecting pins 105 C, 105 D may be replaced by, as an example, but not limited to, ball and joint mechanisms.
A second forked end of the yoke assembly 111 A, 111 B has a dimension sufficient to accommodate coupling to an earpiece 113 A, 113 B. Each earpiece 113 A, 113 B has an open portion 117 A, 117 B ( FIG. 2 ) capable of transmitting sound to the ear of the user. Padding, 116 A, 116 B ( FIG. 2 ), for example, but not limited to, closed-cell foam, is attached to the open portion 117 A, 117 B of the earpiece 113 A, 113 B that is placed against the ear of the user to provide user comfort. The earpiece 113 A, 113 B is coupled approximately at its horizontal centerline to pivot points on the second end of the yoke assembly 111 A, 111 B, allowing the earpiece 113 A, 113 B to fully rotate through the yoke assembly 111 A, 111 B. One of ordinary skill in the art will appreciate that the coupling may be achieved by any method or apparatus providing full rotation of the earpiece 113 A, 113 B through the yoke assembly 111 A, 111 B, including, but not limited to, a shaft, or ball and joint configuration.
In addition to allowing the earpiece 113 A, 113 B to pivot in the vertical plane, the yoke assembly 111 A, 111 B also provides for rotation of the earpiece 113 A, 113 B in the horizontal plane via a shaft (not shown) that axially couples the first end of the yoke assembly 111 A, 111 B to the second end of the yoke assembly 111 A, 111 B. One of ordinary skill in the art will appreciate that the shaft may be replaced by any other device that provides rotation capability between the first end of the yoke assembly 111 A, 111 B and the second end of the yoke assembly 111 A, 111 B. The shaft may be replaced by, as an example, but not limited to, a ball and joint mechanism. Rotation of the earpieces 113 A, 113 B in the horizontal plane provides a comfortable fit for the user during use, and provides proper alignment of the opposed earpieces 113 A, 113 B in the folded configuration.
A pad 115 made of a material including, but not limited to, open-cell foam, covering a substantial length and width of a lower surface of the top-member 101 , is provided for user comfort. Additionally, the pad 115 provides increased clearance between coupling points 102 A, 102 B of the top member 101 to the upper-side members 103 A, 103 B, and the head of the user, thereby preventing discomfort associated with the coupling points 102 A and 102 B coming into contact with the head of the user.
In the folded configuration of the first exemplary embodiment of the headphone unit 100 shown in FIG. 1 , the extension bands 107 A, 107 B are extended, thereby allowing the earpieces 113 A, 113 B to pivot in the yoke assemblies 111 A, 111 B such that the open portions 117 A, 117 B of the earpieces 113 A, 1133 B are opposed as the yoke assemblies 111 A, 111 B are folded upward. Folding the headphone unit 100 in this manner provides protection for the sensitive components inside the earpieces 113 A, 113 B against exterior elements and/or conditions. When the headphone unit 100 is unfolded for use, the earpieces 113 A, 113 B may be properly positioned over the ears of the user by extending or retracting the lower-side members 109 A, 109 B.
FIG. 2 is an illustration of the headphone unit 100 of FIG. 1 in an unfolded configuration, with the upper-side members 103 A, 103 B fixedly coupled to the extension bands 107 A, 107 B. The extension bands 107 A, 107 B are slideably coupled to lower-side members 109 A, 109 B that are longer to accommodate the length of the extension bands 107 A, 107 B as they are retracted into the lower-side members 109 A, 109 B.
Continuing with the description of FIG. 3 from above, FIG. 3 is an illustration in accordance with a second exemplary embodiment of the headphone unit 200 , where the headphone unit 200 is in an unfolded configuration. In the second exemplary embodiment of the headphone unit 200 , the upper-side members 203 A, 203 B are longer to accommodate the length of the extension bands 207 A, 207 B as they are retracted into the upper-side members 203 A, 203 B. The lower-side members 209 A, 209 B, alternatively, are fixedly coupled to the extension bands 207 A, 207 B. It should be noted that a third exemplary embodiment of the headphone unit may also be provided where the upper-side members 103 A, 103 B and the lower-side members 109 A, 109 B have the same length.
It should be emphasized that the above-described embodiments of the present invention are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and protected by the following claims. | A system and method for a collapsible headphone unit is provided. Generally, the system contains a first extendable sidepiece and a second extendable sidepiece, both rotatably attached to a top member. The first extendable sidepiece is attached to a first earpiece, and the second extendable sidepiece is attached to a second earpiece. Each earpiece has an open portion that fits against the ear of the user. The first and second extendable sidepieces may be extended, thereby allowing the first and second earpieces to pivot, resulting in the open portions of the first and second earpieces being directly opposed, and allowing the first and second earpieces and the first and second extendable sidepieces to fold upward toward the top member. | Briefly summarize the main idea's components and working principles as described in the context. | [
"FIELD OF THE INVENTION The present invention is generally related to headphones, and more particularly is related to headphones that may be folded.",
"BACKGROUND OF THE INVENTION Technology has enabled a decrease in size of many categories of audio devices including, but not limited to, Compact Disc (CD) and Moving Pictures Experts Group-audio layer 3 (MP3) players, thereby making portability of such devices both feasible and desirable.",
"It is equally desirable that headphones utilized in association with these audio devices be small for ease of portability.",
"Currently, headphones incorporate different combinations of pivot points, extensions, and beam and hinge configurations to allow for folding.",
"Certain foldable headphones contain a central pivot point located on a headband at a point corresponding to a top portion of the head of a user.",
"This configuration typically uses an additional pivot point at each earpiece, or the earpieces are mounted on slideable extensions.",
"An example of headphones that have a central pivot point with an additional pivot point at each earpiece is provided by U.S. Pat. No. 6,385,325, issued May 7, 2002, to Koji Nageno (herinafter “Nageno”).",
"Generally, Nageno provides “collapsible”",
"headphones having earpieces that fold inward towards the headband, while the headband folds in on itself.",
"Unfortunately, the earpieces of Nageno are not protected from damage that may be provided by exterior elements and/or conditions.",
"Another example of foldable headphones is provided by U.S. Pat. No. 4,409,442, issued Oct. 11, 1983, to Tomohiko Kamimura (hereinafter “Kamimura”).",
"Generally, Kamimura provides foldable headphones that contain a central pivot point and slideable extensions.",
"In addition, Kamimura provides earpieces that are fully retracted on extensions, towards the headband, and the headband is folded in on itself.",
"Foldable headphones may also have a beam and hinge configuration.",
"An example of such headphones is provided by U.S. Pat. No. 4,609,786, issued Sep. 2, 1986, to Hideo Omoto (herinafter “Omoto”).",
"Generally, Omoto provides earpieces that roll inside the headband in a coiled fashion.",
"Unfortunately, once again, the earpieces of Omoto are not protected from exterior elements and/or conditions.",
"Variations of these configurations suffer similar disadvantages, specifically, unprotected earpieces, minimal foldability, or both.",
"Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.",
"SUMMARY OF THE INVENTION Embodiments of the present invention provide a foldable headphone unit and method for folding the headphone unit.",
"Briefly described, one embodiment of the invention, among others, can be implemented as follows.",
"The foldable headphone unit has a first extendable sidepiece and a second extendable sidepiece, both rotatably attached to a top member.",
"The first extendable sidepiece is attached to a first earpiece, and the second extendable sidepiece is attached to a second earpiece.",
"Each earpiece has an open portion that fits against the ear of the user.",
"The first and second extendable sidepieces may be extended, thereby allowing the first and second earpieces to pivot, resulting in the open portions of the first and second earpieces being directly opposed, and allowing the first and second earpieces and the first and second extendable sidepieces to fold upward toward the top member.",
"The present invention can also be viewed as providing methods for folding a foldable headphone unit.",
"In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: extending first and second sidepieces;",
"rotating a first yoke assembly towards an inner portion of the first sidepiece;",
"rotating a second yoke assembly toward an inner portion of the second sidepiece;",
"and pivoting the first and second earpieces, resulting in opposed positioning of the open portions of the earpieces.",
"Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description.",
"It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.",
"BRIEF DESCRIPTION OF THE DRAWINGS Many aspects of the invention can be better understood with reference to the following drawings.",
"The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention.",
"Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.",
"FIG. 1 is a front view of a headphone unit in a folded configuration, in accordance with a first exemplary embodiment of the invention.",
"FIG. 2 is an illustration of the headphone unit of FIG. 1 in an unfolded configuration.",
"FIG. 3 is an illustration of the headphone unit of FIG. 1 in accordance with a second exemplary embodiment of the invention, where the headphone unit is in an unfolded configuration.",
"DETAILED DESCRIPTION FIG. 1 is a front view of a headphone unit 100 in a folded configuration, in accordance with a first exemplary embodiment of the invention.",
"As is shown by FIG. 1 , a first end of a top member 101 is rotatably coupled to a first end of a first upper-side member 103 A via a first connecting pin 105 A. Specifically, when the headphone unit 100 is being folded, the first connecting pin 105 A and the top member 101 allow the first upper-side member 103 A to rotate inward towards a lower surface of the top member 101 .",
"When the headphone unit 100 is being unfolded for use, the first connecting pin 105 A and the top member 101 allow the upper-side member 103 A to rotate outward, away from the lower surface of the top member 101 , to form the generally arcuate shape defined by the headphone unit 100 , but prevent further outward rotation.",
"Similarly, a second end of the top member 101 is rotatably coupled to a first end of a second upper-side member 103 B via a second connecting pin 105 B. Rotation of the second upper-side member 103 B is similar to the rotation of the first upper-side member 103 A previously described.",
"One of ordinary skill in the art will appreciate that the connecting pins 105 A, 105 B may be replaced by any other device that provides rotation capability between the top member 101 and the upper-side members 103 A, 103 B. The connecting pins may be replaced by, as an example, but not limited to, ball and joint mechanisms.",
"A first end of a generally arcuate first extension band 107 A is fixedly coupled internal to the first upper-side member 103 A at an approximate midpoint of the first upper-side member 103 A. Similarly, a first end of a generally arcuate second extension band 107 B is fixedly coupled to the second upper-side member 103 B. One of ordinary skill in the art will appreciate that coupling between the upper-side member 103 A, 103 B and the extension band 107 A, 107 B may be achieved by any method or apparatus providing a fixed coupling, internal or external, between the upper-side member 103 A, 103 B and the extension band 107 A, 107 B. The coupling may be achieved by, as an example, but not limited to, welding, bonding, or bolting the upper-side member 103 A, 103 B to the extension band 107 A, 107 B. A second end of the first extension band 107 A passes through a slot in a first end of a first lower-side member 109 A, and is slideably coupled internally to the first lower-side member 109 A, the coupling forming a frictional fit between the first lower-side member 109 A and the first extension band 107 A. Similarly, a second extension band 107 B is slideably coupled to a second lower-side member 109 B. The lower-side members 109 A, 109 B may be extended away from the upper-side members 103 A, 103 B, or retracted towards the upper-side members 103 A, 103 B along the slideably coupled extension bands 107 A, 107 B. Further, the frictional fit holds the lower-side members 109 A, 109 B in an extended or retracted position as required by the user for folding or use of the headphone unit 100 .",
"One of ordinary skill in the art will appreciate that the slideable coupling between the extension bands 107 A, 107 B and the lower-side members 109 A, 109 B may be made internally or externally to the lower-side members 109 A, 109 B, and may be achieved by any method, including, but not limited to, opposing frictional surfaces, or a detent arrangement.",
"Alternatively, in accordance with a second exemplary embodiment of the headphone unit 200 shown in FIG. 3 , a first end of a generally arcuate extension band 207 A, 207 B is slideably coupled internally to an upper-side member 203 A, 203 B, and a second end of the extension band 207 A, 207 B is fixedly coupled to a lower-side member 209 A, 209 B. In this second exemplary embodiment, the top member 101 and the upper-side members 203 A, 203 B may be extended away from the lower-side members 209 A, 209 B, or be retracted towards the lower-side members 209 A, 209 B along the slideably coupled extension bands 207 A, 207 B. One of ordinary skill in the art will appreciate that the above-described methods of providing fixed coupling and slideable coupling between the extension bands 207 A, 207 B, the upper-side members 203 A, 203 B, and the lower-side members 209 A, 209 B apply similarly to this second exemplary embodiment of the invention.",
"FIG. 3 is further described below.",
"Returning to FIG. 1 , the top member 101 , upper-side members 103 A, 103 B, extension bands 107 A, 107 B, and lower-side members 109 A, 109 B may be made of a resilient material, for example, but not limited to, plastic, and define a generally arcuate shape.",
"A second end of the first lower-side member 109 A is rotatably coupled to a first end of a first yoke assembly 111 A via a third connecting pin 105 C. Specifically, when the headphone unit 100 is being folded, the third connecting pin 105 C and the first lower-side member 109 A allow the first yoke assembly 111 A to rotate upward towards an inner surface of the first lower-side member 109 A. When the headphone unit 100 is being unfolded for use, the third connecting pin 105 C and the first lower-side member 109 A allow the first yoke assembly 111 A to rotate downward, away from the inner surface of the first lower-side member 109 A, to form the generally arcuate shape defined by the headphone unit 100 , but prevent further outward rotation.",
"Similarly, a second end of a second lower-side member 109 B is rotatably coupled to a first end of a second yoke assembly 111 B via a fourth connecting pin 105 D. One of ordinary skill in the art will appreciate that the connecting pins 105 C, 105 D may be replaced by any other device that provides rotation capability between the lower-side members 109 A, 109 B and the yoke assemblies 111 A, 111 B. The connecting pins 105 C, 105 D may be replaced by, as an example, but not limited to, ball and joint mechanisms.",
"A second forked end of the yoke assembly 111 A, 111 B has a dimension sufficient to accommodate coupling to an earpiece 113 A, 113 B. Each earpiece 113 A, 113 B has an open portion 117 A, 117 B ( FIG. 2 ) capable of transmitting sound to the ear of the user.",
"Padding, 116 A, 116 B ( FIG. 2 ), for example, but not limited to, closed-cell foam, is attached to the open portion 117 A, 117 B of the earpiece 113 A, 113 B that is placed against the ear of the user to provide user comfort.",
"The earpiece 113 A, 113 B is coupled approximately at its horizontal centerline to pivot points on the second end of the yoke assembly 111 A, 111 B, allowing the earpiece 113 A, 113 B to fully rotate through the yoke assembly 111 A, 111 B. One of ordinary skill in the art will appreciate that the coupling may be achieved by any method or apparatus providing full rotation of the earpiece 113 A, 113 B through the yoke assembly 111 A, 111 B, including, but not limited to, a shaft, or ball and joint configuration.",
"In addition to allowing the earpiece 113 A, 113 B to pivot in the vertical plane, the yoke assembly 111 A, 111 B also provides for rotation of the earpiece 113 A, 113 B in the horizontal plane via a shaft (not shown) that axially couples the first end of the yoke assembly 111 A, 111 B to the second end of the yoke assembly 111 A, 111 B. One of ordinary skill in the art will appreciate that the shaft may be replaced by any other device that provides rotation capability between the first end of the yoke assembly 111 A, 111 B and the second end of the yoke assembly 111 A, 111 B. The shaft may be replaced by, as an example, but not limited to, a ball and joint mechanism.",
"Rotation of the earpieces 113 A, 113 B in the horizontal plane provides a comfortable fit for the user during use, and provides proper alignment of the opposed earpieces 113 A, 113 B in the folded configuration.",
"A pad 115 made of a material including, but not limited to, open-cell foam, covering a substantial length and width of a lower surface of the top-member 101 , is provided for user comfort.",
"Additionally, the pad 115 provides increased clearance between coupling points 102 A, 102 B of the top member 101 to the upper-side members 103 A, 103 B, and the head of the user, thereby preventing discomfort associated with the coupling points 102 A and 102 B coming into contact with the head of the user.",
"In the folded configuration of the first exemplary embodiment of the headphone unit 100 shown in FIG. 1 , the extension bands 107 A, 107 B are extended, thereby allowing the earpieces 113 A, 113 B to pivot in the yoke assemblies 111 A, 111 B such that the open portions 117 A, 117 B of the earpieces 113 A, 1133 B are opposed as the yoke assemblies 111 A, 111 B are folded upward.",
"Folding the headphone unit 100 in this manner provides protection for the sensitive components inside the earpieces 113 A, 113 B against exterior elements and/or conditions.",
"When the headphone unit 100 is unfolded for use, the earpieces 113 A, 113 B may be properly positioned over the ears of the user by extending or retracting the lower-side members 109 A, 109 B. FIG. 2 is an illustration of the headphone unit 100 of FIG. 1 in an unfolded configuration, with the upper-side members 103 A, 103 B fixedly coupled to the extension bands 107 A, 107 B. The extension bands 107 A, 107 B are slideably coupled to lower-side members 109 A, 109 B that are longer to accommodate the length of the extension bands 107 A, 107 B as they are retracted into the lower-side members 109 A, 109 B. Continuing with the description of FIG. 3 from above, FIG. 3 is an illustration in accordance with a second exemplary embodiment of the headphone unit 200 , where the headphone unit 200 is in an unfolded configuration.",
"In the second exemplary embodiment of the headphone unit 200 , the upper-side members 203 A, 203 B are longer to accommodate the length of the extension bands 207 A, 207 B as they are retracted into the upper-side members 203 A, 203 B. The lower-side members 209 A, 209 B, alternatively, are fixedly coupled to the extension bands 207 A, 207 B. It should be noted that a third exemplary embodiment of the headphone unit may also be provided where the upper-side members 103 A, 103 B and the lower-side members 109 A, 109 B have the same length.",
"It should be emphasized that the above-described embodiments of the present invention are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the invention.",
"Many variations and modifications may be made to the above-described embodiments of the invention without departing substantially from the spirit and principles of the invention.",
"All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and protected by the following claims."
] |
BACKGROUND
Steel support beams have many applications. They may be used to support architectural forms and building structures. Steel support beams may also be used in building vehicles or rebuilding damaged vehicles.
Typically, a support beam, whether constructed of steel or another support material, is constructed of pieces joined at angular intersections. For example, two portions of a steel beam may be welded at a 45-degree angle, or a 90-degree angle, or another angle appropriate to the final use of the beam. Beams made of other materials may be adhered to one another, or may be bolted together with brackets, etc.
A beam that includes smooth curves will often require the use of a jig or fixture and heavy tools to form its final structure. For example, placing a beam in a jig and bending it progressively to a final structure may result in construction of a curved beam. Alternatively, first portions of a beam may be removed so that other portions may be bent, with the first portions (or replacement portions) of the beam then being placed in their final configuration.
Because standard support beams are limited in their ability to assume nonstandard shapes (such as a beam with smooth curves, or a beam with one or more broadened portions), and because support beams often require heavy tools to form, it would be desirable to make a beam with complex shapes and/or with a minimum of tooling and reshaping. The described support beams, and the method of making those beams, have such characteristics. It should be appreciated that the disclosed beams and methods may be constructed of a variety of materials, as desired for a given application, and used in many situations.
Typical steel support beams and their methods of manufacture are found in U.S. Pat. Nos. 2,794,650, 2,844,864, 5,210,921, 6,058,673, 6,092,864, 6,305,136, 6,557,930, 6,733,040, 6,896,320, and 7,156,422, the disclosures of which are incorporated herein by reference.
SUMMARY
The present disclosure relates generally to a beam for providing support to a vehicle body, an architectural structure, or any other structure needing support. More specifically, it relates to a steel beam manufactured without the use of extensive machinery, and containing compound curves made without a dedicated fixture or jig.
One method of manufacturing a support beam may include providing a first piece and a second piece of beam material, arranging the first and second pieces of beam material in close spatial relation, and securing to each other the first and second pieces of beam material to form the support beam. A support beam formed by the method may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, where the length dimension is measured from a first end to a second end of the support beam, and the second end of the beam may be displaced from the first end along both the first and second axes.
The pieces of beam material used in the manufacturing method may be cut or otherwise formed from material stock, and the stocks for the first and second pieces may be substantially the same material (such as steel, wood, plastic, or another material) or they may be of different materials (such as one of steel and one of a plastic). Typically, for pieces made from a stock material, such as steel, the pieces may be cut by water jet cutting or laser cutting, but any appropriate method of cutting or forming the component pieces of a beam may be used.
An extension of the method described above may further include providing a third piece of beam material, and arranging the third piece of beam material in close spatial relation to the first and second pieces of beam material such that the first, second, and third pieces of beam material form an I-shaped support beam. In some embodiments, the I-shaped support beam may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, with the length dimension measured from a first end to a second end of the I-shaped support beam, and the second end of the I-shaped support beam may be displaced from the first end along both the first and second axes of the I-shaped support beam.
A further extension of the method described above may include providing fourth and fifth pieces of beam material, arranging the fourth and fifth pieces of beam material in close spatial relation to the first, second and third pieces of beam material, and securing the fourth and fifth pieces of beam material to the first, second, and third pieces of beam material to form a boxed, I-shaped support beam. In some embodiments, the boxed, I-shaped support beam may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, with the length dimension measured from a first end to a second end of the boxed, I-shaped support beam, and the second end of the boxed, I-shaped support beam may be displaced from the first end along both the first and second axes of the boxed, I-shaped support beam.
Another method of manufacturing a support beam may include providing first and second pieces of beam material, arranging the first and second pieces of beam material in close spatial relation, and aligning into an aligned spatial relation the first and second pieces of beam material with an alignment apparatus, where the alignment apparatus is configured reversibly to embrace the first and second pieces of beam material.
This may further include securing to each other the aligned pieces of beam material such that the first and second pieces of beam material remain in an aligned spatial relation upon removal of the alignment apparatus.
An extension of this method may further include providing a third piece of beam material, and arranging the third piece of beam material in close spatial relation to the first and second pieces of beam material, where the first, second, and third pieces of beam material may be aligned with the alignment apparatus, which may reversibly embrace the first, second, and third pieces of beam material. The alignment apparatus may have a number of alignment, or support, openings having shapes complementary to the pieces of beam material, and the openings may be adjustable in position to each other and the body of the alignment apparatus.
A further extension of this method may include securing to each other the aligned pieces of beam material such that the first, second, and third pieces of beam material remain in an aligned spatial relation upon removal of the alignment apparatus.
A support beam fashioned according to this method may assume an I-beam form, or any other appropriate form for a given structural function.
The present disclosure also provides for a support beam having a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, where the length dimension may be measured from a first end to a second end of the beam, and where the second end of the beam is displaced from the first end along both the first and second axes of the beam. The beam may also include at least one smooth curve between the first end and the second end.
To provide structural support, the beam may have at least a partial I-beam shape, having a first flange with first and second edges and a midline between the first and second edges, and a first web with first and second edges, where the web is secured to the flange such that either the first or second edge of the web is coupled to the midline of the first flange. The beam may also include a second flange having first and second edges and a midline between the first and second edges, where the second flange is secured to the first web such that a first or second edge of the web is coupled to the midline of the second flange.
In this structure, the first flange and the first web of the support beam may be configured to be held reversibly in alignment by an alignment tool including first and second support openings having shapes complementary to the first flange and the first web. In some embodiments, the alignment tool may be adjustable, allowing adjustment of the relative locations of the first and second support openings and, thus, the relative orientations of the flange(s) and web.
To further provide structural support, the I-beam shape may be boxed, with the beam including first and second walls each having first and second edges, where the first edges of the first and second walls are secured to the first flange, and where the second edges of the first and second walls are secured to the second flange.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left perspective view of a first embodiment of a steel beam according to the present disclosure.
FIG. 2 is a right perspective view of the steel beam of FIG. 1 .
FIG. 3 is a side view of the steel beam of FIG. 1 .
FIG. 4 is a front view of a first embodiment of the steel beam of FIG. 1 .
FIG. 5 is a right perspective view of components used to form a second embodiment of a steel beam according to the present disclosure.
FIG. 6 is a perspective view of a first embodiment of an alignment tool according to the present disclosure.
FIG. 7 is a front view of an operational relationship between the alignment tool of FIG. 6 and the steel beam of FIG. 1 , according to the present disclosure.
FIG. 8 is a plan cutaway view of a third embodiment of a steel beam according to the present disclosure.
FIG. 9 is a plan cutaway view of a fourth embodiment of a steel beam according to the present disclosure.
FIG. 10 is a partial left perspective view of an intermediate step in a method of constructing a first embodiment of a steel beam according to the present disclosure.
DETAILED DESCRIPTION
The present disclosure describes a support beam. The support beam is typically a steel beam, and it may be used as, for example, a structural support beam in a vehicle frame. Alternatively, the support beam may be used in any application requiring a strong structural support beam including nonstandard shapes (i.e. other than a typical cylinder, tube, typical combinations of those shapes, etc.). The illustrated support beam of the present disclosure is a beam having a roughly rectangular cross-section but also having complex curves along its length, which can be manufactured by a straightforward process requiring only a minimum of effort. In other embodiments, the support beam may follow a semicircular path, may include multiple curves, or take another non-standard shape.
FIGS. 1-4 show an illustrated first embodiment of a support beam 10 according to the present disclosure. The illustrated embodiment is a steel beam having a boxed I-beam shape. As such, the central portion of the beam includes a number of support elements, such as a web 12 , a first flange 14 , and a second flange 16 . To “box” this central I-beam backbone, the illustrated beam might include a first wall 18 and a second wall 20 . As illustrated, the support beam has, essentially, three vertical portions (web 12 , wall 18 , and wall 20 ) bracketed by two horizontal portions (flange 14 and flange 16 ). Although illustrated in this manner, it is understood that the beam may be constructed with fewer walls, fewer flanges, more webs, or any other desired combination of these support elements.
Initially, the illustrated beam can be described as having a first leg 22 and a second leg 24 at either end of a curved midportion 26 . The midportion can be any shape necessary as needed for a particular application of the support beam, but the illustrated embodiment includes a first curve 28 and a second curve 30 . Each of the first and second legs 22 , 24 of the support beam may follow a short, substantially linear path. As such, a length edge 32 of the first leg 22 may define an axis L along which a length of a support beam may be measured. A length edge 34 of the second leg 24 may be parallel to edge 32 and, as such, may be parallel to the axis L. Typically, the length of the illustrated support beam may be measured as the distance along axis L from a first end 36 to a second end 38 of the beam.
The illustrated support beam may also have height and width dimensions. A height edge 40 may follow a substantially linear path so as to define an axis H along which a height of a support beam may be measured. In the same way, a width edge 42 may follow a substantially linear path and define an axis W along which a width of a support beam may be measured. As with the length edges 32 , 34 , height edge 40 of the first end 36 may have an analogous height edge 44 at the second end 38 , and width edge 42 of first end 36 may have an analogous width edge 46 at the second end 38 .
As is apparent from the Figures, the length, height, and width of a support beam may be measured in multiple ways. For example, the length of a support beam could be measured as the distance from the first end to the second end along the axis L. As an alternative, if the first and second ends were located closely in space (as in a support beam having a horseshoe shape, or following a semicircular path), then the length might be measured as the separation distance along axis L between the two most-separated points on the support beam.
As another example, the width of the support beam could be measured as the distance from the first wall to the second wall along the axis W (this could correspond to the width of a first or second flange, depending on construction of the beam). An alternative width could be measured as the separation distance along axis W between the two most-separated points on the support beam. In the illustrated embodiment, for example, the greatest separation on the width axis W is not the width of the first or second flanges because the illustrated support beam is not a linear structure, and the second end is displaced along the W axis from the first end (seen most clearly in FIG. 3 ).
As another exemplary measurement, the height of the support beam could be measured as the distance from the first flange to the second flange along the axis H (this could correspond to the width of the web, or first or second wall, depending on construction of the beam). An alternative height could be measured as the separation distance along axis H between the two most-separated points on the support beam. In the illustrated embodiment, for example, the greatest separation on the height axis H is not the height of web 12 , or first wall 18 or second wall 20 because the illustrated support beam does not lie on a planar surface, the second end being displaced along the H axis from the first end (seen most clearly in FIG. 4 ).
The illustrated steel beam has a non-standard shape which can be described relative to a set of axes defined by the beam. In the illustrated embodiment of a support beam, the second end 38 of the support beam is displaced from the first end 36 along both the W and H axes at its location on the L axis. This three-dimensional displacement of one end from the other in the illustrated beam is the result of the presence of the first curve 28 and the second curve 30 in the midportion 26 of the beam. In other words, moving along the L axis of the beam, a comparison of the first end of the beam to the second end of the beam shows that the second end of the beam is displaced upward along the H axis and rightward on the W axis from the first end (if the point of origin of the axes is considered to be the first end of the beam).
FIGS. 2-4 show other views of the support beam of FIG. 1 , making clear the complex structure of the illustrated embodiment and the two-dimensional displacement (along axes W and H) of the first and second ends of the beam. Though showing a very similar beam, FIG. 4 illustrates a beam having reverse curvature to the beams of FIGS. 1-3 (the second end of the beam of FIG. 4 is displaced to the left relative to the first end of the beam).
FIG. 5 shows two component parts, a web 12 ′ and a flange 16 ′, used in making a second embodiment of a steel beam according to the present disclosure. FIG. 5 shows that the component parts used in making a beam can each have multiple curves in the plane of the component material, each curve having different characteristics, to form a final beam having multiple complex curves rather than a pair of relatively simple curves (as shown in FIGS. 1-4 ). Additionally, web 12 ′ and flange 16 ′ may each be described as having a longitudinal centerline running the length of the part. Examples of these centerlines are labeled A and B, respectively, in FIG. 5 .
FIG. 6 is an illustration of an alignment tool 50 according to the present disclosure, which can be used in a method of manufacturing the illustrated beams of FIGS. 1-5 , and other beams according to the present disclosure. The alignment tool may generally be constructed of a relatively stiff material, being configured to hold portions of the illustrated support beam in alignment during a support beam manufacturing process. However, other materials appropriate for performing the manufacturing method described below may be used. In some embodiments, the support beam 10 and alignment body 50 are of substantially the same materials, while in other embodiments the support beam and alignment body are of substantially or somewhat different materials.
The exemplary alignment tool 50 of FIG. 6 has a roughly rectangular alignment body 52 supporting a pair of alignment legs 54 , 56 . In the illustrated embodiment, the alignment legs are somewhat longer than the central portion of the alignment body, thus forming an alignment surface 58 between the alignment legs. The illustrated alignment body also includes alignment openings 60 , 62 , formed by the close, but not complete, abutment between the alignment surface and the alignment legs.
As is apparent from the Figures, the alignment tool can be placed into an operative relationship with elements of the support beam, facilitating the manufacture of the beam. FIG. 7 is an illustration of one possible operational relationship between the alignment tool of FIG. 6 and the steel beams of FIGS. 1-5 , according to the present disclosure. FIG. 7 makes clear that a given alignment tool may be useful for making a given embodiment of a support beam, since the various alignment portions of the tool may be designed to place components of the support beam into a close, temporarily fixed relationship. The temporary alignment of the elements of the support beam can then be made more permanent by, for example, welding the elements of the support beam to one another.
FIG. 7 shows an aligning relationship between alignment tool 50 and portions of a support beam 10 , partway through a method of manufacturing the support beam (described in more detail below). In FIG. 7 one can see that a first flange 14 and a second flange 16 can each be slidingly inserted into alignment openings 60 and 62 , respectively. As well, web 12 can be placed between the flanges so that it lays against the alignment surface 58 . In this way, the central spine of the boxed I-beam can be laid out, with the three components of the central spine in temporary alignment with one another. As seen in FIG. 7 , the web is aligned with the two flanges so that the web is positioned roughly along the midline of the two flanges (i.e. about midway between the two edges of each flange). Other arrangements or alignments are possible depending on the use or desired construction of the beam. For example, in some embodiments, the web may be positioned away from the midline of each flanges, such that it lies closer to one side or the other of each flange.
As is clear from the Figures, the illustrated embodiment of alignment tool 50 in FIGS. 6 and 7 is uniquely suited to making the illustrated embodiment of a support beam 10 in FIGS. 1-5 because of the placement of the alignment legs, surface, and openings. In like manner, another embodiment of alignment tool 50 could be uniquely suited for making a subtly different, or substantially different, embodiment of a support beam. For example, the alignment tool could have alignment openings that are placed at angles relative to each other, forming a beam with flanges or walls that are angled relative to each other or the web. Another embodiment might have shallower alignment openings, to accommodate or align narrower flanges. As another example, an alignment tool might be adjustable, where the alignment legs, surface, and/or openings could be moved relative to one another and then temporarily fixed in place (for example, with a series of nuts and bolts). Such an alignment tool could allow a manufacturer to make multiple types of beams with a single tool.
It bears repeating that the illustrated beam is simply one embodiment of a non-standard beam shape possible to be constructed with the method of manufacture described below. For example, the beam might follow a semi-circular path; it might contain more than two curves; and so on. Also, although the beam of the present disclosure is shown as a boxed I-beam with a web that is continuous from the first end to the second end, other designs are possible, such as a beam with a discontinuous web, or flanges with projections (as seen in FIG. 5 ), etc.
It also bears noting that a unique feature of the illustrated beam is the ability of the beam to embody complex curves with a minimum of effort on the part of a manufacturer of the beam. As is clear from the description of the above Figures, each of the pieces forming the central I-beam structure is a substantially planar element cut out of a substantially planar stock material. Each substantially planar element embodies a curve in a single dimension (i.e. in the plane of the stock material from which the element was cut). However, when brought together into an I-beam structure, the combination of two substantially planar elements, each having a curve in a single dimension, results in a non-planar I-beam embodying at least one complex curve (i.e. a curve having components in at least two dimensions). In the illustrated embodiment, for example, the central I-beam structure has complex curves embodying both the substantially one-dimensional “upward” (along the H axis) curve of web 12 (or 12 ′) and the substantially one-dimensional “sideways” (along the W axis) curve of flanges 14 , 16 (or 16 ′).
An exemplary embodiment of a beam containing more than one continuous or discontinuous web within an otherwise uniform exterior is shown in cross-section in FIG. 8 . Such a design may allow a beam to have a relatively shallow side profile (i.e. a small dimension along axis H) while still providing increased strength relative to the beams illustrated in FIGS. 1-5 . In the embodiment of FIG. 8 , the beam 10 may include a midportion 26 that is broader than the beam's first and second legs. The midportion may be broadened to include multiple webs 12 spaced from each other. Though the illustrated beam embodiment includes two walls 18 , 20 and three webs (two continuous webs 12 a , 12 b passing from end-to-end, and one discontinuous web 12 c only in the midportion), other numbers of webs are possible according to the desired performance parameters of the support beam.
An exemplary embodiment of a beam having a relatively broader midportion between two relatively narrower portions, with the broader portion housing multiple webs or a web having a nonlinear portion is shown in cross-section in FIG. 9 . Like the embodiment of FIG. 8 , this beam embodiment may allow increased strength with a shallow side profile.
In the embodiment of FIG. 9 , the walls may extend outward along the midportion 26 of the support beam, much like the embodiment of FIG. 8 . Rather than housing multiple webs, however, the larger midportion of the beam of FIG. 9 may house a nonstandard central web 12 . The central web of the embodiment of FIG. 9 may be configured as a single-thickness plate at either of its ends. The central portion, however, of the web of this embodiment may be “split” in the middle (i.e. configured with two web arms 63 extending from the web toward the sides of the beam) such that the central portion of the web is configured as a roughly hexagonal web loop 64 . As an alternative, loop 64 could be configured as a rectangular, pentagonal, ovoid, or other appropriate shape for providing structure within the larger midportion 26 of the illustrated beam.
Having described exemplary embodiments of support beams and an alignment tool, there follows a description of a method of making a typical support beam with a typical tool. The described method does not require heavy shop equipment unless heavy-gauge steel (or other material that is difficult to manipulate) is utilized in the construction. For example, 12-gauge and 10-gauge (about ⅛ inch) plate steel can be worked by hand, while ¼-inch plate steel may need to be worked with machinery, powered or otherwise.
The method may include a first step and a second step of providing a first piece of beam material; for example, providing pieces of steel from steel stock. One way of providing these pieces of steel is to cut (by, for example, laser or water jet cutting) shaped pieces of steel from a steel sheet. As noted, for easier working, the steel may be about ⅛ of an inch in thickness.
For making a boxed I-beam structure of the types illustrated in FIGS. 1-5 , a user may require five pieces of shaped steel: one piece for the central web, two pieces each for the first and second flanges, and two pieces each for the first and second walls. The pieces may be held individually or as a group at one end, with the other end of each piece being manipulated by a user, or a group of cooperating users, making a support beam. Typically, a pair of users may work together to align the pieces of the support beam before fastening them into place.
The one or more users may arrange first and second pieces of the beam material into close spatial relation. One way to do this would be to align the pieces using an alignment tool 50 like the one illustrated in FIGS. 6 and 7 . Initially, a user may slide an edge of one flange 14 into one of the alignment openings 60 on the alignment tool. The user may then place a web piece 12 on the alignment surface 58 of the alignment tool. In this way, an edge of the web piece may abut a midline of the adjacent flange. When one piece “abuts” another, the pieces may actually be in contact or they may merely be in sufficiently close spatial relation so that they may be connected later with a minimum of further adjustment in their positions (i.e. they may be close enough that they could be welded, glued, or otherwise fastened).
The user or cooperating users may then secure to each other the first and second pieces of beam material to form all or a portion of the support beam. To secure the first and second pieces of beam material, the user may simply tack-weld the pieces to each other as they are held in place by the alignment tool. Alternative methods of attachment may be used according the desired use of the beam or further work to be done in finishing the beam. If, for example, a simple support beam is desired, it may be enough to form the beam by securing a single flange and a single web by welding. As another example, a user or group of users may align the components of the beam with the alignment tools, and then use a series of clamps to hold the components in place. A final tack welding may then be performed along the whole length of the beam in one step.
If the support beam will have a central I-beam structure, the user may add another flange 16 to the arrangement of pieces, for example by sliding an edge of the flange 16 into an unoccupied alignment opening 62 of alignment tool 50 . In this way, a relatively simple alignment tool like the one in FIGS. 6 and 7 may align two flange pieces 14 , 16 and a web 12 so that each edge of the central web abuts a midline of a different flange. The web may then be tack-welded to the flange pieces or completely welded to the flange pieces, depending on the performance requirements of the beam.
An exemplary arrangement during the process described above is shown in FIG. 10 , where two flanges 14 , 16 and a central web 12 are in operative association with alignment tools 50 . In the Figure, first and second alignment tools 50 are closely positioned, with each tool's alignment opening supporting a flange and the alignment surface contacting the web (as in FIG. 7 ); thus, the alignment tools may be said to “bracket” the central I-beam structure. As illustrated in the Figure, a user may use the pair of tools 50 to initially align two flanges and a web at a given point. The user may then secure the pieces in place with a clamp 66 , allowing the alignment tools to be moved to the next location along the nascent beam that has flanges and a web to be aligned. Alternatively, the user could tack weld 68 the aligned portion of the I-beam before moving the alignment tools. In either case, using a pair of alignment tools at the same time can allow a user to precisely align the components of the I-beam before tack welding or clamping the aligned arrangement before moving to and aligning the next section of the beam.
To form a beam like the one illustrated in FIGS. 1-5 , the central “I” structure may only be tack-welded in place, as walls will be added to the final structure. In this case, the central “I” structure may act as a pattern for the final boxed I-beam. Once the central spine of the boxed I-beam is formed, the side walls, also cut or otherwise formed as pieces from stock material, may be lined up with the edges of the flanges. Once in final placement, the walls may be welded into place, securing them firmly with the flanges.
The alignment tool may not be necessary for the final step of securing the walls to the I-beam spine, but it may be necessary to hold the walls in place with clamps or other tools while the final fixing occurs. Typically, final placement could be done with two users and a series of clamps, with no requirement for heavy tools or machinery.
Although the present invention has been shown and described with reference to the foregoing operational principles and preferred embodiments, it will be apparent to those skilled in the art that various changes in form and detail can be made without departing from the spirit and scope of the invention. The present invention is intended to embrace all such alternatives, modifications and variances. The subject matter of the present invention includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed through presentation of claims in a subsequent application. | The present invention generally relates to a beam suitable for providing support to, for example, an automobile body. More specifically, the present invention relates to a steel boxed I-beam structure having compound curves, formed without use of a dedicated fixture or jig. Typically, the steel boxed I-beam structure provides a strong support that can be manufactured with a minimum of effort, and without the use of heavier shop machinery. | Summarize the patent information, clearly outlining the technical challenges and proposed solutions. | [
"BACKGROUND Steel support beams have many applications.",
"They may be used to support architectural forms and building structures.",
"Steel support beams may also be used in building vehicles or rebuilding damaged vehicles.",
"Typically, a support beam, whether constructed of steel or another support material, is constructed of pieces joined at angular intersections.",
"For example, two portions of a steel beam may be welded at a 45-degree angle, or a 90-degree angle, or another angle appropriate to the final use of the beam.",
"Beams made of other materials may be adhered to one another, or may be bolted together with brackets, etc.",
"A beam that includes smooth curves will often require the use of a jig or fixture and heavy tools to form its final structure.",
"For example, placing a beam in a jig and bending it progressively to a final structure may result in construction of a curved beam.",
"Alternatively, first portions of a beam may be removed so that other portions may be bent, with the first portions (or replacement portions) of the beam then being placed in their final configuration.",
"Because standard support beams are limited in their ability to assume nonstandard shapes (such as a beam with smooth curves, or a beam with one or more broadened portions), and because support beams often require heavy tools to form, it would be desirable to make a beam with complex shapes and/or with a minimum of tooling and reshaping.",
"The described support beams, and the method of making those beams, have such characteristics.",
"It should be appreciated that the disclosed beams and methods may be constructed of a variety of materials, as desired for a given application, and used in many situations.",
"Typical steel support beams and their methods of manufacture are found in U.S. Pat. Nos. 2,794,650, 2,844,864, 5,210,921, 6,058,673, 6,092,864, 6,305,136, 6,557,930, 6,733,040, 6,896,320, and 7,156,422, the disclosures of which are incorporated herein by reference.",
"SUMMARY The present disclosure relates generally to a beam for providing support to a vehicle body, an architectural structure, or any other structure needing support.",
"More specifically, it relates to a steel beam manufactured without the use of extensive machinery, and containing compound curves made without a dedicated fixture or jig.",
"One method of manufacturing a support beam may include providing a first piece and a second piece of beam material, arranging the first and second pieces of beam material in close spatial relation, and securing to each other the first and second pieces of beam material to form the support beam.",
"A support beam formed by the method may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, where the length dimension is measured from a first end to a second end of the support beam, and the second end of the beam may be displaced from the first end along both the first and second axes.",
"The pieces of beam material used in the manufacturing method may be cut or otherwise formed from material stock, and the stocks for the first and second pieces may be substantially the same material (such as steel, wood, plastic, or another material) or they may be of different materials (such as one of steel and one of a plastic).",
"Typically, for pieces made from a stock material, such as steel, the pieces may be cut by water jet cutting or laser cutting, but any appropriate method of cutting or forming the component pieces of a beam may be used.",
"An extension of the method described above may further include providing a third piece of beam material, and arranging the third piece of beam material in close spatial relation to the first and second pieces of beam material such that the first, second, and third pieces of beam material form an I-shaped support beam.",
"In some embodiments, the I-shaped support beam may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, with the length dimension measured from a first end to a second end of the I-shaped support beam, and the second end of the I-shaped support beam may be displaced from the first end along both the first and second axes of the I-shaped support beam.",
"A further extension of the method described above may include providing fourth and fifth pieces of beam material, arranging the fourth and fifth pieces of beam material in close spatial relation to the first, second and third pieces of beam material, and securing the fourth and fifth pieces of beam material to the first, second, and third pieces of beam material to form a boxed, I-shaped support beam.",
"In some embodiments, the boxed, I-shaped support beam may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, with the length dimension measured from a first end to a second end of the boxed, I-shaped support beam, and the second end of the boxed, I-shaped support beam may be displaced from the first end along both the first and second axes of the boxed, I-shaped support beam.",
"Another method of manufacturing a support beam may include providing first and second pieces of beam material, arranging the first and second pieces of beam material in close spatial relation, and aligning into an aligned spatial relation the first and second pieces of beam material with an alignment apparatus, where the alignment apparatus is configured reversibly to embrace the first and second pieces of beam material.",
"This may further include securing to each other the aligned pieces of beam material such that the first and second pieces of beam material remain in an aligned spatial relation upon removal of the alignment apparatus.",
"An extension of this method may further include providing a third piece of beam material, and arranging the third piece of beam material in close spatial relation to the first and second pieces of beam material, where the first, second, and third pieces of beam material may be aligned with the alignment apparatus, which may reversibly embrace the first, second, and third pieces of beam material.",
"The alignment apparatus may have a number of alignment, or support, openings having shapes complementary to the pieces of beam material, and the openings may be adjustable in position to each other and the body of the alignment apparatus.",
"A further extension of this method may include securing to each other the aligned pieces of beam material such that the first, second, and third pieces of beam material remain in an aligned spatial relation upon removal of the alignment apparatus.",
"A support beam fashioned according to this method may assume an I-beam form, or any other appropriate form for a given structural function.",
"The present disclosure also provides for a support beam having a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, where the length dimension may be measured from a first end to a second end of the beam, and where the second end of the beam is displaced from the first end along both the first and second axes of the beam.",
"The beam may also include at least one smooth curve between the first end and the second end.",
"To provide structural support, the beam may have at least a partial I-beam shape, having a first flange with first and second edges and a midline between the first and second edges, and a first web with first and second edges, where the web is secured to the flange such that either the first or second edge of the web is coupled to the midline of the first flange.",
"The beam may also include a second flange having first and second edges and a midline between the first and second edges, where the second flange is secured to the first web such that a first or second edge of the web is coupled to the midline of the second flange.",
"In this structure, the first flange and the first web of the support beam may be configured to be held reversibly in alignment by an alignment tool including first and second support openings having shapes complementary to the first flange and the first web.",
"In some embodiments, the alignment tool may be adjustable, allowing adjustment of the relative locations of the first and second support openings and, thus, the relative orientations of the flange(s) and web.",
"To further provide structural support, the I-beam shape may be boxed, with the beam including first and second walls each having first and second edges, where the first edges of the first and second walls are secured to the first flange, and where the second edges of the first and second walls are secured to the second flange.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a left perspective view of a first embodiment of a steel beam according to the present disclosure.",
"FIG. 2 is a right perspective view of the steel beam of FIG. 1 .",
"FIG. 3 is a side view of the steel beam of FIG. 1 .",
"FIG. 4 is a front view of a first embodiment of the steel beam of FIG. 1 .",
"FIG. 5 is a right perspective view of components used to form a second embodiment of a steel beam according to the present disclosure.",
"FIG. 6 is a perspective view of a first embodiment of an alignment tool according to the present disclosure.",
"FIG. 7 is a front view of an operational relationship between the alignment tool of FIG. 6 and the steel beam of FIG. 1 , according to the present disclosure.",
"FIG. 8 is a plan cutaway view of a third embodiment of a steel beam according to the present disclosure.",
"FIG. 9 is a plan cutaway view of a fourth embodiment of a steel beam according to the present disclosure.",
"FIG. 10 is a partial left perspective view of an intermediate step in a method of constructing a first embodiment of a steel beam according to the present disclosure.",
"DETAILED DESCRIPTION The present disclosure describes a support beam.",
"The support beam is typically a steel beam, and it may be used as, for example, a structural support beam in a vehicle frame.",
"Alternatively, the support beam may be used in any application requiring a strong structural support beam including nonstandard shapes (i.e. other than a typical cylinder, tube, typical combinations of those shapes, etc.).",
"The illustrated support beam of the present disclosure is a beam having a roughly rectangular cross-section but also having complex curves along its length, which can be manufactured by a straightforward process requiring only a minimum of effort.",
"In other embodiments, the support beam may follow a semicircular path, may include multiple curves, or take another non-standard shape.",
"FIGS. 1-4 show an illustrated first embodiment of a support beam 10 according to the present disclosure.",
"The illustrated embodiment is a steel beam having a boxed I-beam shape.",
"As such, the central portion of the beam includes a number of support elements, such as a web 12 , a first flange 14 , and a second flange 16 .",
"To “box”",
"this central I-beam backbone, the illustrated beam might include a first wall 18 and a second wall 20 .",
"As illustrated, the support beam has, essentially, three vertical portions (web 12 , wall 18 , and wall 20 ) bracketed by two horizontal portions (flange 14 and flange 16 ).",
"Although illustrated in this manner, it is understood that the beam may be constructed with fewer walls, fewer flanges, more webs, or any other desired combination of these support elements.",
"Initially, the illustrated beam can be described as having a first leg 22 and a second leg 24 at either end of a curved midportion 26 .",
"The midportion can be any shape necessary as needed for a particular application of the support beam, but the illustrated embodiment includes a first curve 28 and a second curve 30 .",
"Each of the first and second legs 22 , 24 of the support beam may follow a short, substantially linear path.",
"As such, a length edge 32 of the first leg 22 may define an axis L along which a length of a support beam may be measured.",
"A length edge 34 of the second leg 24 may be parallel to edge 32 and, as such, may be parallel to the axis L. Typically, the length of the illustrated support beam may be measured as the distance along axis L from a first end 36 to a second end 38 of the beam.",
"The illustrated support beam may also have height and width dimensions.",
"A height edge 40 may follow a substantially linear path so as to define an axis H along which a height of a support beam may be measured.",
"In the same way, a width edge 42 may follow a substantially linear path and define an axis W along which a width of a support beam may be measured.",
"As with the length edges 32 , 34 , height edge 40 of the first end 36 may have an analogous height edge 44 at the second end 38 , and width edge 42 of first end 36 may have an analogous width edge 46 at the second end 38 .",
"As is apparent from the Figures, the length, height, and width of a support beam may be measured in multiple ways.",
"For example, the length of a support beam could be measured as the distance from the first end to the second end along the axis L. As an alternative, if the first and second ends were located closely in space (as in a support beam having a horseshoe shape, or following a semicircular path), then the length might be measured as the separation distance along axis L between the two most-separated points on the support beam.",
"As another example, the width of the support beam could be measured as the distance from the first wall to the second wall along the axis W (this could correspond to the width of a first or second flange, depending on construction of the beam).",
"An alternative width could be measured as the separation distance along axis W between the two most-separated points on the support beam.",
"In the illustrated embodiment, for example, the greatest separation on the width axis W is not the width of the first or second flanges because the illustrated support beam is not a linear structure, and the second end is displaced along the W axis from the first end (seen most clearly in FIG. 3 ).",
"As another exemplary measurement, the height of the support beam could be measured as the distance from the first flange to the second flange along the axis H (this could correspond to the width of the web, or first or second wall, depending on construction of the beam).",
"An alternative height could be measured as the separation distance along axis H between the two most-separated points on the support beam.",
"In the illustrated embodiment, for example, the greatest separation on the height axis H is not the height of web 12 , or first wall 18 or second wall 20 because the illustrated support beam does not lie on a planar surface, the second end being displaced along the H axis from the first end (seen most clearly in FIG. 4 ).",
"The illustrated steel beam has a non-standard shape which can be described relative to a set of axes defined by the beam.",
"In the illustrated embodiment of a support beam, the second end 38 of the support beam is displaced from the first end 36 along both the W and H axes at its location on the L axis.",
"This three-dimensional displacement of one end from the other in the illustrated beam is the result of the presence of the first curve 28 and the second curve 30 in the midportion 26 of the beam.",
"In other words, moving along the L axis of the beam, a comparison of the first end of the beam to the second end of the beam shows that the second end of the beam is displaced upward along the H axis and rightward on the W axis from the first end (if the point of origin of the axes is considered to be the first end of the beam).",
"FIGS. 2-4 show other views of the support beam of FIG. 1 , making clear the complex structure of the illustrated embodiment and the two-dimensional displacement (along axes W and H) of the first and second ends of the beam.",
"Though showing a very similar beam, FIG. 4 illustrates a beam having reverse curvature to the beams of FIGS. 1-3 (the second end of the beam of FIG. 4 is displaced to the left relative to the first end of the beam).",
"FIG. 5 shows two component parts, a web 12 ′ and a flange 16 ′, used in making a second embodiment of a steel beam according to the present disclosure.",
"FIG. 5 shows that the component parts used in making a beam can each have multiple curves in the plane of the component material, each curve having different characteristics, to form a final beam having multiple complex curves rather than a pair of relatively simple curves (as shown in FIGS. 1-4 ).",
"Additionally, web 12 ′ and flange 16 ′ may each be described as having a longitudinal centerline running the length of the part.",
"Examples of these centerlines are labeled A and B, respectively, in FIG. 5 .",
"FIG. 6 is an illustration of an alignment tool 50 according to the present disclosure, which can be used in a method of manufacturing the illustrated beams of FIGS. 1-5 , and other beams according to the present disclosure.",
"The alignment tool may generally be constructed of a relatively stiff material, being configured to hold portions of the illustrated support beam in alignment during a support beam manufacturing process.",
"However, other materials appropriate for performing the manufacturing method described below may be used.",
"In some embodiments, the support beam 10 and alignment body 50 are of substantially the same materials, while in other embodiments the support beam and alignment body are of substantially or somewhat different materials.",
"The exemplary alignment tool 50 of FIG. 6 has a roughly rectangular alignment body 52 supporting a pair of alignment legs 54 , 56 .",
"In the illustrated embodiment, the alignment legs are somewhat longer than the central portion of the alignment body, thus forming an alignment surface 58 between the alignment legs.",
"The illustrated alignment body also includes alignment openings 60 , 62 , formed by the close, but not complete, abutment between the alignment surface and the alignment legs.",
"As is apparent from the Figures, the alignment tool can be placed into an operative relationship with elements of the support beam, facilitating the manufacture of the beam.",
"FIG. 7 is an illustration of one possible operational relationship between the alignment tool of FIG. 6 and the steel beams of FIGS. 1-5 , according to the present disclosure.",
"FIG. 7 makes clear that a given alignment tool may be useful for making a given embodiment of a support beam, since the various alignment portions of the tool may be designed to place components of the support beam into a close, temporarily fixed relationship.",
"The temporary alignment of the elements of the support beam can then be made more permanent by, for example, welding the elements of the support beam to one another.",
"FIG. 7 shows an aligning relationship between alignment tool 50 and portions of a support beam 10 , partway through a method of manufacturing the support beam (described in more detail below).",
"In FIG. 7 one can see that a first flange 14 and a second flange 16 can each be slidingly inserted into alignment openings 60 and 62 , respectively.",
"As well, web 12 can be placed between the flanges so that it lays against the alignment surface 58 .",
"In this way, the central spine of the boxed I-beam can be laid out, with the three components of the central spine in temporary alignment with one another.",
"As seen in FIG. 7 , the web is aligned with the two flanges so that the web is positioned roughly along the midline of the two flanges (i.e. about midway between the two edges of each flange).",
"Other arrangements or alignments are possible depending on the use or desired construction of the beam.",
"For example, in some embodiments, the web may be positioned away from the midline of each flanges, such that it lies closer to one side or the other of each flange.",
"As is clear from the Figures, the illustrated embodiment of alignment tool 50 in FIGS. 6 and 7 is uniquely suited to making the illustrated embodiment of a support beam 10 in FIGS. 1-5 because of the placement of the alignment legs, surface, and openings.",
"In like manner, another embodiment of alignment tool 50 could be uniquely suited for making a subtly different, or substantially different, embodiment of a support beam.",
"For example, the alignment tool could have alignment openings that are placed at angles relative to each other, forming a beam with flanges or walls that are angled relative to each other or the web.",
"Another embodiment might have shallower alignment openings, to accommodate or align narrower flanges.",
"As another example, an alignment tool might be adjustable, where the alignment legs, surface, and/or openings could be moved relative to one another and then temporarily fixed in place (for example, with a series of nuts and bolts).",
"Such an alignment tool could allow a manufacturer to make multiple types of beams with a single tool.",
"It bears repeating that the illustrated beam is simply one embodiment of a non-standard beam shape possible to be constructed with the method of manufacture described below.",
"For example, the beam might follow a semi-circular path;",
"it might contain more than two curves;",
"and so on.",
"Also, although the beam of the present disclosure is shown as a boxed I-beam with a web that is continuous from the first end to the second end, other designs are possible, such as a beam with a discontinuous web, or flanges with projections (as seen in FIG. 5 ), etc.",
"It also bears noting that a unique feature of the illustrated beam is the ability of the beam to embody complex curves with a minimum of effort on the part of a manufacturer of the beam.",
"As is clear from the description of the above Figures, each of the pieces forming the central I-beam structure is a substantially planar element cut out of a substantially planar stock material.",
"Each substantially planar element embodies a curve in a single dimension (i.e. in the plane of the stock material from which the element was cut).",
"However, when brought together into an I-beam structure, the combination of two substantially planar elements, each having a curve in a single dimension, results in a non-planar I-beam embodying at least one complex curve (i.e. a curve having components in at least two dimensions).",
"In the illustrated embodiment, for example, the central I-beam structure has complex curves embodying both the substantially one-dimensional “upward”",
"(along the H axis) curve of web 12 (or 12 ′) and the substantially one-dimensional “sideways”",
"(along the W axis) curve of flanges 14 , 16 (or 16 ′).",
"An exemplary embodiment of a beam containing more than one continuous or discontinuous web within an otherwise uniform exterior is shown in cross-section in FIG. 8 .",
"Such a design may allow a beam to have a relatively shallow side profile (i.e. a small dimension along axis H) while still providing increased strength relative to the beams illustrated in FIGS. 1-5 .",
"In the embodiment of FIG. 8 , the beam 10 may include a midportion 26 that is broader than the beam's first and second legs.",
"The midportion may be broadened to include multiple webs 12 spaced from each other.",
"Though the illustrated beam embodiment includes two walls 18 , 20 and three webs (two continuous webs 12 a , 12 b passing from end-to-end, and one discontinuous web 12 c only in the midportion), other numbers of webs are possible according to the desired performance parameters of the support beam.",
"An exemplary embodiment of a beam having a relatively broader midportion between two relatively narrower portions, with the broader portion housing multiple webs or a web having a nonlinear portion is shown in cross-section in FIG. 9 .",
"Like the embodiment of FIG. 8 , this beam embodiment may allow increased strength with a shallow side profile.",
"In the embodiment of FIG. 9 , the walls may extend outward along the midportion 26 of the support beam, much like the embodiment of FIG. 8 .",
"Rather than housing multiple webs, however, the larger midportion of the beam of FIG. 9 may house a nonstandard central web 12 .",
"The central web of the embodiment of FIG. 9 may be configured as a single-thickness plate at either of its ends.",
"The central portion, however, of the web of this embodiment may be “split”",
"in the middle (i.e. configured with two web arms 63 extending from the web toward the sides of the beam) such that the central portion of the web is configured as a roughly hexagonal web loop 64 .",
"As an alternative, loop 64 could be configured as a rectangular, pentagonal, ovoid, or other appropriate shape for providing structure within the larger midportion 26 of the illustrated beam.",
"Having described exemplary embodiments of support beams and an alignment tool, there follows a description of a method of making a typical support beam with a typical tool.",
"The described method does not require heavy shop equipment unless heavy-gauge steel (or other material that is difficult to manipulate) is utilized in the construction.",
"For example, 12-gauge and 10-gauge (about ⅛ inch) plate steel can be worked by hand, while ¼-inch plate steel may need to be worked with machinery, powered or otherwise.",
"The method may include a first step and a second step of providing a first piece of beam material;",
"for example, providing pieces of steel from steel stock.",
"One way of providing these pieces of steel is to cut (by, for example, laser or water jet cutting) shaped pieces of steel from a steel sheet.",
"As noted, for easier working, the steel may be about ⅛ of an inch in thickness.",
"For making a boxed I-beam structure of the types illustrated in FIGS. 1-5 , a user may require five pieces of shaped steel: one piece for the central web, two pieces each for the first and second flanges, and two pieces each for the first and second walls.",
"The pieces may be held individually or as a group at one end, with the other end of each piece being manipulated by a user, or a group of cooperating users, making a support beam.",
"Typically, a pair of users may work together to align the pieces of the support beam before fastening them into place.",
"The one or more users may arrange first and second pieces of the beam material into close spatial relation.",
"One way to do this would be to align the pieces using an alignment tool 50 like the one illustrated in FIGS. 6 and 7 .",
"Initially, a user may slide an edge of one flange 14 into one of the alignment openings 60 on the alignment tool.",
"The user may then place a web piece 12 on the alignment surface 58 of the alignment tool.",
"In this way, an edge of the web piece may abut a midline of the adjacent flange.",
"When one piece “abuts”",
"another, the pieces may actually be in contact or they may merely be in sufficiently close spatial relation so that they may be connected later with a minimum of further adjustment in their positions (i.e. they may be close enough that they could be welded, glued, or otherwise fastened).",
"The user or cooperating users may then secure to each other the first and second pieces of beam material to form all or a portion of the support beam.",
"To secure the first and second pieces of beam material, the user may simply tack-weld the pieces to each other as they are held in place by the alignment tool.",
"Alternative methods of attachment may be used according the desired use of the beam or further work to be done in finishing the beam.",
"If, for example, a simple support beam is desired, it may be enough to form the beam by securing a single flange and a single web by welding.",
"As another example, a user or group of users may align the components of the beam with the alignment tools, and then use a series of clamps to hold the components in place.",
"A final tack welding may then be performed along the whole length of the beam in one step.",
"If the support beam will have a central I-beam structure, the user may add another flange 16 to the arrangement of pieces, for example by sliding an edge of the flange 16 into an unoccupied alignment opening 62 of alignment tool 50 .",
"In this way, a relatively simple alignment tool like the one in FIGS. 6 and 7 may align two flange pieces 14 , 16 and a web 12 so that each edge of the central web abuts a midline of a different flange.",
"The web may then be tack-welded to the flange pieces or completely welded to the flange pieces, depending on the performance requirements of the beam.",
"An exemplary arrangement during the process described above is shown in FIG. 10 , where two flanges 14 , 16 and a central web 12 are in operative association with alignment tools 50 .",
"In the Figure, first and second alignment tools 50 are closely positioned, with each tool's alignment opening supporting a flange and the alignment surface contacting the web (as in FIG. 7 );",
"thus, the alignment tools may be said to “bracket”",
"the central I-beam structure.",
"As illustrated in the Figure, a user may use the pair of tools 50 to initially align two flanges and a web at a given point.",
"The user may then secure the pieces in place with a clamp 66 , allowing the alignment tools to be moved to the next location along the nascent beam that has flanges and a web to be aligned.",
"Alternatively, the user could tack weld 68 the aligned portion of the I-beam before moving the alignment tools.",
"In either case, using a pair of alignment tools at the same time can allow a user to precisely align the components of the I-beam before tack welding or clamping the aligned arrangement before moving to and aligning the next section of the beam.",
"To form a beam like the one illustrated in FIGS. 1-5 , the central “I”",
"structure may only be tack-welded in place, as walls will be added to the final structure.",
"In this case, the central “I”",
"structure may act as a pattern for the final boxed I-beam.",
"Once the central spine of the boxed I-beam is formed, the side walls, also cut or otherwise formed as pieces from stock material, may be lined up with the edges of the flanges.",
"Once in final placement, the walls may be welded into place, securing them firmly with the flanges.",
"The alignment tool may not be necessary for the final step of securing the walls to the I-beam spine, but it may be necessary to hold the walls in place with clamps or other tools while the final fixing occurs.",
"Typically, final placement could be done with two users and a series of clamps, with no requirement for heavy tools or machinery.",
"Although the present invention has been shown and described with reference to the foregoing operational principles and preferred embodiments, it will be apparent to those skilled in the art that various changes in form and detail can be made without departing from the spirit and scope of the invention.",
"The present invention is intended to embrace all such alternatives, modifications and variances.",
"The subject matter of the present invention includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein.",
"Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed through presentation of claims in a subsequent application."
] |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of agrochemical compositions and formulations. In particular, the invention provides a composition comprising a tetraniliprole alone or in combination with other plant protection agents suitable for controlling rootworm larvae in soil.
BACKGROUND OF THE INVENTION
[0002] Insects and plant pests cause millions of dollars worth of damages annually on agricultural products. Rootworms are one of the major agricultural pest insects contributing to the damages to agricultural products. These pests have a wide range of host plants and in their larval form make tunnels through the roots of young plants, stunting or killing them. They are typically native to the soil and will readily infest a field of crop plants, most notoriously corn. These pests include but are not limited to such species as Diabrotica virgifera virgifera ( D. virgifera ), D. undecimpunctata undecimpunctata ( D. undecimpunctata ), D. barberi, D. u. howardi , and D. u. tenella . Some are perennial pests of corn across most of the Corn Belt. Despite ongoing new pesticides and insecticides, resistance continues to emerge among such pests as D. virgifera, D. undecimpunctata, D. barberi, D. u. howardi , and D. u. tenella . Thus, there is a need for new techniques and compositions to combat such species of pests.
SUMMARY OF THE INVENTION
[0003] One aspect of the present invention provides compositions that exhibit enhanced activity against rootworms in their larval form. Another aspect of the present invention provides novel methods for controlling rootworms.
[0004] In one embodiment, the compositions of the present invention contain an effective amount of a diamide insecticide as the sole active ingredient. In this embodiment, the diamide insecticide includes but is not limited to tetraniliprole, chlorantraniliprole, flubendiamide, and cyantraniliprole. In certain embodiments, the diamide insecticide is tetraniliprole.
[0005] In another embodiment, the composition may further contain a plant protection agent selected from the group consisting of pesticide, arthropodicide, insecticide, acaricide, nematocide, fungicide, herbicide, plant growth regulator and a combination thereof. In a preferred embodiment, the pesticide is a pyrethroid selected from bifenthrin, cypermethrin, beta-cypermethrin, zeta-cypermethrin, deltamethrin, cis-permethrin, gamma-cyhalothrin, tralomethrin, cyfluthrin, beta-cyfluthrin, esfenvalerate and fluvalinate.
[0006] In another embodiment of the present invention, methods of controlling, stunting or killing rootworms at all stages of their life cycle in a region susceptible to their growth are described. In one embodiment, the methods are directed to controlling these pests at their larval (1 st instar, 2 nd instar, 3 rd instar, 4 th instar), pupal, and adult stages. In a preferred embodiment, the rootworms include but are not limited to such species as D. virgifera, D. barberi, D. u. howardi, D. u. tenella , and D. undecimpunctata.
[0007] In another embodiment, the composition of the present invention is present in the liquid form of a microemulsion, an oil-in-water concentrated emulsion, a suspension, a suspension concentrate, an emulsifiable concentrate, or a microencapsulate. In at least one embodiment, the composition of the present invention is in the form of a suspension concentrate (SC). In yet another embodiment, the suspension concentrate is stable over a time period of two years or more wherein the suspended particles do not aggromelate. In yet another embodiment, the diamide compound is tetraniliprole as a 200 SC formulation (Test Formula).
[0008] In an alternate embodiment, the composition of the present invention is a combination of the diamide insecticide and a plant protecting agent such as a pyrethorid. In one embodiment, the diamide insecticide is tetraniliprole and the plant protecting agent is bifenthrin.
[0009] In another embodiment, the composition may further contain a dispersant, a preservative, a foaming agent, and/or at least one foam stabilizer. In another embodiment, the composition may be applied in a furrow in the form of foam. In certain embodiments, the foaming agent can be sodium lauryl sulfate, sodium dodecylbenzene sulfonate, or a combination thereof. In another embodiment, the foam stabilizer can be glycerine, xanthan gum, or a combination thereof. In yet another embodiment, the foam may have an expansion factor of 15, 25, 40, 50, 60 or 70.
[0010] In another embodiment, the compositions of the present invention may be mixed into water and/or liquid fertilizer and applied in-furrow at a volume of 10, 9, 8, 7, 6, 5, 4, 3, 2 gallons or less per acre.
[0011] In another embodiment, tetraniliprole and a plant protection agent may be applied each at a rate ranging from about 0.05 lb ai/acre to about 10 lb ai/acre, all sub-ranges and sub-values included. In exemplary embodiments, tetraniliprole and the plant protection agent may be applied independently at a rate of about 0.05, about 0.1, about 0.15, about 0.2, about 0.25, about 0.3, about 0.35, about 0.4, about 0.45, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, about 1.0, about 1.2, about 1.4, about 1.6, about 1.8, about 2.0, about 2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 6, about 7, about 8, about 9, or about 10 lb/acre.
[0012] In another embodiment, the formulation can be applied to the soil or to the plant as a rescue treatment or post-plant to control rootworm larvae.
[0013] Another objective of the present invention is to reduce the application rates and broaden the activity spectrum of the compositions claimed herein by reducing the total amount of active compounds applied. In another embodiment, It is an objective of the present invention to provide a composition which, when applied to a crop, results in a decreased amount of residues in the crop, thereby reducing the risk of resistance formation and nevertheless providing efficient plant disease control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A detailed description of drawings is provided here to illustrate various aspects and features of the present subject matter.
[0015] FIGS. 1 -A to 1 -G provides schematic representation of methodology steps for assessing rootworms within treated soil. ( FIG. 1 -A) pre-water submerged corn seeds are placed between layers of moisten paper towel. ( FIG. 1 -B) Test Formulation according to the present invention was mixed with the soil. ( FIGS. 1 -C and 1 -D) treated soil was placed in the container along with two germinated corn seeds on top. ( FIGS. 1 -E and 1 -F) 5 larvae of Southern Corn Root Worms (SCRW) and Western Corn Root Worms (WCRW) were placed onto the soil in a container and capped ( FIG. 1 -G) arenas containing soil, corn, and larvae to be evaluated.
[0016] FIGS. 2 -A and 2 -B shows WCRW larvae extracted from the untreated soil after 6 d ( FIG. 2 -A) and the soil treated with the Test Formulation 57 days after the treatment ( FIG. 2 -B) (designated as number 8) at 67 ppm and pH of 8.
[0017] FIGS. 3 -A to 3 -C depicts the corn plants extracted from a soil that has been treated with Test Formulation at 15 g ai/ha ( FIG. 3 -A), Capture LFR at 112 g ai/ha ( FIG. 3 -B), or the soil that was untreated ( FIG. 3 -C). The extraction occurred 5 days after being within the subject soils. The respective soils were infested with 5, 2nd instar WCRW larvae.
[0018] FIGS. 4 -A to 4 -B depicts the damage to corn roots and shoots caused by 2nd instar WCRW infested into the respective treated soil. ( FIG. 4 -A) depicts the damage to the crop in soil treated with Test Formulation at 60 g ai/ha=1069 ppm. ( FIG. 4 -B) depicts the damage to the crop in an untreated soil. The assessment was done at 144 hour post WCRW infestation.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Various embodiments of the present invention provide an agricultural composition for controlling rootworms. At least one aspect of the present invention is directed to the novel discovery of compositions containing diamide compounds that exhibit potent activities in controlling and suppressing rootworm pests, particularly in their larval form. Even more surprising and unexpected is the activity spectrum of tetraniliprole against these pests.
[0020] As used in this specification and unless otherwise indicated, the term “rootworms” includes but is not limited to D. virgifera (also known and refereed herein as Western corn rootworm “WCRW”), D. barberi (also known and referred herein as Northern corn rootworm “NCR”), D. u. howardi, D. u. tenella , and D. undecimpunctata (also known and referred herein as Southern corn rootworm “SCRW”).
[0021] As used in this specification and unless otherwise indicated the term “plant protection agent” refers to a molecule or combination of molecules which express biological activity as a pesticide, arthropodicide, insecticide, acaricide, nematocide, fungicide, herbicide, plant growth regulator or a combination of two or more of these biological activities.
[0022] As used in this specification and unless otherwise indicated, the term “controlling” refers to reducing, inhibiting, or eliminating the presence of rootworm species during one or more of its growth stages. For example, the compositions of the present invention may be used for controlling the growth of rootworms at any instar stages as well as its pupil and adult forms.
[0023] As used in this specification and unless otherwise indicated, the term “insecticide” refers to a molecule or combination of molecules that repels, retards, or kills insects, and can be used for plant protection, edifice protection, turf protection, or protection of a person.
[0024] The term “liquid fertilizer” refers to a fertilizer in a fluid or liquid form containing various ratios of nitrogen, phosphorous and potassium (for example, but not limited to, 10% nitrogen, 34% phosphorous and 0% potassium) and micronutrients, commonly known as starter fertilizers that are high in phosphorus and promote rapid and vigorous root growth. Liquid fertilizers are commonly aqueous-based. As used herein, the term “aqueous-based” indicates that the predominant solvent or vehicle is water. The term “ambient temperature” as utilized herein shall mean any suitable temperature found in a laboratory or other working environment, and is generally not below about 15° C. nor above about 30° C.
[0025] The modifier “about” is used herein to indicate that certain preferred operating ranges, such as ranges for molar ratios for reactants, material amounts, and temperature, are not fixedly determined. The meaning will often be apparent to one of ordinary skill. For example, a recitation of a concentration of about 200 grams per liter in reference to, for example, a formulation would be interpreted to include other like concentrations that can be expected to provide similar effect for the concentration, such as 180 grams per liter or 220 grams per liter. Where guidance from the experience of those of ordinary skill is lacking, guidance from the context is lacking, and where a more specific rule is not recited below, the “about” range shall be not more than 10% of the absolute value of an end point or 10% of the range recited, whichever is less.
[0026] In one aspect of the present invention, novel compositions are described for controlling rootworms that contain at least one diamide compound selected from the group consisting of flubendiamide, chloranthraniliprole, cyanthraniliprole and tetraniliprole in a carrier system in amounts effective to inhibit the infestation of the larvae in a location of interest. In at least another aspect of the invention, combinations of a diamide compound with one or more plant protection agents are described to broaden the spectrum for insecticidal efficacy.
[0027] In another aspect of the present invention, methods for controlling infestation of Diabrotica larvae in a location of interest are described. In at least one embodiment, the controlling of larvae results in at least 60, 70, 80, 90 or 100% inhibition of larvae in such location. According to certain embodiments, methods of controlling infestation Diabrotica larvae at all its life stages can be achieved by applying a composition comprising a diamide compound selected from the group consisting of flubendiamide, chloranthraniliprole, cyanthraniliprole or tetraniliprole and a carrier system in amounts effective to inhibit the infestation of the larvae in a location of interest. In another embodiment, the diamide compound is tetraniliprole.
[0028] In another embodiment a method for controlling infestation of Diabrotica larvae in a location is described comprising (a) applying an amount of a composition comprising a liquid agricultural formulation comprising an active ingredient selected from the group consisting of flubendiamide, chloranthraniliprole, cyanthraniliprole and tetraniliprole and an agriculturally suitable carrier system in amounts effective and optionally a plant protecting agent, and (b) inducing mortality in at least 60% of said larvae. In one embodiment, the larve mortality rate is in at least 70%, 80%, 90%, 95%, 98%, or 99% in such locations. In at least one embodiment, the location of interest is on the plant itself, plant seed, plant roots, plant part, foliage, seedling or substrate for growing the plant or crop. In another embodiment, the larvae is NCR, WCRW, SCRW, or a combination thereof.
[0029] In at least another embodiment, the methods according to the present invention provide greater control at all instar stages of rootworm larvae as compared to other diamide insecticides such as chlorantraniliprole flubendiamide, and cyantraniliprole at a comparable rate of administration to the soil or the area of interest. In at least one embodiment, a tetraniliprole containing composition according to the the present invention unexpectedly provides a statistically greater control of SCRW and WCRW as compared to cyantraniliprole and chlorantranilipole. In another embodiment, the tetraniliprole containing compositions of the present invention are administered at ranges between 2.5 to 100 g ai/ha, or 7.5 to 60 g ai/ha to provide a larval mortality rate of at least 60%, 70%, 80%, 90%, 95%, 98%, or 99% in administered locations.
[0030] In another aspect of the present invention, the compositions according to the present invention consist essentially of tetraniliprole or a derivative thereof. In another embodiment, the composition contains solely a single diamide insecticide. In certain embodiments, the diamide insecticide is tetraniliprole.
[0031] In another embodiment, the compositions of the present invention further include a plant protecting agent. Suitable plant protecting agents include the following:
[0032] Insecticides: A1) the class of carbamates consisting of aldicarb, alanycarb, benfuracarb, carbaryl, carbofuran, carbosulfan, methiocarb, methomyl, oxamyl, pirimicarb, propoxur and thiodicarb; A2) the class of organophosphates consisting of acephate, azinphos-ethyl, azinphos-methyl, chlorfenvinphos, chlorpyrifos, chlorpyrifos-methyl, demeton-S-methyl, diazinon, dichlorvos/DDVP, dicrotophos, dimethoate, disulfoton, ethion, fenitrothion, fenthion, isoxathion, malathion, methamidaphos, methidathion, mevinphos, monocrotophos, oxymethoate, oxydemeton-methyl, parathion, parathion-methyl, phenthoate, phorate, phosalone, phosmet, phosphamidon, pirimiphos-methyl, quinalphos, terbufos, tetrachlorvinphos, triazophos and trichlorfon; A3) the class of cyclodiene organochlorine compounds such as endosulfan; A4) the class of fiproles consisting of ethiprole, fipronil, pyrafluprole and pyriprole; A5) the class of neonicotinoids consisting of acetamiprid, chlothianidin, dinotefuran, imidacloprid, nitenpyrathiacloprid and thiamethoxam; A6) the class of spinosyns such as spinosad and spinetoram; A7) chloride channel activators from the class of mectins consisting of abamectin, emamectin benzoate, ivermectin, lepimectin and milbemectin; A8) juvenile hormone mimics such as hydroprene, kinoprene, methoprene, fenoxycarb and pyriproxyfen; A9) selective homopteran feeding blockers such as pymetrozine, flonicamid and pyrifluquinazon; A10) mite growth inhibitors such as clofentezine, hexythiazox and etoxazole; A11) inhibitors of mitochondrial ATP synthase such as diafenthiuron, fenbutatin oxide and propargite; uncouplers of oxidative phosphorylation such as chlorfenapyr; A12) nicotinic acetylcholine receptor channel blockers such as bensultap, cartap hydrochloride, thiocyclam and thiosultap sodium; A13) inhibitors of the chitin biosynthesis type 0 from the benzoylurea class consisting of bistrifluron, diflubenzuron, flufenoxuron, hexaflumuron, lufenuron, novaluron and teflubenzuron; A14) inhibitors of the chitin biosynthesis type 1 such as buprofezin; A15) moulting disruptors such as cyromazine; A16) ecdyson receptor agonists such as methoxyfenozide, tebufenozide, halofenozide and chromafenozide; A17) octopamin receptor agonists such as amitraz; A18) mitochondrial complex electron transport inhibitors pyridaben, tebufenpyrad, tolfenpyrad, flufenerim, cyenopyrafen, cyflumetofen, hydramethylnon, acequinocyl or fluacrypyrim; A19) voltage-dependent sodium channel blockers such as indoxacarb and metaflumizone; A20) inhibitors of the lipid synthesis such as spirodiclofen, spiromesifen and spirotetramat; A21) ryanodine receptor-modulators from the class of diamides consisting of flubendiamide, the phthalamide compounds (R)-3-Chlor-N1-{2-methyl-4-[1,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid and (S)-3-Chlor-N1-{2-methyl-441,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid, chloranthraniliprole, and cyanthraniliprole; A22) compounds of unknown or uncertain mode of action such as azadirachtin, amidoflumet, bifenazate, fluensulfone, piperonyl butoxide, pyridalyl, sulfoxaflor; or A23) sodium channel modulators from the class of pyrethroids consisting of acrinathrin, allethrin, bifenthrin, cyfluthrin, lambda-cyhalothrin, cyper-methrin, alpha-cypermethrin, beta-cypermethrin, zeta-cypermethrin, deltamethrin, esfenvalerate, etofenprox, fenpropathrin, fenvalerate, flucythrinate, tau-fluvalinate, permethrin, silafluofen and tralomethrin.
[0033] Fungicides: B1) azoles selected from the group consisting of bitertanol, bromuconazole, cyproconazole, difenoconazole, diniconazole, enilconazole, epoxiconazole, fluquinconazole, fenbuconazole, flusilazole, flutriafol, hexaconazole, imibenconazole, ipconazole, metconazole, myclobutanil, penconazole, propiconazole, prothioconazole, simeconazole, triadimefon, triadimenol, tebuconazole, tetraconazole, triticonazole, prochloraz, pefurazoate, imazalil, triflumizole, cyazofamid, benomyl, carbendazim, thia-bendazole, fuberidazole, ethaboxam, etridiazole and hymexazole, azaconazole, diniconazole-M, oxpoconazol, paclobutrazol, uniconazol, 1-(4-chloro-phenyl)-2-([1,2,4]triazol-1-yl)-cycloheptanol and imazalilsulfphate; B2) strobilurins selected from the group consisting of azoxystrobin, dimoxystrobin, enestroburin, fluoxastrobin, kresoxim-methyl, methominostrobin, orysastrobin, picoxystrobin, pyraclostrobin, trifloxystrobin, enestroburin, methyl (2-chloro-5-[1-(3-methylbenzyloxyimino)ethyl]benzyl)carbamate, methyl (2-chloro-5-[1-(6-methylpyridin-2-ylmethoxyimino)ethyl]benzyl)carbamate and methyl 2-(ortho-(2,5-dimethylphenyloxymethylene)-phenyl)-3-methoxyacrylate, 2-(2-(6-(3-chloro-2-methyl-phenoxy)-5-fluoro-pyrimidin-4-yloxy)-phenyl)-2-methoxyimino-N-methyl-acetamide and 3-methoxy-2-(2-(N-(4-methoxy-phenyl)-cyclopropanecarboximidoylsulfanylmethyl)-phenyl)-acrylic acid methyl ester; B3) carboxamides selected from the group consisting of carboxin, benalaxyl, benalaxyl-M, fenhexamid, flutolanil, furametpyr, mepronil, metalaxyl, mefenoxam, ofurace, oxadixyl, oxycarboxin, penthiopyrad, isopyrazam, thifluzamide, tiadinil, 3,4-dichloro-N-(2-cyanophenyl)isothiazole-5-carboxamide, dimethomorph, flumorph, flumetover, fluopicolide (picobenzamid), zoxamide, carpropamid, diclocymet, mandipropamid, N-(2-(443-(4-chlorophenyl)prop-2-ynyloxyl-3-methoxyphenyl)ethyl)-2-methanesulfonyl-amino-3-methylbutyramide, N-(2-(4-[3-(4-chloro-phenyl)prop-2-ynyloxy]-3-methoxy-phenyl)ethyl)-2-ethanesulfonylamino-3-methylbutyramide, methyl 3-(4-chlorophenyl)-3-(2-isopropoxycarbonyl-amino-3-methyl-butyrylamino)propionate, N-(4′-bromobiphenyl-2-yl)-4-difluoromethylA-methylthiazole-6-carboxamide, N-(4′-trifluoromethyl-biphenyl-2-yl)-4-difluoromethyl-2-methylthiazole-5-carboxamide, N-(4′-chloro-3′-fluorobiphenyl-2-yl)-4-difluoromethyl-2-methyl-thiazole-5-carboxamide, N-(3 \4′-dichloro-4-fluorobiphenyl-2-yl)-3-difluoro-methyl-1-methyl-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-3-difluoromethyl-1-methylpyrazole-4-carboxamide, N-(2-cyano-phenyl)-3,4-dichloroisothiazole-5-carboxamide, 2-amino-4-methyl-thiazole-5-carboxanilide, 2-chloro-N-(1,1,3-trimethyl-indan-4-yl)-nicotinamide, N-(2-(1,3-dimethylbutyl)-phenyl)-1,3-dimethyl-5-fluoro-1H-pyrazole-4-carboxamide, N-(4′-chloro-3′,5-difluoro-biphenyl-2-yl)-3-difluoromethyl-1-methyl-I H-pyrazole-4-carboxamide, N-(4′-chloro-3′,5-difluoro-biphenyl-2-yl)-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluoro-biphenyl-2-yl)-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(3′,5-difluoro-4′-methyl-biphenyl-2-yl)-3-difluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(3′,5-difluoro-4′-methyl-biphenyl-2-yl)-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(cis-2-bicyclopropyl-2-yl-phenyl)-3-difluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(trans-2-bicyclopropyl-2-yl-phenyl)-3-difluoro-methyl-1-methyl-1H-pyrazo le-4-c arbox amide, fluopyram, N-(3-ethyl-3,5-5-trimethyl-cyclohexyl)-3-formylamino-2-hydroxy-benzamide, oxytetracyclin, silthiofam, N-(6-methoxy-pyridin-3-yl) cyclopropanecarboxamide, 2-iodo-N-phenyl-benzamide, N-(2-bicyclo-propyl-2-yl-phenyl)-3-difluormethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethyl-5-fluoropyrazol-4-yl-carboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1,3-dimethyl-pyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-fluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-(chlorofluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-5-fluoro-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′, 4′, 5′-trifluorobiphenyl-2-yl)-3-(chlorodifluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-fluoro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethyl-5-fluoropyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1,3-dimethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-fluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-(chlorofluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-5-fluoro-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-(chlorodifluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-fluoro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(3′,4′-dichloro-3-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-3-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-3-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-3-fluorobiphenyl-2-yl)-1-methyl-S-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′-chloro-4′-fluoro-3-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-4-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-4-fluorobiphenyl-2-yl)-1-methyl-S-trifluoromethyl-I H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-4-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-4-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′-chloro-4′-fluoro-4-fluorobiphenyl-2-yl)-1-methyl-S-difluoromethyl-I H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-1-methyl-S-difluoromethyl-I H-pyrazole-carboxamide, N-(3′,4′-difluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(3′-chloro-4′-fluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-4-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-chloro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-methyl-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(4′-chloro-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(4′-methyl-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-6-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-chloro-6-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-[2-(1,1,2,3,3,3-hexafluoropropoxy)-phenyl]-3-difluoromethyl-1-methyl-1H-pyrazo le-4-carbox amide, N-[4′-(trifluoromethylthio)-biphenyl-2-yl]-3-difluoromethyl-1-methyl-1H-pyrazole-4-carboxamide and N-[4′-(trifluoromethylthio)-biphenyl-2-yl]-1-methyl-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide; B4) heterocyclic compounds selected from the group consisting of fluazinam, pyrifenox, bupirimate, cyprodinil, fenarimol, ferimzone, mepanipyrim, nuarimol, pyrimethanil, triforine, fenpiclonil, fludioxonil, aldimorph, dodemorph, fenpropimorph, tridemorph, fenpropidin, iprodione, procymidone, vinclozolin, famoxadone, fenamidone, octhilinone, proben-azole, 5-chloro-7-(4-methyl-piperidin-1-yl)-6-(2,4,6-trifluorophenyl)41,2,4]triazolo[1,5-alpyrimidine, anilazine, diclomezine, pyroquilon, proquinazid, tricyclazole, 2-butoxy-6-iodo-3-propylchromen-4-one, acibenzolar-S-methyl, captafol, captan, dazomet, folpet, fenoxanil, quinoxyfen, N,N-dimethyl-3-(3-bromo-6-fluoro-2-methylindole-1-sulfonyl)-[1,2,4]triazole-1-sulfonamide, 5-ethyl-6-octyl41,2,4]triazolo[1,5-a]pyrimidin-2,7-diamine, 2,3,5,6-tetrachloro-4-methanesulfonyl-pyridine, 3,4,5-trichloro-pyridine-2,6-di-carbonitrile, N-(1-(5-bromo-3-chloro-pyridin-2-yl)-ethyl)-2,4-dichloro-nicotinamide, N-((5-bromo-3-chloro pyridin-2-yl)-methyl)-2,4-dichloro-nicotinamide, diflumetorim, nitrapyrin, dodemorphacetate, fluoroimid, blasticidin-S, chinomethionat, debacarb, difenzoquat, difenzoquat-methylsulphat, oxolinic acid and piperalin; B5) carbamates selected from the group consisting of mancozeb, maneb, metam, methasulphocarb, metiram, ferbam, propineb, thiram, zineb, ziram, diethofencarb, iprovalicarb, benthiavalicarb, propamocarb, propamocarb hydrochlorid, 4-fluorophenyl N-(1-(1-(4-cyanophenyl)-ethanesulfonyl)but-2-yl)carbamate, methyl 3-(4-chloro-phenyl)-3-(2-isopropoxycarbonylamino-3-methyl-butyrylamino)propanoate; or B6) other fungicides selected from the group consisting of guanidine, dodine, dodine free base, iminoctadine, guazatine, antibiotics: kasugamycin, streptomycin, polyoxin, validamycin A, nitrophenyl derivatives: binapacryl, dinocap, dinobuton, sulfur-containing heterocyclyl compounds: dithianon, isoprothiolane, organometallic compounds: fentin salts, organophosphorus compounds: edifenphos, iprobenfos, fosetyl, fosetyl-aluminum, phosphorous acid and its salts, pyrazophos, tolclofos-methyl, organochlorine compounds: dichlofluanid, flusulfamide, hexachloro-benzene, phthalide, pencycuron, quintozene, thiophanate-methyl, tolylfluanid, others: cyflufenamid, cymoxanil, dimethirimol, ethirimol, furalaxyl, metrafenone and spiroxamine, guazatine-acetate, iminoc-tadine-triacetate, iminoctadine-tris(albesilate), kasugamycin hydrochloride hydrate, dichlorophen, pentachlorophenol and its salts, N-(4-chloro-2-nitro-phenyl)-N-ethyl-4-methyl-benzenesulfonamide, dicloran, nitrothal-isopropyl, tecnazen, biphenyl, bronopol, diphenylamine, mildiomycin, oxincopper, prohexadione calcium, N-(cyclopropylmethoxyimino-(6-difluoromethoxy-2,3-difluoro-phenyl)-methyl)-2-phenyl acetamide, N′-(4-(4-chloro-3-trifluoromethyl-phenoxy)-2,5-dimethyl-phenyl)-N-ethyl-N-methyl formamidine, N′-(4-(4-fluoro-3-trifluoromethyl-phenoxy)-2,5-dimethyl-phenyl)-N-ethyl-N-methyl formamidine, N′-(2-methyl-5-trifluormethyl-4-(3-trimethylsilanyl-propoxy)-phenyl)-N-ethyl-N-methylformamidine and N′-(5-difluormethyl-2-methyl-4-(3-trimethylsilanyl-propoxy)-phenyl)-N-ethyl-N-methyl formamidine.
[0034] Herbicides: C1) acetyl-CoA carboxylase inhibitors (ACC), for example cyclohexenone oxime ethers, such as alloxydim, clethodim, cloproxydim, cycloxydim, sethoxydim, tralkoxydim, butroxydim, clefoxydim or tepraloxydim; phenoxyphenoxypropionic esters, such as clodinafop-propargyl, cyhalofop-butyl, diclofop-methyl, fenoxaprop-ethyl, fenoxaprop-P-ethyl, fenthiapropethyl, fluazifop-butyl, fluazifop-P-butyl, haloxyfop-ethoxyethyl, haloxyfop-methyl, haloxyfop-P-methyl, isoxapyrifop, propaquizafop, quizalofop-ethyl, quizalofop-P-ethyl or quizalofop-tefuryl; or arylaminopropionic acids, such as flamprop-methyl or flamprop-isopropyl; C2 acetolactate synthase inhibitors (ALS), for example imidazolinones, such as imazapyr, imazaquin, imazamethabenz-methyl (imazame), imazamox, imazapic or imazethapyr; pyrimidyl ethers, such as pyrithiobac-acid, pyrithiobac-sodium, bispyribac-sodium. KIH-6127 or pyribenzoxym; sulfonamides, such as florasulam, flumetsulam or metosulam; or sulfonylureas, such as amidosulfuron, azimsulfuron, bensulfuron-methyl, chlorimuron-ethyl, chlorsulfuron, cinosulfuron, cyclosulfamuron, ethametsulfuron-methyl, ethoxysulfuron, flazasulfuron, halosulfuron-methyl, imazosulfuron, metsulfuron-methyl, nicosulfuron, primisulfuron-methyl, prosulfuron, pyrazosulfuron-ethyl, rimsulfuron, sulfometuron-methyl, thifensulfuron-methyl, triasulfuron, tribenuron-methyl, triflusulfuron-methyl, tritosulfuron, sulfosulfuron, foramsulfuron or iodosulfuron; C3) amides, for example allidochlor (CDAA), benzoylprop-ethyl, bromobutide, chiorthiamid. diphenamid, etobenzanidibenzchlomet), fluthiamide, fosamin or monalide; C4) auxin herbicides, for example pyridinecarboxylic acids, such as clopyralid or picloram; or 2,4-D or benazolin; C5) auxin transport inhibitors, for example naptalame or diflufenzopyr; C6) carotenoid biosynthesis inhibitors, for example benzofenap, clomazone (dimethazone), diflufenican, fluorochloridone, fluridone, pyrazolynate, pyrazoxyfen, isoxaflutole, isoxachlortole, mesotrione, sulcotrione (chlormesulone), ketospiradox, flurtamone, norflurazon or amitrol; C7) enolpyruvylshikimate-3-phosphate synthase inhibitors (EPSPS), for example glyphosate or sulfosate; C8) glutamine synthetase inhibitors, for example bilanafos (bialaphos) or glufosinate-ammonium; C9) lipid biosynthesis inhibitors, for example anilides, such as anilofos or mefenacet; chloroacetanilides, such as dimethenamid, S-dimethenamid, acetochlor, alachlor, butachlor, butenachlor, diethatyl-ethyl, dimethachlor, metazachlor, metolachlor, S-metolachlor, pretilachlor, propachlor, prynachlor, terbuchlor, thenylchlor or xylachlor; thioureas, such as butylate, cycloate, di-allate, dimepiperate, EPTC. esprocarb, molinate, pebulate, prosulfocarb, thiobencarb (benthiocarb), tri-allate or vemolate; or benfuresate or perfluidone; C10) mitosis inhibitors, for example carbamates, such as asulam, carbetamid, chlorpropham, orbencarb, pronamid (propyzamid), propham or tiocarbazil; dinitroanilines, such as benefin, butralin, dinitramin, ethalfluralin, fluchloralin, oryzalin, pendimethalin, prodiamine or trifluralin; pyridines, such as dithiopyr or thiazopyr; or butamifos, chlorthal-dimethyl (DCPA) or maleic hydrazide; C11) protoporphyrinogen IX oxidase inhibitors, for example diphenyl ethers, such as acifluorfen, acifluorfen-sodium, aclonifen, bifenox, chlomitrofen (CNP), ethoxyfen, fluorodifen, fluoroglycofen-ethyl, fomesafen, furyloxyfen, lactofen, nitrofen, nitrofluorfen or oxyfluorfen; oxadiazoles, such as oxadiargyl or oxadiazon; cyclic imides, such as azafenidin, butafenacil, carfentrazone-ethyl, cinidon-ethyl, flumiclorac-pentyl, flumioxazin, flumipropyn, flupropacil, fluthiacet-methyl, sulfentrazone or thidiazimin; or pyrazoles, such as ET-751.JV 485 or nipyraclofen; C12) photosynthesis inhibitors, for example propanil, pyridate or pyridafol; benzothiadiazinones, such as bentazone; dinitrophenols, for example bromofenoxim, dinoseb, dinoseb-acetate, dinoterb or DNOC; dipyridylenes, such as cyperquat-chloride, difenzoquat-methylsulfate, diquat or paraquat-dichloride; ureas, such as chlorbromuron, chlorotoluron, difenoxuron, dimefuron, diuron, ethidimuron, fenuron, fluometuron, isoproturonisouron, linuron, methabenzthiazuron, methazole, metobenzuron, metoxuron, monolinuron, neburon, siduron or tebuthiuron; phenols, such as bromoxynil or ioxynil; chloridazon; triazines, such as ametryn, atrazine, cyanazine, desmein, dimethamethryn, hexazinone, prometon, prometryn, propazine, simazine, simetryn, terbumeton, terbutryn, terbutylazine or trietazine; triazinones, such as metamitron or metribuzin; uracils, such as bromacil, lenacil or terbacil; or biscarbamates, such as desmedipham or phenmedipham; C13) synergists, for example oxiranes, such as tridiphane; C14) CIS cell wall synthesis inhibitors, for example isoxaben or dichlobenil; C16) various other herbicides, for example dichloropropionic acids, such as dalapon; dihydrobenzofurans, such as ethofumesate; phenylacetic acids, such as chlorfenac (fenac); or aziprotryn, barban, bensulide, benzthiazuron, benzofluor, buminafos, buthidazole, buturon, cafenstrole, chlorbufam, chlorfenprop-methyl, chloroxuron, cinmethylin, cumyluron, cycluron, cyprazine, cyprazole, dibenzyluron, dipropetryn, dymron, eglinazin-ethyl, endothall, ethiozin, flucabazone, fluorbentranil, flupoxam, isocarbamid, isopropalin, karbutilate, mefluidide, monuron, napropamide, napropanilide, nitralin, oxaciclomefone, phenisopham, piperophos, procyazine, profluralin, pyributicarb, secbumeton, sulfallate (CDEC), terbucarb, triaziflam, triazofenamid or trimeturon; or their environmentally compatible salts.
[0035] Plant Growth Regulators: D1) Antiauxins, such as clofibric acid, 2,3,5-tri-iodobenzoic acid; D2) Auxins such as 4-CPA, 2,4-D, 2,4-DB, 2,4-DEP, dichlorprop, fenoprop, IAA, IBA, naphthaleneacetamide, a-naphthaleneacetic acids, 1-naphthol, naphthoxyacetic acids, potassium naphthenate, sodium naphthenate, 2,4,5-T; D3) cytokinins, such as 2iP, benzyladenine, 4-hydroxyphenethyl alcohol, kinetin, zeatin; D4) defoliants, such as calcium cyanamide, dimethipin, endothal, ethephon, merphos, metoxuron, pentachlorophenol, thidiazuron, tribufos; D5) ethylene inhibitors, such as aviglycine, 1-methylcyclopropene; D6) ethylene releasers, such as ACC, etacelasil, ethephon, glyoxime; D7) gametocides, such as fenridazon, maleic hydrazide; D8) gibberellins, such as gibberellins, gibberellic acid; D9) growth inhibitors, such as abscisic acid, ancymidol, butralin, carbaryl, chlorphonium, chlorpropham, dikegulac, flumetralin, fluoridamid, fosamine, glyphosine, isopyrimol, jasmonic acid, maleic hydrazide, mepiquat, piproctanyl, prohydrojasmon, propham, tiaojiean, 2,3,5-tri-iodobenzoic acid; D10) morphactins, such as chlorfluren, chlorflurenol, dichlorflurenol, flurenol; D11) growth retardants, such as chlormequat, daminozide, flurprimidol, mefluidide, paclobutrazol, tetcyclacis, uniconazole; D12) growth stimulators, such as brassinolide, brassinolide-ethyl, DCPTA, forchlorfenuron, hymexazol, prosuler, triacontanol; D13) unclassified plant growth regulators, such as bachmedesh, benzofluor, buminafos, carvone, choline chloride, ciobutide, clofencet, cyanamide, cyclanilide, cycloheximide, cyprosulfamide, epocholeone, ethychlozate, ethylene, fuphenthiourea, furalane, heptopargil, holosulf, inabenfide, karetazan, lead arsenate, methasulfocarb, prohexadione, pydanon, sintofen, triapenthenol, trinexapac.
[0036] The presently described compositions may be in any appropriate conventional form, for example an emulsion concentrate (EC), a suspension concentrate (SC), a suspo-emulsion (SE), a capsule suspension (CS), a water dispersible granule (WG), an emulsifiable granule (EG), a water in oil emulsion (EO), an oil in water emulsion (EW), a micro-emulsion (ME), an oil dispersion (OD), an oil miscible flowable (OF), an oil miscible liquid (OL), a soluble concentrate (SL), an ultra-low volume suspension (SU), an ultra-low volume liquid (UL), a dispersible concentrate (DC), a wettable powder (WP) or any technically feasible formulation in combination with agriculturally acceptable adjuvants. In one embodiment, the compositions can be administered directly or can be provided in a tank mix.
[0037] In another embodiment, the presently described compositions may be in the form of foamable formulations. Suitable foaming agents include, but are not limited to, nonionic surfactants, including alkanolamides (such as cocamide diethanolamide, lauric acid monoisopropanolamide, and ethoxylated myristamide), xyethylene fatty acid esters, polyoxyethylene fatty alcohol ethers (such as alkylaryl polyglycol ethers) and fluorocarbons (such as ethoxylated polyfluorinated alcohol); anionic surfactants including alkyl-, alkylaryl- and arylsulfonates (such as sodium lauryl sarcosinate and such as sodium alkylbenzenesulfonate), alkyl-, alkylaryl- and arylsulfates, protein hydrolysates, derivatives of polycarboxylic acid (such as ammonium lauryl ether carboxylate), olefin sulfonates (such as sodium alpha olefin sulfonate), sarcosinates (such as ammonium cyclohexyl palmitoyl taurinate), succinates (such as disodium N-octadecyl sulfosuccinamate), phosphorus derivatives (such as phosphoric acid esters and their equivalent salts); cationic surfactants including alkylbenzyltrimethylammonium chloride; and amphoteric surfactants including betaine. Particularly preferred foaming agents include Bio-Soft D-40, Bioterge AS-40, Ammonyx DO, Ammonyx LO, Steol CA-330, Cedepal TD-407, and Polystep B-25. The total concentration of foaming agents in the formulation will be dependent on the foaming agents used, and may comprise between about 0.1% and about 50% of the final formulation, preferably between about 0.3% and about 30%, more preferably between about 5% and 25%, and even more preferably between about 17% and about 23%.
[0038] In some embodiments, the composition is formulated as a suspension, preferably as a suspension concentrate. A suspension concentrate may contain, for example, about 50, 80, 10, 150, 200, 250, 300, 350, or 400 grams of the diamide active ingredient per liter. The concentrate can be diluted with a solvent, for example water, before being applied to a plant or soil. Tetraniliprole and its combination with one or more plant protection agents can also be prepared as a SC formulation. Various methods are known to prepare a SC formulation. An exemplary procedure is provided in U.S. Pat. No. 9,253,981, the entire disclosure of which is hereby incorporated by reference. The SC formulation may contain additional components such as a surfactant, an antifoam agent, a preservative, a thickener, water, and a suspending agent. Water is used as a diluent and preferably is purified water, for example, deionized or distilled water, and is present in an amount that would dilute the active ingredient to a desired concentration.
[0039] In some embodiments, the formulated composition is homogenous at storage condition (20-25° C.). In another embodiment, the formulated composition stays shelf stable at storage condition for at least a period of 6 years, 5 years, 4 years, 3 years, 2 years, 1 year or at least 6 months.
[0040] Preferred plant protecting agents include those that when combined with tetraniliprole, sequentially or in the same formulation would not reduce the activity of teraniliprole or compromise the stability of the formulation containing tetraaniliprole. Preferred insecticides are selected from the group consisting of abamectin, aldicarb, bendiacarb, carbaryl, carbofuran, methomyl, oxamyl, propoxur, thiodicarb, fenoxycarb, acephate, azinphos-methyl, phosmet, terbufos, endosulfan, fipronil, spinosad, milbemectin, fenoxycarb, pyriproxyfen, pymetrozine, clofentezine, etoxazole, chlorfenapyr, cartap hydrochloride, diflubenzuron, clorfluazuron, hexaflumuron, novaluron, teflubenzuron, buprofezin, cyromazine, methoxyfenozide, chromafenozide, amitraz, indoxacarb, azadirachtin and pyridaben. Preferred fungicides are selected from the group consisting of bitertanol, bromuconazole, cyproconazole, difenoconazole, diniconazole, enilconazole, epoxiconazole, fluquinconazole, fenbuconazole, flusilazole, flutriafol, hexaconazole, imibenconazole, ipconazole, metconazole, myclobutanil, penconazole, propiconazole, prothioconazole, simeconazole, triadimefon, triadimenol, tebuconazole, tetraconazole, triticonazole, pefurazoate, imazalil, triflumizole, cyazofamid, benomyl, carbendazim, thiabendazole, fuberidazole, ethaboxam, etridiazole and hymexazole, azaconazole, diniconazole-M, oxpoconazol, paclobutrazol, uniconazol, imazalilsulfphate, azoxystrobin, dimoxystrobin, fluoxastrobin, kresoxim-methyl, orysastrobin, picoxystrobin, pyraclostrobin, trifloxystrobin, enestroburin, carboxin, benalaxyl, benalaxyl-M, fenhexamid, flutolanil, furametpyr, mepronil, metalaxyl, mefenoxam, ofurace, oxadixyl, oxycarboxin, penthiopyrad, isopyrazam, thifluzamide, tiadinil, dimethomorph, flumorph, fluopicolide (picobenzamid), zoxamide, carpropamid, diclocymet, mandipropamid, bixafen, fluazinam, cyprodinil, fenarimol, ferimzone, mepanipyrim, nuarimol, pyrimethanil, fenpiclonil, fludioxonil, aldimorph, dodemorph, fenpropimorph, iprodione, procymidone, vinclozolin, famoxadone, fenamidone, probenazole, acibenzolar-S-methyl, captafol, captan, dazomet, folpet, fenoxanil, quinoxyfen, nitrapyrin, fluoroimid, blasticidin-S, chinomethionat, difenzoquat-methylsulphate, oxolinic acid, mancozeb, maneb, methasulphocarb, metiram, ferbam, propineb, thiram, zineb, ziram, diethofencarb, iprovalicarb, benthiavalicarb, propamocarb hydrochloride, guanidine, dodine, kasugamycin, validamycin A, binapacryl, dinobuton, dithianon, isoprothiolane, fosetyl-aluminum, pyrazophos, tolclofos-methyl, dichlofluanid, flusulfamide, hexachlorobenzene, phthalide, pencycuron, quintozene, thiophanate-methyl, tolylfluanid, cyflufenamid, cymoxanil, ethirimol, furalaxyl, metrafenone, iminoctadine-triacetate, iminoctadine-tris(albesilate), kasugamycin hydrochlorid-hydrat, dichlorophen, pentachlorophenol and its salts, dicloran, nitrothal-isopropyl, tecnazen, biphenyl, bronopol, diphenylamine, mildiomycin, oxine-copper and prohexadione calcium.
[0041] In some embodiments, the plant protection agent is a pyrethroid compound. Non-limiting exemplary pyrethoids include acrinathrin, allethrin, bifenthrin, bioallethrin, bioresmethrin, cyclo professional Trindade (cycloprothrin), cyfluthrin, beta-cyfluthrin, cyhalothrin, cancer better halo Trindade (gamma-cyhalothrin), lambda cyhalothrin (lambda-cyhalothrin), cypermethrin, alpha-cypermethrin, beta-cypermethrin, theta cypermethrin, zeta cypermethrin (zeta-cypermethrin), cyphenothrin, deltamethrin, empenthrin, esfenvalerate, ethofenprox, Fenpropathrin, fenvalerate, flucythrinate, flumethrin, fluvalinate, tau full burr sulfonate, halfenprox, hepta full Trindade (heptafluthrin), imiprothrin, Kadesurin, Meperufurutorin (meperfluthrin), Mon-fluoro Trindade (momfluorothrin), permethrin, phenothrin, prallethrin, pyrethrins, resmethrin, silafluofen, tefluthrin, tetramethrin, tetramethyl full Trindade, tralomethrin and Transfluthrin. In some embodiments, the plant protection agent is a pyrethroid selected from bifenthrin or zeta cypermethrin.
[0042] The plant protection agent is preferably present in a concentration of from about 1% by weight to about 55% by weight, more particularly, from about 15% by weight to about 35% by weight based upon the total weight of all components in the composition. Other exemplary ranges include from about 10% to about 35%, from about 10% to about 30%, from about 10% to about 20% by weight.
[0043] In certain embodiments where tetraniliprole is the diamide insecticide, the ratio between tetraniliprole and the plant protection agent in weight may range from about 1:100 to about 100:1, and all subranges included. In some embodiments, the ratio between tetraniliprole and the plant protection agent is in the ranges of about 1:30 to 30:1. In some embodiments, the ratio between tetraniliprole and the plant protection agent is in the ranges of about 1:15 to about 15:1. Non-limiting examples of the ratio between tetraniliprole and bifenthrin or zeta-cypermthrin include about 1:20, about 1:19, about 1:18, about 1:17, about 1:16, about 1:15, about 1:14, about 1:13, about 1:12, about 1:11, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1, about 2:1, about 3:1, about 4:1, about 5:1, about 6:1, about 7:1, about 8:1, about 9:1, about 10:1, about 11:1, about 12:1, about 13:1, about 14:1, about 15:1, about 16:1, about 17:1, about 18:1, about 19:1, and about 20:1.
[0044] In some exemplary embodiments, tetraniliprole accounts for about 1%, about 2%, about 3%, about 4%, or about 5% of the composition by weight. In some embodiments, the plant protection agent accounts for less than about 1%, about 1%, about 2%, about 3%, about 4%, about 5% of the composition by weight.
[0045] In another embodiment, the composition may include at least one additive selected from the group consisting of freeze agents, anti-foam agents and biocides. These formulation components are well-known in the agrochemical arts. In some embodiments, the anti-freeze agent is a polyalkylene glycol, preferably propylene glycol, and when present, is present in an amount from about 5% to about 9% by weight of the total of all components in the composition. In some embodiments, the anti-foam agent is an alkylcyclotetrasiloxane, preferably an octamethylcyclo-tetrasiloxane silicone emulsion, for example, DOW CORNING® AF Emulsion or DOWCORNING® ANTIFOAM C Emulsion (Dow Corning Corporation). If and when present in a non-foam formulation, the anti-foam agent is present in an amount of from about 0.001% to about 1% by weight of all the components in the total formulation. The preservative can be an isothiazolone or a mixture of isothiazolones, for example, KATHON® CG/ICP preservative or LEGEND® MK preservative (Rohm and Haas Corporation) or PROXEL™ BR preservative (Avecia Corporation). When present, the preservative is present in an amount of from about 0.001% to about 1% by weight of the total of all components in the formulation.
[0046] The compositions of the present invention may also contain a pH modifier. Exemplary pH ranges suitable for the present compositions include about 4-8, 4-7, 5-6, and 6-7, which includes any pH in the range of from: pH 3.5 to 3.9; 4.0 to 4.4; pH 4.5 to 5.4; pH 5.5 to pH 6.4; pH 6.5 to pH 7.4.
[0047] In another embodiment, formulations encompass a combination of the compositions according to the present invention with liquid fertilizers to be applied in one application in a single piece of equipment. One application of such a combination or formulation provides nutrients for the plant growth, while eliminating or controlling unwanted insects that can also affect the health and vitality of the desirable plants. Accordingly, the composition of the present invention may also contain a liquid fertilizer. In some embodiments, the liquid fertilizer is aqueous-based. In some embodiments, the liquid fertilizer is present in a concentration of about 95.0% by weight to about 99.99% by weight based on the total weight of all components in the composition.
[0048] According to the present invention invention carrier system is an acceptable agricultural carrier and may be a liquid, a powder, in spray or foam form to allow delivery of agriculturally effective amounts of the diamide insecticides. In at least embodiments that tetraniliprole is the diamide insecticide alone or in combination with one or more plant protection agents, the carrier system may be in the form of a suspension concentrate. Various methods are known to prepare a SC formulation. An exemplary procedure is provided in U.S. Pat. No. 9,253,981, the entire disclosure of which is hereby incorporated by reference. The SC formulation may contain additional components such as a surfactant, an antifoam agent, a preservative, a thickener, water, and a suspending agent. Water is used as a diluent and preferably is purified water, for example, deionized or distilled water, and is present in an amount that would dilute the active ingredient to a desired concentration.
[0049] Another aspect of the invention provides a method for controlling rootworms including NCR, WCRW, and SCRW at all stages of their lifecycle, egg, larva, pupa and adult form in plants and crops using the compositions of the present invention. In at least one embodiment, controlling infestation of rootworm in the corn crop can be accomplished in any soil pH. In one embodiment, the soil of the area to be protected from rootworm infestation may posses a pH in the range of from about pH 4 to about pH 9, which includes a pH in the range of from 3.5 to 9.4, or a pH of: about pH 4, about pH 5, about pH 6, about pH 7, about pH 8, or about pH 9. The method includes the step of applying to a plant or soil an effective amount of diamide insecticide including, but not limited to, flubendiamide, the phthalamide compounds (R)-3-Chlor-N1-{2-methyl-4-[1,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid and (S)-3-Chlor-N1-{2-methyl-441,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid, chloranthraniliprole, cyanthraniliprole and tetraniliprole. In one embodiment, the composition may contain essentially just tetraniliprole as the sole active ingredient or may include at least one plant protection agent.
[0050] The method of the present invention can be used in pest-infested areas. However, it is also suitable for pest prevention purposes. The pests to be controlled may inhabit various places, including for example, rice paddies, fields, tea plantations, orchards, non-plant lands, houses, nursery trays or nursery boxes, nursery soil and nursery mats, and the like in the soil or at the foliage. Accordingly, the compositions can be applied in different means and forms depending on specific needs to control pests. For example, both direct spray and foliar applications can effectively control the egg production on the plant. Certainly, the method of the present invention is by no means limited to plant foliage application; other processes such as soil treatment and seed disinfection are also contemplated within the scope of the present invention. In one embodiment, the targeted pests are any WCRW and SCRW and their adult forms.
[0051] Prior to application, the concentrations of the compositions may be readjusted. For example, tetraniliprole and the plant protection agent may account for about 0.0005 to 40% by weight in the composition. Other exemplary ranges include about 0.05 to about 10%, about 0.1 to about 10%, about 0.5 to about 10%, about 1 to about 10%, and about 1 to about 5%.
[0052] In certain embodiments, tetraniliprole and the plant protection agent may be applied at a rate ranging from about 1 to 20 gallons per acre. Non-limiting examples include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8 and about 9 gallons per acre.
[0053] As described above, tetraniliprole and the plant protection agent may be mixed together and applied in the same formulation. Alternatively, tetraniliprole and the plant protection agent can be applied sequentially. The length of the interval between the applications depends on factors such as the target pest and concentration of the ingredients and can be determined by one of ordinary skill in the art without undue experimentation.
[0054] The plants to be protected by the compositions of the present invention include, for example, agricultural crops, fruit trees and trees other than fruit trees, grass crops, and weeds. The plants can be, for example, floricultural plants, and ornamentals. Examples of agricultural crops include, but are not limited to, corn, peanut, alfalfa, rice, wheat, barley, rye, oats, sorghum, cotton, soybean, pin-nuts, buckwheat, sugar beet, rapeseed, sunflower, sugar cane, tobacco, etc., vegetables; Solanaceae vegetables (eggplant, tomato, pin-Man, peppers, potatoes, etc.), Cucurbitaceae vegetables (cucumber, pumpkin, Zucchi-two, watermelon, melon, etc.), cruciferous vegetables (radish, turnip, horseradish, co-Rurabi, Chinese cabbage, cabbage, mustard, broccoli-, cauliflower-, etc.), Asteraceae vegetables (burdock, garland chrysanthemum , A-Ticho-clause, lettuce, etc.), Liliaceae vegetables (leek, onion, garlic, asparagus), Umbelliferae vegetables (carrot, parsley, celery, parsnip, etc.), Chenopodiaceae vegetables (spinach, Swiss chard, etc.), Labiatae vegetables ( perilla , mint, basil, etc.), strawberry, sweet potato, yam, taro, etc., flowers, and foliage plants. Examples of fruit trees include pome fleshy fruits (apple, pear, Japanese pear, quince, quince, etc.), stone fruit (peach, plum, nectarine, plum, cherry, apricot, pull-down, etc.), citrus (satsuma mandarin, orange, lemon, lime, gray-Pufuru-Tsu, etc.), Kenhate-rui (chestnut, walnut, hazel, A-Monde, pistachio, cashew-nuts, macadamia nuts, etc.), berries, grape, persimmon, Cage-parts, loquat, banana, co-Non-, date palm, and coconut. Examples of trees other than fruit trees include, but are not limited to, tea, mulberry, flowers and trees, street trees (ash, birch, dogwood, Yu-Cali, ginkgo, lilac, maple, oak, poplar, Cercis chinensis , SEAL, sycamore, zelkova Kurobe, fir, hemlock, juniper, pine, spruce, yew), and the like.
[0055] When and if employed with a liquid fertilizer, a hydrated aluminum-magnesium silicate may be used in the composition according to the present invention, preferably selected from montmorillonite and attapulgite. Such compositions may further include phosphate ester dispersants selected from a nonyl phenol phosphate ester and a tridecyl alcohol ethoxylated phosphate potassium salt. The dispersant or dispersants are preferably present in a total concentration of from about 0.02% by weight to about 20% by weight based upon the total weight of all components in the composition.
[0056] In one embodiment, the compositions of the present claims are superior in controlling rootworms as compared to diamide standards such as Exirel® (cyantraniliprole) and Coragen® when applied as a soil treatment against all stages and types of rootworms, particularly SCRW and WCRW larvae. In one embodiment, the tetraniliprole SC formulation of the present invention at ranges between 150 ppm to 250 ppm, preferably 200 to 225 pm and more preferably at 213.8 ppm, provided more than 90% control to larvae and provided statistically greater control compared to all rates of Exirel (cyantraniliprole). In another embodiment, the compositions according to the present invention against WCRW, at ranges between 150 ppm to 250 ppm, preferably 200 to 225 pm and more preferably at 213.8 ppm, provide more than 92% control and statistically outperformed Exirel at similar rate and was further numerically greater than Exirel and Coragen® (chlorantraniliprole) against rootworms.
[0057] In another embodiment, the compositions of the present invention were superior in controlling rootworms when applied foliarly to infested leafs with adult beetles of Diabrotica virgifera virgifera . In another embodiment, compositions according to the present invention controlled rootworm larve in natural ambient condition regardless of differing water pHs 6, 7, or 8. In at least one embodiment, the composition is a tetratraniliprole SC formulation.
[0058] In another embodiment, soil treated with the formulations of the present invention containing a diamide compound provided ≧90, 95, or 98% control of 1 st and/or 2 nd instar NCR, SCRW, WCRW larvae at 64 day after treatment (DAT). In at least another embodiment, the diamide compound and bifenthrin administered in combination or sequentially provided more than ≧90, 95, or 98% control of 2 nd instar SCRW, WCRW larvae at 64 day after treatment DAT. In another embodiment, the diamide compound is tetratraniliprole.
[0059] In at least one embodiment, the present invention contains: (1) between about 1% to about 35% by weight of tetraniliprole; (2) between about about 1% to about 35% by weight of the plant protecting agent, (3) between about 1% to about 20% by weight of hydrated aluminum-magnesium silicate, and optionally (4) between about 0.2% to about 20% by weight of at least one dispersant selected from the group consisting of a sucrose ester, a lignosulfonate, an alkylpolyglycoside, a naphthalenesulfonic acid formaldehyde condensate and a phosphate ester.
[0060] In another embodiment, methods of using such formulations are described to provide ≧90, 95, or 98% control of 1 st and/or 2 nd instar NCR, SCRW, or WCRW larvae at 64 days after treatment (DAT). In at least another embodiment, the administration of tetraniliprole and bifentrin in combination or sequentially provided more than ≧90, 95, 98% control of 2 nd instar SCRW, WCRW larvae at 64 DAT.
[0061] In another embodiment, the present invention may be in the form of a foamable formulation. Certain embodiments include stable, aqueous compositions suitable for the generation of air foams in a suitable system to provide in furrow or in situ treatment. As a result in at least one embodiment, the tetraniliprole SC formulation according to the present invention is of such consistency and flowability to generate foam when applied directly in-furrow to the seeds or if needed to form an in situ product.
[0062] The foamable formulations of the present disclosure include at least one active ingredient including traniliprole, at least one foaming agent, and at least one foam stabilizer. It is recognized that the foamable formulations may include more than one active ingredient, foaming agent and/or foam stabilizer. They may be prepared and used without dilution, or they may be diluted with water before use. The formulation may be diluted by mixing with water in the storage tank on the tractor (“tank mixing”), in these embodiments the formulation can be configured such that the mixture will remain stable upon mixing (i.e. introducing water to the formulation).
[0063] Alternatively, the formulation can be configured such that the mixture will require agitation prior to foaming, wherein the agitation can be provided by a mechanical mixture member (not shown) located within the tank. Additionally or alternatively, the mixing motion can be provided by the vibration and oscillation induced by normal operation of the tractor over the terrain. In other embodiments, mixing the formulation with water can occur within the line while it is being pumped to the foaming chamber. In an exemplary embodiment, the mixing can occur at a location upstream of the discharge or ejection nozzle(s).
[0064] In at least one embodiment, the tank mix chemical formulation has a suitable viscosity to allow the active ingredient in the foamable formulation to be delivered at a range of from 0.75-4.00 lbs a.i./gallon, and preferably from 0.75-2.00 lbs a.i./gallon. In at least one embodiment, the viscosity of the formulation is adjusted to the speed of the apparatus to provide optimal foaming at a range of speeds including approximately 4-16 ounces of chemical formulation per acre, and 24-64 ounces of water per acre and a ground speed ranging from 2-7 miles per hour. In at least one embodiment, the present invention provides the delivery of the chemical formulation with at least 0.75 lbs a.i./gallon to be delivered at a rate of at least 0.25 gallons/acre. In at least one embodiment, the tetratranilipole containing formulation is administered at a rate of about 5 to about 100 g ai/ha or about 7.5 to about 60 g ai/ha. Another aspect of the instant invention provides a foamable formulation with an expansion factor of at least 30, 40, 50, or 60.
[0065] Suitable foam stabilizers act to stabilize the foam generated from the liquid, foamable formulation. Examples of suitable foam stabilizers include, but are not limited to, glycerine, Kelzan, carrageenan, xanthan gum, guar gum, gum Arabic, gum tragacanth, polyox, alginin, and sodium alginate. Glycerine and Kelzan are particularly preferred. The total concentration of foam stabilizers in the formulation will be dependent on the foaming agents used, and may comprise between 0.1% and 15% of the total formulation, preferably 1-14%, more preferably 7-12%.
[0066] The foamable formulations of the present invention may also include dispersants, and/or preservatives. Suitable dispersants include, but are not limited to, nonionic and/or ionic substances, for example from the classes of the alcohol-POE and/or -POP ethers, acid and/or POP POE esters, alkylaryl and/or POP POE ethers, fat and/or POP POE adducts, POE- and/or POP-polyol derivatives, POE- and/or POP-sorbitan or -sugar adducts, alkyl or aryl sulfates, alkyl- or arylsulfonates and alkyl or aryl phosphates or the corresponding PO-ether adducts, and mixtures thereox. Alkyl polyglucosides and phosphate esters are preferred dispersants.
[0067] Suitable preservatives include but are not limited to C 12 to C 15 alkyl benzoates, alkyl p-hydroxybenzoates, aloe vera extract, ascorbic acid, benzalkonium chloride, benzoic acid, benzoic acid esters of C 9 to C 15 alcohols, butylated hydroxytoluene, butylated hydroxyanisole, tert-butylhydroquinone, castor oil, cetyl alcohols, chlorocresol, citric acid, cocoa butter, coconut oil, diazolidinyl urea, diisopropyl adipate, dimethyl polysiloxane, DMDM hydantoin, ethanol, ethylenediaminetetraacetic acid, fatty acids, fatty alcohols, hexadecyl alcohol, hydroxybenzoate esters, iodopropynyl butylcarbamate, isononyl iso-nonanoate, jojoba oil, lanolin oil, mineral oil, oleic acid, olive oil, parabens, polyethers, polyoxypropylene butyl ether, polyoxypropylene cetyl ether, potassium sorbate, propyl gallate, silicone oils, sodium propionate, sodium benzoate, sodium bisulfite, sorbic acid, stearic fatty acid, sulfur dioxide, vitamin E, vitamin E acetate and derivatives, esters, salts and mixtures thereof. Preferred preservatives include sodium o-phenylphenate, 5-chloro-2-methyl-4-isothiazolin-3-one, 2-methyl-4-isothiazolin-3-one, and 1,2-benisothiazolin-3-one.
[0068] The compositions and methods of the present invention are further illustrated by the examples below. These examples serve only to illustrate the invention and should not be interpreted as limiting the scope of the invention in any way, since further modifications encompassed by the disclosed invention will be apparent to those skilled in the art. All such modifications are deemed to be within the scope of the invention as defined in the present specification and claims.
EXAMPLES
Example 1: Determination of the Insecticidal Activity of Test Formulation in Midwestern Soil
[0069] In this Example, a formulation according to the present invention provided greater control to 2 nd instar SCRW and WCRW larvae compared to the commercially available diamide standards, Exirel® (cyantraniliprole) and Coragen (chlorantraniliprole), when applied as a soil treatment.
Methodology
[0070] In order to induce seed germination prior to test initiation, corn seed was submerged in water for 12 h and then placed between layers of moistened paper towel for 48 h ( FIG. 1A ). Plastic Dart® containers (1 oz./30 ml) were utilized for the assay ( FIGS. 1C-D ). Treatments included Test Formula (tetraniliprole 200 SC formulation), Rugby® (cadusafos), and chlorantraniliprole. A 60 g ai/ha foliar rate applied at a volume of 30 GPA which equates to 213.8 ppm. If this application rate was condensed into a 6″ T-ban application that assumed a 30″ row spacing, the ppm rate would increase to 1069 ppm (213.8 ppm×5); thus, three rates were selected for all experimental and standard treatments (213.8, 534, and 1069 ppm).
[0071] Dilutions of Test Formula (Table 1) were mixed into dry, sifted, Midwestern soil ( FIG. 1B ), from Wyoming, Ill., by adding 49.5 mLs of solution into 330 g of soil and equated to approximate 15% soil moisture value; soil clumped when pinched.
[0072] An estimated 0.75 cm of treated soil was placed into the bottom of each container, two germinated corn seeds were placed onto the soil, and then the arenas were capped with a lid until rootworms were infested ( FIG. 1C-D ). Using a fine tipped paint brush, 5 larvae (2 nd instar) of each rootworm species (SCRW and WCRW) were transferred onto the soil of each replicate ( FIG. 1E ), covered with approximately 1.75 cm of treated soil, and capped ( FIG. 1F ).
[0073] There were 7 replicates and 35 larvae per treatment. Arenas containing soil, corn, and larvae were transferred into the Insectary room (≈23° C., 0 L:24 D) and evaluated 6 days later for the presence of living SCRW and WCRW larvae. Larvae not recovered within each arena were considered dead. Longest root for each seed was recorded. All data was analyzed by ANOVA/GLM with an alpha of 0.1 (Minitab 16.0). Data points having the same letter within each column are not significantly different and were assessed using ANOVA: GLM (α=0.1) (Table 1). The results are depicted in Table 1 below:
[0000]
TABLE 1
Rates Tested
Rates Tested
WRCW
SCRW
Treatment
(ppm)
(g ai/ha)
% Control
% Control
Test Formula
213.8
60
94.3ab
91.4a
Test Formula
534
150
100a
100a
Test Formula
1,069
300
100a
100a
Exirel
213.8
60
2.96f
8.6c
Exirel
534
150
74.3 bc
22.9c
Exirel
1069
300
86.6ab
45.7b
Coragen
213.8
60
54.3cd
11.4c
Coragen
534
150
25.7ef
8.6c
Coragen
1,069
300
34.3de
17.1c
Untreated
UTC
—
11.4ef
5.7c
* Conversion from g ai/ha to ppm is based upon an application volume of 30 GPA (Galloons per Acre).
Note:
Values in each column that have the same letter are not statistically different when analyzed at a 90% CI, ANOVA, GLM.
[0074] As indicated in the Table 1, in a rate to rate comparison, Test Formula provided greater control to 2 nd instar SCRW and WCRW larvae compared to the diamide standards, Exirel and Coragen, when applied as a soil treatment. Coragen did not provide adequate control to rootworm larvae at any rate tested. Against SCRW, Test Formula at 213.8 ppm (91.4% a) provided statistically greater control to 2 nd instar larvae compared to all rates of Exirel. Against WCRW, Test Formula at 213.8 ppm (94.3% control) statistically outperformed Exirel at 213.8 ppm (2.9%) and was numerically greater than Exirel at 534 (74.3% bc). All surviving larvae within Test Formula treated soil (213.8 ppm) were controlled, stunted, had not grown, and differed from all other surviving larvae within other treatments and rates.
Conclusion
[0075] In conclusion, against SCRW, Test Formula at 213.8 ppm provided some 91.4% control to larvae and provided statistically greater control compared to all rates of cyantraniliprole. Against WCRW, Test Formula at 213.8 ppm provided 94.3% control, and statistically outperformed cyantraniliprole. In fact, Test Formula of the present invention outperformed cyantraniliprole at 535 ppm.
Example 2
[0076] In this example, Test Formula was compared with Belt®, Coragen®, and Exirel® in both direct spray and foliar applications against SCRW and WCRW. The results indicated that the Test Formula provided greater control to SCRW and WCRW adults (direct contact and feeding). In addition, against SCRW and WCRW adults, Test Formula was more effective than Belt, Coragen, and Exirel in both direct spray and foliar applications against Southern and Western corn rootworm adults (SCRW+WCRW).
Methodology
[0077] Direct Spray: Three replicates of five adult beetles (n=15) were placed into 12 oz. Styrofoam containers on the day of application. Both southern and western corn rootworms (SCRW and WCRW) were evaluated in the bioassay. Treatments and rates are listed in Table 1 and were applied using a DeVilbiss sprayer in accordance with SOP 529.00 with the deviation of beetles being sprayed at 40 p.s.i. Beetles were immediately transferred to clean containers and provisioned with a water source and a clipped cucumber leaf. At 2 Days After Administeration (DAA), mortality and % feeding damage were assessed. Because leaves varied in size, a single untreated check leaf was used as a reference to compare to all other replicates. After the initial assessment of feeding damage, the leaf was discarded and a freshly cut, untreated cucumber leaf was placed back into each arena. At 4 DAA, mortality was recorded.
[0078] Foliar Spray: Four leaf staged cucumber plants were trimmed down to the two youngest leaves, the upper and lower leaves sprayed with the DeVilbiss at 40 p.s.i., and placed in the drying hood until dry. A single leaf was cut and placed over the water source within a 12 oz. Styrofoam container. Scissors were cleaned with 70% EtOH between treatments. Three replicates of five adult beetles (n=15) were infested onto the leaf of each container. Both southern and western corn rootworms (SCRW and WCRW) were evaluated in the bioassay. Assessment timing and methods were synonymous to the direct spray component of the assay.
[0079] The results of the direct spray applications are depicted in Table 2 below:
[0000]
TABLE 2
DIRECT SPRAY
Avg % Control to SCRW
Avg % Control to WCRW
% Feeding Damage at 2DAA
Treatment
Rate (g ai/ha)
2DAA
4DAA
2DAA
4DAA
SCRW
WCRW
Exirel
7.5
13.3c
13.3b
13.3c
40.0bcde
27.7abcd
21.7cd
15
6.7c
6.7b
0.0c
13.3de
9.0cde
7.7de
30
0.0c
8.3b
13.3c
20.0cde
10.7bcde
7.3de
60
6.7c
20.0b
0.0c
26.7cde
3.3de
2.0e
Coragen
7.5
0.0c
0.0b
6.7c
6.7e
36.7a
40.0abc
15
13.3c
13.3b
0.0c
8.3de
35.0ab
26.7bc
30
0.0c
6.7b
0.0c
13.3de
38.3a
31.7abc
60
0.0c
0.0b
0.0c
13.3de
31.7abc
36.7abc
Belt
7.5
6.7c
6.7b
0.0c
6.7e
36.7a
45.0ab
15
8.3c
8.3b
30.0bc
48.3bcde
36.7a
30.0abc
30
0.0c
0.0b
6.7c
6.7e
41.7a
46.7a
60
0.0c
0.0b
0.0c
20.0cde
40.0a
38.3abc
Brigade
11
100.0a
100.0a
100.0a
78.3ab
0.0e
0.0e
22
100.0a
100.0a
100.0a
100.0a
0.0e
0.0e
44
100.0a
100.0a
100.0a
100.0a
0.0e
0.0e
88
100.0a
100.0a
100.0a
100.0a
0.0e
0.0e
Test Formula
7.5
13.3c
86.7a
13.3c
46.7bcd
0.0e
1.3e
15
48.3b
93.3a
0.0c
56.7bc
1.7e
1.3e
30
65.0b
93.3a
26.7bc
40.0bcde
0.3e
1.3e
60
65.0b
100.0a
58.3b
71.7ab
0.3e
0.0e
UTC
—
0.0c
0.0b
13.3c
20.0cde
50.0a
33.3abc
Note:
Statistical analysis (GLM/ANOVA; CI = 90%) compared differences within each individual column
[0080] The results of the foliar spray applications are depicted in Table 3 below:
[0000]
TABLE 3
Foliar
Avg % Control to SCRW
Avg % Control to WCRW
% Feeding Damage at 2DAA
Treatment
Rate (g ai/ha)
2DAA
4DAA
2DAA
4DAA
SCRW
WCRW
Exirel
7.5
6.7c
6.7c
6.7d
20.0bc
9.3cde
10.0efg
15
0.0c
0.0c
20.0cd
33.3bc
7.3de
8.0efg
30
0.0c
0.0c
0.0d
13.3c
5.3de
8.3efg
60
5.6c
6.7c
6.7d
25.6bc
3.7e
6.3efg
Coragen
7.5
5.6c
5.6c
6.7d
13.3c
16.7cde
31.7abc
15
0.0c
8.3c
0.0d
20.6bc
25.0bcd
21.7cde
30
0.0c
0.0c
20.0cd
46.7bc
11.0cde
13.0defg
60
0.0c
0.0c
20.0cd
26.7bc
16.7cde
20.0cdef
Belt
7.5
0.0c
0.0c
0.0d
24.4bc
28.3abc
46.7a
15
0.0c
0.0c
6.7d
13.3c
41.7ab
31.7abc
30
0.0c
6.7c
0.0d
13.3c
40.0ab
40.0ab
60
0.0c
0.0c
20.0cd
46.7bc
38.3ab
28.3bcd
Brigade
11
100.0a
94.4ab
100.0a
60.0ab
0.0e
0.0g
22
100.0a
100.0a
100.0a
100.0a
0.0e
0.0g
44
100.0a
100.0a
100.0a
100.0a
0.0e
0.0g
88
100.0a
100.0a
100.0a
100.0a
0.0e
0.0g
Test Formula
7.5
13.3c
26.7c
13.3d
26.7bc
2.7e
5.0fg
15
0.0c
20.0c
40.0bc
53.3bc
3.3e
1.3g
30
53.3b
41.7c
40.0bc
53.3bc
1.3e
2.0g
60
0.0c
47.6bc
53.3b
46.7bc
1.7e
2.0g
UTC
—
0.0c
0.0c
6.7d
20.0bc
46.7a
38.3ab
Note:
Statistical analysis (GLM/ANOVA; CI = 90%) compared differences within each individual column
Conclusion
Direct Spray:
[0081] SCRW: Against Southern corn rootworms, all rates of Test Formula (7.5 g to 60 g ai/ha) were statistically equivalent to Brigade and provided a greater level of control (86.7% to 100%) compared to the diamide standard products Exirel (8% to 20%), Coragen (0% to 13%), and Belt (0% to 8.3%) when applied directly to beetles. At 2 DAA, no feeding on untreated leaves was observed on SCRW sprayed with all rates of Brigade. Feeding damage by SCRW beetles treated with Test Formula ranged between 0.0% to 1.7%, was statistically lower than Coragen and Belt, and numerically reduced compared to Exirel.
[0082] WCRW: Western corn rootworms were less susceptible to direct applications of all treatments compared to SCRW; at 60 g ai/ha, Test Formula provided greater control (72%) compared to the diamide standards, Exirel, Coragen, Belt. Feeding damage by WCRW beetles was similar to the SCRW data; beetles treated with Test Formula had feeding damage ranging between 0.0% and 1.3%, was statistically lower than Coragen and Belt, and numerically reduced compared to Exirel.
Foliar Spray:
[0083] SCRW: At 60 g ai/ha, Test Formula provided 48% control when sprayed to the foliage of cucumber plants compared to Exirel 7%, Coragen, 0%, and Belt, 0%. When Brigade treatments were removed from the statistical evaluation within Minitab, Test Formula provided statistically improved control compared to the standard diamides. Leaves treated with Test Formula had damage ranging between 1.3% and 3.3%, which was statistically lower than Belt, and numerically reduced compared to Coragen and Exirel. The amount of feeding damage was similar to the direct spray beetle component of the assay. Treated leaves were removed at 2 DAA and replaced with untreated leaves; mortality would have likely continued to increase if the beetles remained on treated foliage.
[0084] WCRW: Similar mortality was observed between WCRW and SCRW infested upon Test Formula treated foliage. Accordingly the Test Formula provided 47% control vs. Exirel (27%), Coragen (27%), Belt (47%). The untreated check WCRW adults had 20% mortality at 4 DAA, had the same mortality as the direct spray WCRW untreated checks, but were different cohorts. Brigade at the lowest tested rate (11 g ai/ha) had 40% recovery between 2 DAA and 4 DAA (60% mortality). Untreated check mortality, coupled with the low number of beetles per treatment (N=15), likely prevented statistical separation between treatments.
[0085] In conclusion, in both direct spray and foliar applications Test Formula provided statistically improved control compared to the standard product Belt and numerical and/or statically greater control compared to Coragen and Exirel.
Example 3
[0086] In this example, the activity of Test Formula treatment applied to Midwestern soil had extended residual activity against Diabrotica virgifera virgifera.
Methodology
[0087] Dilutions of Test Formula were mixed into dry, sifted, Midwestern soil ( FIG. 1B ), from Wyoming, Ill., by adding 300 ml of solution into 2000 g of soil and equated to approximate 15% soil moisture value; soil clumped when pinched. Treated soil was maintained in 3″ pots (8 pots per treatment) within greenhouse. Pots were watered from above one time per day to maintain soil at approximately 15% moisture.
[0088] An estimated 0.75 cm of treated soil was placed into the bottom of each container, two germinated corn seeds were placed onto the soil, and then the arenas were capped with a lid until rootworms were infested ( FIG. 1C-D ). Using a fine tipped paint brush, 5 larvae (2 nd instar) of each rootworm species (SCRW and WCRW) were transferred onto the soil of each replicate ( FIG. 1E ), covered with approximately 1.75 cm of treated soil, and capped ( FIG. 1F ).
[0089] There were 8 replicates and 40 larvae per treatment. Arenas containing soil, corn, and larvae were transferred into the Insectary room (≈23° C., 0 L:24 D) and evaluated 6 days later for the presence of living SCRW and WCRW larvae. Larvae not recovered within each arena were considered dead. All data was analyzed by ANOVA/GLM with an alpha of 0.1 (Minitab 16.0). Data points having the same letter within each column are not significantly different and were assessed using ANOVA: GLM (α=0.1). The results are depicted in Table 4 below:
[0000]
TABLE 4
In-furrow
Rates
Application
2nd instar WCRW:
Tested
Rate*
% Mortality
Treatment
(ppm)
(g ai/ha)
14DAT
28DAT
43DAT
Test Formula
66.8
3.75
92.5 a
97.5 a
82.5 b
Test Formula
133.6
7.5
97.5 a
100 a
90 ab
Test Formula
267.3
15
100 a
100 a
100 a
Test Formula
534.5
30
100 a
100 a
97.5 a
Test Formula
1069
60
100 a
100 a
97.5 a
Capture LFR
3,977
223.2
100 a
100 a
100 a
Rugby
1,069
60
100 a
100 a
100 a
Untreated
UTC
10 b
2.5 b
2.5 c
*rates calculated based upon a 6″ T-ban with a 30″ row spacing same letters within a column are not significantly different (ANOVA, CI 90%)
Conclusion
[0090] Test Formula applied to soil maintained in fluctuating ambient conditions within the greenhouse at rates of ≧15 g ai/ha provided 97.5 to 100% control out to 43 DAT. The efficacy provided by the 2 lower rates of Test Formula were beginning to diminish at this time point. The lowest rate tested (3.75 g ai/ha) provided statistically reduced control (83% b) at 43 DAT. This break in treatment efficacy suggests that the product will ultimately break down in soil within a field setting.
Example 4
[0091] Soil treated with a formulation according to the present invention and maintained outdoors was evaluated for activity for WCRW larvae.
[0092] The efficacy of the formulation of the present invention on control of rootworm larve was evaluated after it was applied to soil and maintained in natural ambient condition and was subjected to differing water pHs (6, 7, and 8) applied daily to soil.
Methodology
[0093] A solution of the Test Formula A was prepared by making dilutions in water to form a solution. Dry, Midwestern soil was brought up to 15% moisture with treatment solutions (Table 5). Buckets of treated soil were carted outside daily between Monday and Friday and exposed to direct sunlight. Carts were not wheeled out on days that forecasted precipitation. At the end of each day, soil buckets were brought back into the laboratory, weighed, the appropriate amount of water added to the soil to bring it back up to 15% moisture, and covered overnight; daily records of weights and amount of water added to each bucket was recorded. The deionized water (dH 2 O) had a pH of approximately 5.0 and was altered with 0.5M KOH to a final pH of 6, 7, and 8.
[0094] At 30 DAT, 42 DAT, 57 DAT, and 85 DAT, 2 nd instar WCRW larvae were infested into treated soil containing and germinating corn seed and evaluated 6 days after infestation (6 DAI) for percent control and larval stunting. There were 6 replicates per infestation date with 5 larvae per replicate (n=30). Treatments applied to dry Midwestern soil for assessment of residual WCRW included Test Formula at 67, 267, and 1,069 ppm, Capture LFR at 1988.5 and 3,977 ppm.
[0095] Table 5 below provides the mortality rates of 2 nd instar WCRW larvae infested into treated soil exposed to direct sunlight at 85 days after treatment.
[0000]
No Dead per replicate
Rate
(n = 5) at 85 DAT
Avg %
Treatment
(ppm)
pH
1
2
3
4
5
6
Mortality
Test
67
6
5
5
5
4
5
5
96.67 a
Formula
Test
67
7
4
5
4
4
5
4
86.67 a
Formula
Test
67
8
3
4
5
5
4
5
86.67 a
Formula
Capture
1988.5
7
5
5
5
5
5
5
100.0 a
LFR
Untreated
—
7
1
0
0
1
2
0
13.33 b
Check
Note:
same letters within a column are not significantly different when analyzed via ANOVA: GLM (α = 0.1)
[0096] All three rates of tetraniliprole Test Formula as shown in Table 5 above, provided 100% control up to 42 DAT. The lowest rate of tetraniliprole (67 ppm) was further assessed at 57 DAT and 85 DAT. No statistical difference in the level of WCRW control was detected between tetraniliprole treated soil kept at 15% moisture using pH (6, 7, or 8) altered, deionized water (Table 5). At 57 DAT and 85 DAT, all surviving larvae recovered from Test Formula treated soil were severely stunted compared to the non-treated check ( FIG. 2 ). At 85 DAT, Test Formula treated soil that had moisture maintained with water at a pH of 6 provided 97% control but was not significantly different from pH 7 or pH 8.
Conclusion
[0097] A solution containing tetraniliprole at 67 ppm (3.75 g ai/ha) was incorporated into Midwestern soil (15% moisture) and maintained outdoors provided control to WCRW larvae. This amount of tetraniliprole was equivalent to Capture LFR (α=0.1). Soil of each treatment was manipulated daily with water at pH 6, 7, or 8. A tetraniliprole containing formulation according to the present invention provided ≧87% control with all surviving larvae being severely stunted compared to the non-treated check
Example 5: Efficacy of Test Formula Treated Soil Against WCRW Larvae
[0098] In this example residual activity and stability of tetraniliprole test treatments within microbially active Midwestern soil against 2 nd nymphal stage WCRW- Diabrotica virgifera virgifera was assessed in corn field and further compared to Capture LFR and Rugby.
Methodology
[0099] In order to induce seed germination prior to test initiation, corn seed was submerged in water for 12 h and then placed between layers of moistened paper towel for 72 h. Plastic Dart® containers (1 oz/30 ml) were utilized for the assay. Treatments included tetraniliprole Test Formula according to the present invention, Capture LFR® (bifenthrin), and Rugby® (cadusafos). A 60 g ai/ha foliar rate applied at a volume of 30 GPA equates to 213.8 ppm. If this application rate was condensed into a 6″ T-band application that assumed a 30″ row spacing, the ppm rate would increase to 1069 ppm (213.8 ppm×5). Five rates were selected for the experimental treatment (Test Formula) and compared to a single rate of two standard treatments (Capture LFR and Rugby). Treatment solutions (Table 4) were mixed into dry, sifted, Midwestern soil, from Wyoming, Ill., by adding 300 mLs of solution into 2000 g of soil and equates to approximate 15% soil moisture value; soil clumped when pinched.
[0100] An estimated 0.75 cm of treated soil was placed into the bottom of each container, one germinated corn seed was placed onto the soil, and then the arenas were capped with a lid until rootworms were infested. Corn was covered with approximately 1.75 cm of treated soil. Using a fine tipped paint brush, 5 WCRW larvae (2 nd instar) were transferred onto the soil of each replicate and then capped. There were 8 replicates and 40 larvae per treatment. Arenas containing soil, corn, and larvae were transferred into the Insectary room (≈23° C., 0 L:24 D) and evaluated 6 days later for the presence of living larvae. Larvae not recovered within each arena were considered dead. Additional treated soil was maintained within a 5 gallon bucket, covered with aluminum soil, and weights recorded. Additional water was added every Monday in order to maintain a 15% soil moisture level.
[0101] All mortality data was analyzed by ANOVA/GLM with an alpha of 0.1 (Minitab 16.0). Data points having the same letter within each column are not significantly different and were assessed using the Tukey Method (Table 5).
[0102] At 0 DAT: tetraniliprole treated soil at 30 and 60 g ai/ha provided 97.5% control to 2 nd instar WCRW. This bioassay confirms the activity of tetraniliprole against rootworms as shown in Example 1. Stunted larvae were detected in all tetraniliprole treated soils compared to the untreated check. At the lowest rate tested (3.75 g aiha), larvae were approximately half the size as the untreated check; a single, drastically stunted larvae were found at the two highest rates tested. Protection to the root and shoot system of corn was evident with all tetraniliprole treated soils ( FIG. 3 ). The lowest two rates of tetraniliprole (3.75 g and 7.5 g ai/ha) were not infested at 14 DAT due to rates providing <80% control at 0 DAT.
[0103] At 14 DAT: The 15 g ai/ha rate of tetraniliprole formulation according to the present invention provided greater control at 14 DAT compared to 0 DAT. Those of ordinary skill in the art would understand that the lower rates (3.75 and 7.5 g ai/ha) at residual evaluation dates would be as effective in future assays.
[0104] At 28, 50, and 64 DAT: All soil treatments remaining in the bioassay provided ≧95% control out to 64 DAT (Table 6).
[0000]
TABLE 6
Mortality of 2 nd instar WCRW after 144 h within treated soil.
In-furrow
Application
2nd instar WCRW:
Rates Tested
Rate*
% Mortality
Treatment
(ppm)
(g ai/ha)
0 DAT
14 DAT
28 DAT
50 DAT
64 DAT
Test Formula
66.8
3.75
57.5 c
—
—
—
—
Test Formula
133.6
7.5
77.5 bc
—
—
—
—
Test Formula
267.3
15
87.5 ab
95.0 a
100.0 a
100.0 a
95.0 a
Test Formula
534.5
30
97.5 ab
100.0 a
100.0 a
100.0 a
95.0 a
Test Formula
1069
60
97.5 ab
100.0 a
100.0 a
100.0 a
100.0 a
Capture LFR
3,977
223.2
100.0 a
100.0 a
100.0 a
100.0 a
100.0 a
Rugby
1,069
60
100.0 a
100.0 a
100.0 a
100.0 a
100.0 a
Untreated
UTC
2.5 d
0.0 b
7.5 b
0 b
17.5 b
*rates calculated based upon a 6″ T-ban with a 30″ row spacing
—treated soil not infested after 0 DAT
Note:
rows having the same letter are not significanly different when analyzed via ANOVA: GLM (a = 0.1)
Conclusion
[0105] Tetraniliprole treated Midwestern soil (15, 30, 60 g ai/ha) maintained in the lab at a 15% moisture level provides ≧95% control to 2 nd instar WCRW larvae at 64 DAT. Both Capture LFR® (bifenthrin) and Rugby® (cadusafos) provided 100% mortality.
[0106] While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred compositions and methods can be used and that it is intended that the invention can be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the claims that follow. | Tetraniliprole containing formulations and methods for using them for controlling rootworm infestation are discussed. The formulations of the present invention provide improved delivery active ingredients by the ability to provide substantially higher degree of control as compared to other diamide counterparts. | Summarize the key points of the given patent document. | [
"FIELD OF THE INVENTION [0001] The present invention relates to the field of agrochemical compositions and formulations.",
"In particular, the invention provides a composition comprising a tetraniliprole alone or in combination with other plant protection agents suitable for controlling rootworm larvae in soil.",
"BACKGROUND OF THE INVENTION [0002] Insects and plant pests cause millions of dollars worth of damages annually on agricultural products.",
"Rootworms are one of the major agricultural pest insects contributing to the damages to agricultural products.",
"These pests have a wide range of host plants and in their larval form make tunnels through the roots of young plants, stunting or killing them.",
"They are typically native to the soil and will readily infest a field of crop plants, most notoriously corn.",
"These pests include but are not limited to such species as Diabrotica virgifera virgifera ( D. virgifera ), D. undecimpunctata undecimpunctata ( D. undecimpunctata ), D. barberi, D. u. howardi , and D. u. tenella .",
"Some are perennial pests of corn across most of the Corn Belt.",
"Despite ongoing new pesticides and insecticides, resistance continues to emerge among such pests as D. virgifera, D. undecimpunctata, D. barberi, D. u. howardi , and D. u. tenella .",
"Thus, there is a need for new techniques and compositions to combat such species of pests.",
"SUMMARY OF THE INVENTION [0003] One aspect of the present invention provides compositions that exhibit enhanced activity against rootworms in their larval form.",
"Another aspect of the present invention provides novel methods for controlling rootworms.",
"[0004] In one embodiment, the compositions of the present invention contain an effective amount of a diamide insecticide as the sole active ingredient.",
"In this embodiment, the diamide insecticide includes but is not limited to tetraniliprole, chlorantraniliprole, flubendiamide, and cyantraniliprole.",
"In certain embodiments, the diamide insecticide is tetraniliprole.",
"[0005] In another embodiment, the composition may further contain a plant protection agent selected from the group consisting of pesticide, arthropodicide, insecticide, acaricide, nematocide, fungicide, herbicide, plant growth regulator and a combination thereof.",
"In a preferred embodiment, the pesticide is a pyrethroid selected from bifenthrin, cypermethrin, beta-cypermethrin, zeta-cypermethrin, deltamethrin, cis-permethrin, gamma-cyhalothrin, tralomethrin, cyfluthrin, beta-cyfluthrin, esfenvalerate and fluvalinate.",
"[0006] In another embodiment of the present invention, methods of controlling, stunting or killing rootworms at all stages of their life cycle in a region susceptible to their growth are described.",
"In one embodiment, the methods are directed to controlling these pests at their larval (1 st instar, 2 nd instar, 3 rd instar, 4 th instar), pupal, and adult stages.",
"In a preferred embodiment, the rootworms include but are not limited to such species as D. virgifera, D. barberi, D. u. howardi, D. u. tenella , and D. undecimpunctata.",
"[0007] In another embodiment, the composition of the present invention is present in the liquid form of a microemulsion, an oil-in-water concentrated emulsion, a suspension, a suspension concentrate, an emulsifiable concentrate, or a microencapsulate.",
"In at least one embodiment, the composition of the present invention is in the form of a suspension concentrate (SC).",
"In yet another embodiment, the suspension concentrate is stable over a time period of two years or more wherein the suspended particles do not aggromelate.",
"In yet another embodiment, the diamide compound is tetraniliprole as a 200 SC formulation (Test Formula).",
"[0008] In an alternate embodiment, the composition of the present invention is a combination of the diamide insecticide and a plant protecting agent such as a pyrethorid.",
"In one embodiment, the diamide insecticide is tetraniliprole and the plant protecting agent is bifenthrin.",
"[0009] In another embodiment, the composition may further contain a dispersant, a preservative, a foaming agent, and/or at least one foam stabilizer.",
"In another embodiment, the composition may be applied in a furrow in the form of foam.",
"In certain embodiments, the foaming agent can be sodium lauryl sulfate, sodium dodecylbenzene sulfonate, or a combination thereof.",
"In another embodiment, the foam stabilizer can be glycerine, xanthan gum, or a combination thereof.",
"In yet another embodiment, the foam may have an expansion factor of 15, 25, 40, 50, 60 or 70.",
"[0010] In another embodiment, the compositions of the present invention may be mixed into water and/or liquid fertilizer and applied in-furrow at a volume of 10, 9, 8, 7, 6, 5, 4, 3, 2 gallons or less per acre.",
"[0011] In another embodiment, tetraniliprole and a plant protection agent may be applied each at a rate ranging from about 0.05 lb ai/acre to about 10 lb ai/acre, all sub-ranges and sub-values included.",
"In exemplary embodiments, tetraniliprole and the plant protection agent may be applied independently at a rate of about 0.05, about 0.1, about 0.15, about 0.2, about 0.25, about 0.3, about 0.35, about 0.4, about 0.45, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, about 1.0, about 1.2, about 1.4, about 1.6, about 1.8, about 2.0, about 2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 6, about 7, about 8, about 9, or about 10 lb/acre.",
"[0012] In another embodiment, the formulation can be applied to the soil or to the plant as a rescue treatment or post-plant to control rootworm larvae.",
"[0013] Another objective of the present invention is to reduce the application rates and broaden the activity spectrum of the compositions claimed herein by reducing the total amount of active compounds applied.",
"In another embodiment, It is an objective of the present invention to provide a composition which, when applied to a crop, results in a decreased amount of residues in the crop, thereby reducing the risk of resistance formation and nevertheless providing efficient plant disease control.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0014] A detailed description of drawings is provided here to illustrate various aspects and features of the present subject matter.",
"[0015] FIGS. 1 -A to 1 -G provides schematic representation of methodology steps for assessing rootworms within treated soil.",
"( FIG. 1 -A) pre-water submerged corn seeds are placed between layers of moisten paper towel.",
"( FIG. 1 -B) Test Formulation according to the present invention was mixed with the soil.",
"( FIGS. 1 -C and 1 -D) treated soil was placed in the container along with two germinated corn seeds on top.",
"( FIGS. 1 -E and 1 -F) 5 larvae of Southern Corn Root Worms (SCRW) and Western Corn Root Worms (WCRW) were placed onto the soil in a container and capped ( FIG. 1 -G) arenas containing soil, corn, and larvae to be evaluated.",
"[0016] FIGS. 2 -A and 2 -B shows WCRW larvae extracted from the untreated soil after 6 d ( FIG. 2 -A) and the soil treated with the Test Formulation 57 days after the treatment ( FIG. 2 -B) (designated as number 8) at 67 ppm and pH of 8.",
"[0017] FIGS. 3 -A to 3 -C depicts the corn plants extracted from a soil that has been treated with Test Formulation at 15 g ai/ha ( FIG. 3 -A), Capture LFR at 112 g ai/ha ( FIG. 3 -B), or the soil that was untreated ( FIG. 3 -C).",
"The extraction occurred 5 days after being within the subject soils.",
"The respective soils were infested with 5, 2nd instar WCRW larvae.",
"[0018] FIGS. 4 -A to 4 -B depicts the damage to corn roots and shoots caused by 2nd instar WCRW infested into the respective treated soil.",
"( FIG. 4 -A) depicts the damage to the crop in soil treated with Test Formulation at 60 g ai/ha=1069 ppm.",
"( FIG. 4 -B) depicts the damage to the crop in an untreated soil.",
"The assessment was done at 144 hour post WCRW infestation.",
"DETAILED DESCRIPTION OF THE INVENTION [0019] Various embodiments of the present invention provide an agricultural composition for controlling rootworms.",
"At least one aspect of the present invention is directed to the novel discovery of compositions containing diamide compounds that exhibit potent activities in controlling and suppressing rootworm pests, particularly in their larval form.",
"Even more surprising and unexpected is the activity spectrum of tetraniliprole against these pests.",
"[0020] As used in this specification and unless otherwise indicated, the term “rootworms”",
"includes but is not limited to D. virgifera (also known and refereed herein as Western corn rootworm “WCRW”), D. barberi (also known and referred herein as Northern corn rootworm “NCR”), D. u. howardi, D. u. tenella , and D. undecimpunctata (also known and referred herein as Southern corn rootworm “SCRW”).",
"[0021] As used in this specification and unless otherwise indicated the term “plant protection agent”",
"refers to a molecule or combination of molecules which express biological activity as a pesticide, arthropodicide, insecticide, acaricide, nematocide, fungicide, herbicide, plant growth regulator or a combination of two or more of these biological activities.",
"[0022] As used in this specification and unless otherwise indicated, the term “controlling”",
"refers to reducing, inhibiting, or eliminating the presence of rootworm species during one or more of its growth stages.",
"For example, the compositions of the present invention may be used for controlling the growth of rootworms at any instar stages as well as its pupil and adult forms.",
"[0023] As used in this specification and unless otherwise indicated, the term “insecticide”",
"refers to a molecule or combination of molecules that repels, retards, or kills insects, and can be used for plant protection, edifice protection, turf protection, or protection of a person.",
"[0024] The term “liquid fertilizer”",
"refers to a fertilizer in a fluid or liquid form containing various ratios of nitrogen, phosphorous and potassium (for example, but not limited to, 10% nitrogen, 34% phosphorous and 0% potassium) and micronutrients, commonly known as starter fertilizers that are high in phosphorus and promote rapid and vigorous root growth.",
"Liquid fertilizers are commonly aqueous-based.",
"As used herein, the term “aqueous-based”",
"indicates that the predominant solvent or vehicle is water.",
"The term “ambient temperature”",
"as utilized herein shall mean any suitable temperature found in a laboratory or other working environment, and is generally not below about 15° C. nor above about 30° C. [0025] The modifier “about”",
"is used herein to indicate that certain preferred operating ranges, such as ranges for molar ratios for reactants, material amounts, and temperature, are not fixedly determined.",
"The meaning will often be apparent to one of ordinary skill.",
"For example, a recitation of a concentration of about 200 grams per liter in reference to, for example, a formulation would be interpreted to include other like concentrations that can be expected to provide similar effect for the concentration, such as 180 grams per liter or 220 grams per liter.",
"Where guidance from the experience of those of ordinary skill is lacking, guidance from the context is lacking, and where a more specific rule is not recited below, the “about”",
"range shall be not more than 10% of the absolute value of an end point or 10% of the range recited, whichever is less.",
"[0026] In one aspect of the present invention, novel compositions are described for controlling rootworms that contain at least one diamide compound selected from the group consisting of flubendiamide, chloranthraniliprole, cyanthraniliprole and tetraniliprole in a carrier system in amounts effective to inhibit the infestation of the larvae in a location of interest.",
"In at least another aspect of the invention, combinations of a diamide compound with one or more plant protection agents are described to broaden the spectrum for insecticidal efficacy.",
"[0027] In another aspect of the present invention, methods for controlling infestation of Diabrotica larvae in a location of interest are described.",
"In at least one embodiment, the controlling of larvae results in at least 60, 70, 80, 90 or 100% inhibition of larvae in such location.",
"According to certain embodiments, methods of controlling infestation Diabrotica larvae at all its life stages can be achieved by applying a composition comprising a diamide compound selected from the group consisting of flubendiamide, chloranthraniliprole, cyanthraniliprole or tetraniliprole and a carrier system in amounts effective to inhibit the infestation of the larvae in a location of interest.",
"In another embodiment, the diamide compound is tetraniliprole.",
"[0028] In another embodiment a method for controlling infestation of Diabrotica larvae in a location is described comprising (a) applying an amount of a composition comprising a liquid agricultural formulation comprising an active ingredient selected from the group consisting of flubendiamide, chloranthraniliprole, cyanthraniliprole and tetraniliprole and an agriculturally suitable carrier system in amounts effective and optionally a plant protecting agent, and (b) inducing mortality in at least 60% of said larvae.",
"In one embodiment, the larve mortality rate is in at least 70%, 80%, 90%, 95%, 98%, or 99% in such locations.",
"In at least one embodiment, the location of interest is on the plant itself, plant seed, plant roots, plant part, foliage, seedling or substrate for growing the plant or crop.",
"In another embodiment, the larvae is NCR, WCRW, SCRW, or a combination thereof.",
"[0029] In at least another embodiment, the methods according to the present invention provide greater control at all instar stages of rootworm larvae as compared to other diamide insecticides such as chlorantraniliprole flubendiamide, and cyantraniliprole at a comparable rate of administration to the soil or the area of interest.",
"In at least one embodiment, a tetraniliprole containing composition according to the the present invention unexpectedly provides a statistically greater control of SCRW and WCRW as compared to cyantraniliprole and chlorantranilipole.",
"In another embodiment, the tetraniliprole containing compositions of the present invention are administered at ranges between 2.5 to 100 g ai/ha, or 7.5 to 60 g ai/ha to provide a larval mortality rate of at least 60%, 70%, 80%, 90%, 95%, 98%, or 99% in administered locations.",
"[0030] In another aspect of the present invention, the compositions according to the present invention consist essentially of tetraniliprole or a derivative thereof.",
"In another embodiment, the composition contains solely a single diamide insecticide.",
"In certain embodiments, the diamide insecticide is tetraniliprole.",
"[0031] In another embodiment, the compositions of the present invention further include a plant protecting agent.",
"Suitable plant protecting agents include the following: [0032] Insecticides: A1) the class of carbamates consisting of aldicarb, alanycarb, benfuracarb, carbaryl, carbofuran, carbosulfan, methiocarb, methomyl, oxamyl, pirimicarb, propoxur and thiodicarb;",
"A2) the class of organophosphates consisting of acephate, azinphos-ethyl, azinphos-methyl, chlorfenvinphos, chlorpyrifos, chlorpyrifos-methyl, demeton-S-methyl, diazinon, dichlorvos/DDVP, dicrotophos, dimethoate, disulfoton, ethion, fenitrothion, fenthion, isoxathion, malathion, methamidaphos, methidathion, mevinphos, monocrotophos, oxymethoate, oxydemeton-methyl, parathion, parathion-methyl, phenthoate, phorate, phosalone, phosmet, phosphamidon, pirimiphos-methyl, quinalphos, terbufos, tetrachlorvinphos, triazophos and trichlorfon;",
"A3) the class of cyclodiene organochlorine compounds such as endosulfan;",
"A4) the class of fiproles consisting of ethiprole, fipronil, pyrafluprole and pyriprole;",
"A5) the class of neonicotinoids consisting of acetamiprid, chlothianidin, dinotefuran, imidacloprid, nitenpyrathiacloprid and thiamethoxam;",
"A6) the class of spinosyns such as spinosad and spinetoram;",
"A7) chloride channel activators from the class of mectins consisting of abamectin, emamectin benzoate, ivermectin, lepimectin and milbemectin;",
"A8) juvenile hormone mimics such as hydroprene, kinoprene, methoprene, fenoxycarb and pyriproxyfen;",
"A9) selective homopteran feeding blockers such as pymetrozine, flonicamid and pyrifluquinazon;",
"A10) mite growth inhibitors such as clofentezine, hexythiazox and etoxazole;",
"A11) inhibitors of mitochondrial ATP synthase such as diafenthiuron, fenbutatin oxide and propargite;",
"uncouplers of oxidative phosphorylation such as chlorfenapyr;",
"A12) nicotinic acetylcholine receptor channel blockers such as bensultap, cartap hydrochloride, thiocyclam and thiosultap sodium;",
"A13) inhibitors of the chitin biosynthesis type 0 from the benzoylurea class consisting of bistrifluron, diflubenzuron, flufenoxuron, hexaflumuron, lufenuron, novaluron and teflubenzuron;",
"A14) inhibitors of the chitin biosynthesis type 1 such as buprofezin;",
"A15) moulting disruptors such as cyromazine;",
"A16) ecdyson receptor agonists such as methoxyfenozide, tebufenozide, halofenozide and chromafenozide;",
"A17) octopamin receptor agonists such as amitraz;",
"A18) mitochondrial complex electron transport inhibitors pyridaben, tebufenpyrad, tolfenpyrad, flufenerim, cyenopyrafen, cyflumetofen, hydramethylnon, acequinocyl or fluacrypyrim;",
"A19) voltage-dependent sodium channel blockers such as indoxacarb and metaflumizone;",
"A20) inhibitors of the lipid synthesis such as spirodiclofen, spiromesifen and spirotetramat;",
"A21) ryanodine receptor-modulators from the class of diamides consisting of flubendiamide, the phthalamide compounds (R)-3-Chlor-N1-{2-methyl-4-[1,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid and (S)-3-Chlor-N1-{2-methyl-441,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid, chloranthraniliprole, and cyanthraniliprole;",
"A22) compounds of unknown or uncertain mode of action such as azadirachtin, amidoflumet, bifenazate, fluensulfone, piperonyl butoxide, pyridalyl, sulfoxaflor;",
"or A23) sodium channel modulators from the class of pyrethroids consisting of acrinathrin, allethrin, bifenthrin, cyfluthrin, lambda-cyhalothrin, cyper-methrin, alpha-cypermethrin, beta-cypermethrin, zeta-cypermethrin, deltamethrin, esfenvalerate, etofenprox, fenpropathrin, fenvalerate, flucythrinate, tau-fluvalinate, permethrin, silafluofen and tralomethrin.",
"[0033] Fungicides: B1) azoles selected from the group consisting of bitertanol, bromuconazole, cyproconazole, difenoconazole, diniconazole, enilconazole, epoxiconazole, fluquinconazole, fenbuconazole, flusilazole, flutriafol, hexaconazole, imibenconazole, ipconazole, metconazole, myclobutanil, penconazole, propiconazole, prothioconazole, simeconazole, triadimefon, triadimenol, tebuconazole, tetraconazole, triticonazole, prochloraz, pefurazoate, imazalil, triflumizole, cyazofamid, benomyl, carbendazim, thia-bendazole, fuberidazole, ethaboxam, etridiazole and hymexazole, azaconazole, diniconazole-M, oxpoconazol, paclobutrazol, uniconazol, 1-(4-chloro-phenyl)-2-([1,2,4]triazol-1-yl)-cycloheptanol and imazalilsulfphate;",
"B2) strobilurins selected from the group consisting of azoxystrobin, dimoxystrobin, enestroburin, fluoxastrobin, kresoxim-methyl, methominostrobin, orysastrobin, picoxystrobin, pyraclostrobin, trifloxystrobin, enestroburin, methyl (2-chloro-5-[1-(3-methylbenzyloxyimino)ethyl]benzyl)carbamate, methyl (2-chloro-5-[1-(6-methylpyridin-2-ylmethoxyimino)ethyl]benzyl)carbamate and methyl 2-(ortho-(2,5-dimethylphenyloxymethylene)-phenyl)-3-methoxyacrylate, 2-(2-(6-(3-chloro-2-methyl-phenoxy)-5-fluoro-pyrimidin-4-yloxy)-phenyl)-2-methoxyimino-N-methyl-acetamide and 3-methoxy-2-(2-(N-(4-methoxy-phenyl)-cyclopropanecarboximidoylsulfanylmethyl)-phenyl)-acrylic acid methyl ester;",
"B3) carboxamides selected from the group consisting of carboxin, benalaxyl, benalaxyl-M, fenhexamid, flutolanil, furametpyr, mepronil, metalaxyl, mefenoxam, ofurace, oxadixyl, oxycarboxin, penthiopyrad, isopyrazam, thifluzamide, tiadinil, 3,4-dichloro-N-(2-cyanophenyl)isothiazole-5-carboxamide, dimethomorph, flumorph, flumetover, fluopicolide (picobenzamid), zoxamide, carpropamid, diclocymet, mandipropamid, N-(2-(443-(4-chlorophenyl)prop-2-ynyloxyl-3-methoxyphenyl)ethyl)-2-methanesulfonyl-amino-3-methylbutyramide, N-(2-(4-[3-(4-chloro-phenyl)prop-2-ynyloxy]-3-methoxy-phenyl)ethyl)-2-ethanesulfonylamino-3-methylbutyramide, methyl 3-(4-chlorophenyl)-3-(2-isopropoxycarbonyl-amino-3-methyl-butyrylamino)propionate, N-(4′-bromobiphenyl-2-yl)-4-difluoromethylA-methylthiazole-6-carboxamide, N-(4′-trifluoromethyl-biphenyl-2-yl)-4-difluoromethyl-2-methylthiazole-5-carboxamide, N-(4′-chloro-3′-fluorobiphenyl-2-yl)-4-difluoromethyl-2-methyl-thiazole-5-carboxamide, N-(3 \\4′-dichloro-4-fluorobiphenyl-2-yl)-3-difluoro-methyl-1-methyl-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-3-difluoromethyl-1-methylpyrazole-4-carboxamide, N-(2-cyano-phenyl)-3,4-dichloroisothiazole-5-carboxamide, 2-amino-4-methyl-thiazole-5-carboxanilide, 2-chloro-N-(1,1,3-trimethyl-indan-4-yl)-nicotinamide, N-(2-(1,3-dimethylbutyl)-phenyl)-1,3-dimethyl-5-fluoro-1H-pyrazole-4-carboxamide, N-(4′-chloro-3′,5-difluoro-biphenyl-2-yl)-3-difluoromethyl-1-methyl-I H-pyrazole-4-carboxamide, N-(4′-chloro-3′,5-difluoro-biphenyl-2-yl)-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluoro-biphenyl-2-yl)-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(3′,5-difluoro-4′-methyl-biphenyl-2-yl)-3-difluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(3′,5-difluoro-4′-methyl-biphenyl-2-yl)-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(cis-2-bicyclopropyl-2-yl-phenyl)-3-difluoromethyl-1-methyl-1H-pyrazole-4-carboxamide, N-(trans-2-bicyclopropyl-2-yl-phenyl)-3-difluoro-methyl-1-methyl-1H-pyrazo le-4-c arbox amide, fluopyram, N-(3-ethyl-3,5-5-trimethyl-cyclohexyl)-3-formylamino-2-hydroxy-benzamide, oxytetracyclin, silthiofam, N-(6-methoxy-pyridin-3-yl) cyclopropanecarboxamide, 2-iodo-N-phenyl-benzamide, N-(2-bicyclo-propyl-2-yl-phenyl)-3-difluormethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethyl-5-fluoropyrazol-4-yl-carboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1,3-dimethyl-pyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-fluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-(chlorofluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-5-fluoro-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(3′, 4′, 5′-trifluorobiphenyl-2-yl)-3-(chlorodifluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-fluoro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(3′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-1,3-dimethyl-5-fluoropyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1,3-dimethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-fluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-(chlorofluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-difluoromethyl-5-fluoro-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-3-difluoromethyl-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-3-(chlorodifluoromethyl)-1-methylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-fluoro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(2′,4′,5′-trifluorobiphenyl-2-yl)-5-chloro-1-methyl-3-trifluoromethylpyrazol-4-ylcarboxamide, N-(3′,4′-dichloro-3-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-3-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-3-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-3-fluorobiphenyl-2-yl)-1-methyl-S-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′-chloro-4′-fluoro-3-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-4-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-4-fluorobiphenyl-2-yl)-1-methyl-S-trifluoromethyl-I H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-4-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-4-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′-chloro-4′-fluoro-4-fluorobiphenyl-2-yl)-1-methyl-S-difluoromethyl-I H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-difluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-1-methyl-S-difluoromethyl-I H-pyrazole-carboxamide, N-(3′,4′-difluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(3′,4′-dichloro-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(3′-chloro-4′-fluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-difluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-4-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-chloro-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-methyl-5-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(4′-chloro-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(4′-methyl-5-fluorobiphenyl-2-yl)-1,3-dimethyl-1H-pyrazole-4-carboxamide, N-(4′-fluoro-6-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-(4′-chloro-6-fluorobiphenyl-2-yl)-1-methyl-3-trifluoromethyl-1H-pyrazole-4-carboxamide, N-[2-(1,1,2,3,3,3-hexafluoropropoxy)-phenyl]-3-difluoromethyl-1-methyl-1H-pyrazo le-4-carbox amide, N-[4′-(trifluoromethylthio)-biphenyl-2-yl]-3-difluoromethyl-1-methyl-1H-pyrazole-4-carboxamide and N-[4′-(trifluoromethylthio)-biphenyl-2-yl]-1-methyl-3-trifluoromethyl-1-methyl-1H-pyrazole-4-carboxamide;",
"B4) heterocyclic compounds selected from the group consisting of fluazinam, pyrifenox, bupirimate, cyprodinil, fenarimol, ferimzone, mepanipyrim, nuarimol, pyrimethanil, triforine, fenpiclonil, fludioxonil, aldimorph, dodemorph, fenpropimorph, tridemorph, fenpropidin, iprodione, procymidone, vinclozolin, famoxadone, fenamidone, octhilinone, proben-azole, 5-chloro-7-(4-methyl-piperidin-1-yl)-6-(2,4,6-trifluorophenyl)41,2,4]triazolo[1,5-alpyrimidine, anilazine, diclomezine, pyroquilon, proquinazid, tricyclazole, 2-butoxy-6-iodo-3-propylchromen-4-one, acibenzolar-S-methyl, captafol, captan, dazomet, folpet, fenoxanil, quinoxyfen, N,N-dimethyl-3-(3-bromo-6-fluoro-2-methylindole-1-sulfonyl)-[1,2,4]triazole-1-sulfonamide, 5-ethyl-6-octyl41,2,4]triazolo[1,5-a]pyrimidin-2,7-diamine, 2,3,5,6-tetrachloro-4-methanesulfonyl-pyridine, 3,4,5-trichloro-pyridine-2,6-di-carbonitrile, N-(1-(5-bromo-3-chloro-pyridin-2-yl)-ethyl)-2,4-dichloro-nicotinamide, N-((5-bromo-3-chloro pyridin-2-yl)-methyl)-2,4-dichloro-nicotinamide, diflumetorim, nitrapyrin, dodemorphacetate, fluoroimid, blasticidin-S, chinomethionat, debacarb, difenzoquat, difenzoquat-methylsulphat, oxolinic acid and piperalin;",
"B5) carbamates selected from the group consisting of mancozeb, maneb, metam, methasulphocarb, metiram, ferbam, propineb, thiram, zineb, ziram, diethofencarb, iprovalicarb, benthiavalicarb, propamocarb, propamocarb hydrochlorid, 4-fluorophenyl N-(1-(1-(4-cyanophenyl)-ethanesulfonyl)but-2-yl)carbamate, methyl 3-(4-chloro-phenyl)-3-(2-isopropoxycarbonylamino-3-methyl-butyrylamino)propanoate;",
"or B6) other fungicides selected from the group consisting of guanidine, dodine, dodine free base, iminoctadine, guazatine, antibiotics: kasugamycin, streptomycin, polyoxin, validamycin A, nitrophenyl derivatives: binapacryl, dinocap, dinobuton, sulfur-containing heterocyclyl compounds: dithianon, isoprothiolane, organometallic compounds: fentin salts, organophosphorus compounds: edifenphos, iprobenfos, fosetyl, fosetyl-aluminum, phosphorous acid and its salts, pyrazophos, tolclofos-methyl, organochlorine compounds: dichlofluanid, flusulfamide, hexachloro-benzene, phthalide, pencycuron, quintozene, thiophanate-methyl, tolylfluanid, others: cyflufenamid, cymoxanil, dimethirimol, ethirimol, furalaxyl, metrafenone and spiroxamine, guazatine-acetate, iminoc-tadine-triacetate, iminoctadine-tris(albesilate), kasugamycin hydrochloride hydrate, dichlorophen, pentachlorophenol and its salts, N-(4-chloro-2-nitro-phenyl)-N-ethyl-4-methyl-benzenesulfonamide, dicloran, nitrothal-isopropyl, tecnazen, biphenyl, bronopol, diphenylamine, mildiomycin, oxincopper, prohexadione calcium, N-(cyclopropylmethoxyimino-(6-difluoromethoxy-2,3-difluoro-phenyl)-methyl)-2-phenyl acetamide, N′-(4-(4-chloro-3-trifluoromethyl-phenoxy)-2,5-dimethyl-phenyl)-N-ethyl-N-methyl formamidine, N′-(4-(4-fluoro-3-trifluoromethyl-phenoxy)-2,5-dimethyl-phenyl)-N-ethyl-N-methyl formamidine, N′-(2-methyl-5-trifluormethyl-4-(3-trimethylsilanyl-propoxy)-phenyl)-N-ethyl-N-methylformamidine and N′-(5-difluormethyl-2-methyl-4-(3-trimethylsilanyl-propoxy)-phenyl)-N-ethyl-N-methyl formamidine.",
"[0034] Herbicides: C1) acetyl-CoA carboxylase inhibitors (ACC), for example cyclohexenone oxime ethers, such as alloxydim, clethodim, cloproxydim, cycloxydim, sethoxydim, tralkoxydim, butroxydim, clefoxydim or tepraloxydim;",
"phenoxyphenoxypropionic esters, such as clodinafop-propargyl, cyhalofop-butyl, diclofop-methyl, fenoxaprop-ethyl, fenoxaprop-P-ethyl, fenthiapropethyl, fluazifop-butyl, fluazifop-P-butyl, haloxyfop-ethoxyethyl, haloxyfop-methyl, haloxyfop-P-methyl, isoxapyrifop, propaquizafop, quizalofop-ethyl, quizalofop-P-ethyl or quizalofop-tefuryl;",
"or arylaminopropionic acids, such as flamprop-methyl or flamprop-isopropyl;",
"C2 acetolactate synthase inhibitors (ALS), for example imidazolinones, such as imazapyr, imazaquin, imazamethabenz-methyl (imazame), imazamox, imazapic or imazethapyr;",
"pyrimidyl ethers, such as pyrithiobac-acid, pyrithiobac-sodium, bispyribac-sodium.",
"KIH-6127 or pyribenzoxym;",
"sulfonamides, such as florasulam, flumetsulam or metosulam;",
"or sulfonylureas, such as amidosulfuron, azimsulfuron, bensulfuron-methyl, chlorimuron-ethyl, chlorsulfuron, cinosulfuron, cyclosulfamuron, ethametsulfuron-methyl, ethoxysulfuron, flazasulfuron, halosulfuron-methyl, imazosulfuron, metsulfuron-methyl, nicosulfuron, primisulfuron-methyl, prosulfuron, pyrazosulfuron-ethyl, rimsulfuron, sulfometuron-methyl, thifensulfuron-methyl, triasulfuron, tribenuron-methyl, triflusulfuron-methyl, tritosulfuron, sulfosulfuron, foramsulfuron or iodosulfuron;",
"C3) amides, for example allidochlor (CDAA), benzoylprop-ethyl, bromobutide, chiorthiamid.",
"diphenamid, etobenzanidibenzchlomet), fluthiamide, fosamin or monalide;",
"C4) auxin herbicides, for example pyridinecarboxylic acids, such as clopyralid or picloram;",
"or 2,4-D or benazolin;",
"C5) auxin transport inhibitors, for example naptalame or diflufenzopyr;",
"C6) carotenoid biosynthesis inhibitors, for example benzofenap, clomazone (dimethazone), diflufenican, fluorochloridone, fluridone, pyrazolynate, pyrazoxyfen, isoxaflutole, isoxachlortole, mesotrione, sulcotrione (chlormesulone), ketospiradox, flurtamone, norflurazon or amitrol;",
"C7) enolpyruvylshikimate-3-phosphate synthase inhibitors (EPSPS), for example glyphosate or sulfosate;",
"C8) glutamine synthetase inhibitors, for example bilanafos (bialaphos) or glufosinate-ammonium;",
"C9) lipid biosynthesis inhibitors, for example anilides, such as anilofos or mefenacet;",
"chloroacetanilides, such as dimethenamid, S-dimethenamid, acetochlor, alachlor, butachlor, butenachlor, diethatyl-ethyl, dimethachlor, metazachlor, metolachlor, S-metolachlor, pretilachlor, propachlor, prynachlor, terbuchlor, thenylchlor or xylachlor;",
"thioureas, such as butylate, cycloate, di-allate, dimepiperate, EPTC.",
"esprocarb, molinate, pebulate, prosulfocarb, thiobencarb (benthiocarb), tri-allate or vemolate;",
"or benfuresate or perfluidone;",
"C10) mitosis inhibitors, for example carbamates, such as asulam, carbetamid, chlorpropham, orbencarb, pronamid (propyzamid), propham or tiocarbazil;",
"dinitroanilines, such as benefin, butralin, dinitramin, ethalfluralin, fluchloralin, oryzalin, pendimethalin, prodiamine or trifluralin;",
"pyridines, such as dithiopyr or thiazopyr;",
"or butamifos, chlorthal-dimethyl (DCPA) or maleic hydrazide;",
"C11) protoporphyrinogen IX oxidase inhibitors, for example diphenyl ethers, such as acifluorfen, acifluorfen-sodium, aclonifen, bifenox, chlomitrofen (CNP), ethoxyfen, fluorodifen, fluoroglycofen-ethyl, fomesafen, furyloxyfen, lactofen, nitrofen, nitrofluorfen or oxyfluorfen;",
"oxadiazoles, such as oxadiargyl or oxadiazon;",
"cyclic imides, such as azafenidin, butafenacil, carfentrazone-ethyl, cinidon-ethyl, flumiclorac-pentyl, flumioxazin, flumipropyn, flupropacil, fluthiacet-methyl, sulfentrazone or thidiazimin;",
"or pyrazoles, such as ET-751.",
"JV 485 or nipyraclofen;",
"C12) photosynthesis inhibitors, for example propanil, pyridate or pyridafol;",
"benzothiadiazinones, such as bentazone;",
"dinitrophenols, for example bromofenoxim, dinoseb, dinoseb-acetate, dinoterb or DNOC;",
"dipyridylenes, such as cyperquat-chloride, difenzoquat-methylsulfate, diquat or paraquat-dichloride;",
"ureas, such as chlorbromuron, chlorotoluron, difenoxuron, dimefuron, diuron, ethidimuron, fenuron, fluometuron, isoproturonisouron, linuron, methabenzthiazuron, methazole, metobenzuron, metoxuron, monolinuron, neburon, siduron or tebuthiuron;",
"phenols, such as bromoxynil or ioxynil;",
"chloridazon;",
"triazines, such as ametryn, atrazine, cyanazine, desmein, dimethamethryn, hexazinone, prometon, prometryn, propazine, simazine, simetryn, terbumeton, terbutryn, terbutylazine or trietazine;",
"triazinones, such as metamitron or metribuzin;",
"uracils, such as bromacil, lenacil or terbacil;",
"or biscarbamates, such as desmedipham or phenmedipham;",
"C13) synergists, for example oxiranes, such as tridiphane;",
"C14) CIS cell wall synthesis inhibitors, for example isoxaben or dichlobenil;",
"C16) various other herbicides, for example dichloropropionic acids, such as dalapon;",
"dihydrobenzofurans, such as ethofumesate;",
"phenylacetic acids, such as chlorfenac (fenac);",
"or aziprotryn, barban, bensulide, benzthiazuron, benzofluor, buminafos, buthidazole, buturon, cafenstrole, chlorbufam, chlorfenprop-methyl, chloroxuron, cinmethylin, cumyluron, cycluron, cyprazine, cyprazole, dibenzyluron, dipropetryn, dymron, eglinazin-ethyl, endothall, ethiozin, flucabazone, fluorbentranil, flupoxam, isocarbamid, isopropalin, karbutilate, mefluidide, monuron, napropamide, napropanilide, nitralin, oxaciclomefone, phenisopham, piperophos, procyazine, profluralin, pyributicarb, secbumeton, sulfallate (CDEC), terbucarb, triaziflam, triazofenamid or trimeturon;",
"or their environmentally compatible salts.",
"[0035] Plant Growth Regulators: D1) Antiauxins, such as clofibric acid, 2,3,5-tri-iodobenzoic acid;",
"D2) Auxins such as 4-CPA, 2,4-D, 2,4-DB, 2,4-DEP, dichlorprop, fenoprop, IAA, IBA, naphthaleneacetamide, a-naphthaleneacetic acids, 1-naphthol, naphthoxyacetic acids, potassium naphthenate, sodium naphthenate, 2,4,5-T;",
"D3) cytokinins, such as 2iP, benzyladenine, 4-hydroxyphenethyl alcohol, kinetin, zeatin;",
"D4) defoliants, such as calcium cyanamide, dimethipin, endothal, ethephon, merphos, metoxuron, pentachlorophenol, thidiazuron, tribufos;",
"D5) ethylene inhibitors, such as aviglycine, 1-methylcyclopropene;",
"D6) ethylene releasers, such as ACC, etacelasil, ethephon, glyoxime;",
"D7) gametocides, such as fenridazon, maleic hydrazide;",
"D8) gibberellins, such as gibberellins, gibberellic acid;",
"D9) growth inhibitors, such as abscisic acid, ancymidol, butralin, carbaryl, chlorphonium, chlorpropham, dikegulac, flumetralin, fluoridamid, fosamine, glyphosine, isopyrimol, jasmonic acid, maleic hydrazide, mepiquat, piproctanyl, prohydrojasmon, propham, tiaojiean, 2,3,5-tri-iodobenzoic acid;",
"D10) morphactins, such as chlorfluren, chlorflurenol, dichlorflurenol, flurenol;",
"D11) growth retardants, such as chlormequat, daminozide, flurprimidol, mefluidide, paclobutrazol, tetcyclacis, uniconazole;",
"D12) growth stimulators, such as brassinolide, brassinolide-ethyl, DCPTA, forchlorfenuron, hymexazol, prosuler, triacontanol;",
"D13) unclassified plant growth regulators, such as bachmedesh, benzofluor, buminafos, carvone, choline chloride, ciobutide, clofencet, cyanamide, cyclanilide, cycloheximide, cyprosulfamide, epocholeone, ethychlozate, ethylene, fuphenthiourea, furalane, heptopargil, holosulf, inabenfide, karetazan, lead arsenate, methasulfocarb, prohexadione, pydanon, sintofen, triapenthenol, trinexapac.",
"[0036] The presently described compositions may be in any appropriate conventional form, for example an emulsion concentrate (EC), a suspension concentrate (SC), a suspo-emulsion (SE), a capsule suspension (CS), a water dispersible granule (WG), an emulsifiable granule (EG), a water in oil emulsion (EO), an oil in water emulsion (EW), a micro-emulsion (ME), an oil dispersion (OD), an oil miscible flowable (OF), an oil miscible liquid (OL), a soluble concentrate (SL), an ultra-low volume suspension (SU), an ultra-low volume liquid (UL), a dispersible concentrate (DC), a wettable powder (WP) or any technically feasible formulation in combination with agriculturally acceptable adjuvants.",
"In one embodiment, the compositions can be administered directly or can be provided in a tank mix.",
"[0037] In another embodiment, the presently described compositions may be in the form of foamable formulations.",
"Suitable foaming agents include, but are not limited to, nonionic surfactants, including alkanolamides (such as cocamide diethanolamide, lauric acid monoisopropanolamide, and ethoxylated myristamide), xyethylene fatty acid esters, polyoxyethylene fatty alcohol ethers (such as alkylaryl polyglycol ethers) and fluorocarbons (such as ethoxylated polyfluorinated alcohol);",
"anionic surfactants including alkyl-, alkylaryl- and arylsulfonates (such as sodium lauryl sarcosinate and such as sodium alkylbenzenesulfonate), alkyl-, alkylaryl- and arylsulfates, protein hydrolysates, derivatives of polycarboxylic acid (such as ammonium lauryl ether carboxylate), olefin sulfonates (such as sodium alpha olefin sulfonate), sarcosinates (such as ammonium cyclohexyl palmitoyl taurinate), succinates (such as disodium N-octadecyl sulfosuccinamate), phosphorus derivatives (such as phosphoric acid esters and their equivalent salts);",
"cationic surfactants including alkylbenzyltrimethylammonium chloride;",
"and amphoteric surfactants including betaine.",
"Particularly preferred foaming agents include Bio-Soft D-40, Bioterge AS-40, Ammonyx DO, Ammonyx LO, Steol CA-330, Cedepal TD-407, and Polystep B-25.",
"The total concentration of foaming agents in the formulation will be dependent on the foaming agents used, and may comprise between about 0.1% and about 50% of the final formulation, preferably between about 0.3% and about 30%, more preferably between about 5% and 25%, and even more preferably between about 17% and about 23%.",
"[0038] In some embodiments, the composition is formulated as a suspension, preferably as a suspension concentrate.",
"A suspension concentrate may contain, for example, about 50, 80, 10, 150, 200, 250, 300, 350, or 400 grams of the diamide active ingredient per liter.",
"The concentrate can be diluted with a solvent, for example water, before being applied to a plant or soil.",
"Tetraniliprole and its combination with one or more plant protection agents can also be prepared as a SC formulation.",
"Various methods are known to prepare a SC formulation.",
"An exemplary procedure is provided in U.S. Pat. No. 9,253,981, the entire disclosure of which is hereby incorporated by reference.",
"The SC formulation may contain additional components such as a surfactant, an antifoam agent, a preservative, a thickener, water, and a suspending agent.",
"Water is used as a diluent and preferably is purified water, for example, deionized or distilled water, and is present in an amount that would dilute the active ingredient to a desired concentration.",
"[0039] In some embodiments, the formulated composition is homogenous at storage condition (20-25° C.).",
"In another embodiment, the formulated composition stays shelf stable at storage condition for at least a period of 6 years, 5 years, 4 years, 3 years, 2 years, 1 year or at least 6 months.",
"[0040] Preferred plant protecting agents include those that when combined with tetraniliprole, sequentially or in the same formulation would not reduce the activity of teraniliprole or compromise the stability of the formulation containing tetraaniliprole.",
"Preferred insecticides are selected from the group consisting of abamectin, aldicarb, bendiacarb, carbaryl, carbofuran, methomyl, oxamyl, propoxur, thiodicarb, fenoxycarb, acephate, azinphos-methyl, phosmet, terbufos, endosulfan, fipronil, spinosad, milbemectin, fenoxycarb, pyriproxyfen, pymetrozine, clofentezine, etoxazole, chlorfenapyr, cartap hydrochloride, diflubenzuron, clorfluazuron, hexaflumuron, novaluron, teflubenzuron, buprofezin, cyromazine, methoxyfenozide, chromafenozide, amitraz, indoxacarb, azadirachtin and pyridaben.",
"Preferred fungicides are selected from the group consisting of bitertanol, bromuconazole, cyproconazole, difenoconazole, diniconazole, enilconazole, epoxiconazole, fluquinconazole, fenbuconazole, flusilazole, flutriafol, hexaconazole, imibenconazole, ipconazole, metconazole, myclobutanil, penconazole, propiconazole, prothioconazole, simeconazole, triadimefon, triadimenol, tebuconazole, tetraconazole, triticonazole, pefurazoate, imazalil, triflumizole, cyazofamid, benomyl, carbendazim, thiabendazole, fuberidazole, ethaboxam, etridiazole and hymexazole, azaconazole, diniconazole-M, oxpoconazol, paclobutrazol, uniconazol, imazalilsulfphate, azoxystrobin, dimoxystrobin, fluoxastrobin, kresoxim-methyl, orysastrobin, picoxystrobin, pyraclostrobin, trifloxystrobin, enestroburin, carboxin, benalaxyl, benalaxyl-M, fenhexamid, flutolanil, furametpyr, mepronil, metalaxyl, mefenoxam, ofurace, oxadixyl, oxycarboxin, penthiopyrad, isopyrazam, thifluzamide, tiadinil, dimethomorph, flumorph, fluopicolide (picobenzamid), zoxamide, carpropamid, diclocymet, mandipropamid, bixafen, fluazinam, cyprodinil, fenarimol, ferimzone, mepanipyrim, nuarimol, pyrimethanil, fenpiclonil, fludioxonil, aldimorph, dodemorph, fenpropimorph, iprodione, procymidone, vinclozolin, famoxadone, fenamidone, probenazole, acibenzolar-S-methyl, captafol, captan, dazomet, folpet, fenoxanil, quinoxyfen, nitrapyrin, fluoroimid, blasticidin-S, chinomethionat, difenzoquat-methylsulphate, oxolinic acid, mancozeb, maneb, methasulphocarb, metiram, ferbam, propineb, thiram, zineb, ziram, diethofencarb, iprovalicarb, benthiavalicarb, propamocarb hydrochloride, guanidine, dodine, kasugamycin, validamycin A, binapacryl, dinobuton, dithianon, isoprothiolane, fosetyl-aluminum, pyrazophos, tolclofos-methyl, dichlofluanid, flusulfamide, hexachlorobenzene, phthalide, pencycuron, quintozene, thiophanate-methyl, tolylfluanid, cyflufenamid, cymoxanil, ethirimol, furalaxyl, metrafenone, iminoctadine-triacetate, iminoctadine-tris(albesilate), kasugamycin hydrochlorid-hydrat, dichlorophen, pentachlorophenol and its salts, dicloran, nitrothal-isopropyl, tecnazen, biphenyl, bronopol, diphenylamine, mildiomycin, oxine-copper and prohexadione calcium.",
"[0041] In some embodiments, the plant protection agent is a pyrethroid compound.",
"Non-limiting exemplary pyrethoids include acrinathrin, allethrin, bifenthrin, bioallethrin, bioresmethrin, cyclo professional Trindade (cycloprothrin), cyfluthrin, beta-cyfluthrin, cyhalothrin, cancer better halo Trindade (gamma-cyhalothrin), lambda cyhalothrin (lambda-cyhalothrin), cypermethrin, alpha-cypermethrin, beta-cypermethrin, theta cypermethrin, zeta cypermethrin (zeta-cypermethrin), cyphenothrin, deltamethrin, empenthrin, esfenvalerate, ethofenprox, Fenpropathrin, fenvalerate, flucythrinate, flumethrin, fluvalinate, tau full burr sulfonate, halfenprox, hepta full Trindade (heptafluthrin), imiprothrin, Kadesurin, Meperufurutorin (meperfluthrin), Mon-fluoro Trindade (momfluorothrin), permethrin, phenothrin, prallethrin, pyrethrins, resmethrin, silafluofen, tefluthrin, tetramethrin, tetramethyl full Trindade, tralomethrin and Transfluthrin.",
"In some embodiments, the plant protection agent is a pyrethroid selected from bifenthrin or zeta cypermethrin.",
"[0042] The plant protection agent is preferably present in a concentration of from about 1% by weight to about 55% by weight, more particularly, from about 15% by weight to about 35% by weight based upon the total weight of all components in the composition.",
"Other exemplary ranges include from about 10% to about 35%, from about 10% to about 30%, from about 10% to about 20% by weight.",
"[0043] In certain embodiments where tetraniliprole is the diamide insecticide, the ratio between tetraniliprole and the plant protection agent in weight may range from about 1:100 to about 100:1, and all subranges included.",
"In some embodiments, the ratio between tetraniliprole and the plant protection agent is in the ranges of about 1:30 to 30:1.",
"In some embodiments, the ratio between tetraniliprole and the plant protection agent is in the ranges of about 1:15 to about 15:1.",
"Non-limiting examples of the ratio between tetraniliprole and bifenthrin or zeta-cypermthrin include about 1:20, about 1:19, about 1:18, about 1:17, about 1:16, about 1:15, about 1:14, about 1:13, about 1:12, about 1:11, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1, about 2:1, about 3:1, about 4:1, about 5:1, about 6:1, about 7:1, about 8:1, about 9:1, about 10:1, about 11:1, about 12:1, about 13:1, about 14:1, about 15:1, about 16:1, about 17:1, about 18:1, about 19:1, and about 20:1.",
"[0044] In some exemplary embodiments, tetraniliprole accounts for about 1%, about 2%, about 3%, about 4%, or about 5% of the composition by weight.",
"In some embodiments, the plant protection agent accounts for less than about 1%, about 1%, about 2%, about 3%, about 4%, about 5% of the composition by weight.",
"[0045] In another embodiment, the composition may include at least one additive selected from the group consisting of freeze agents, anti-foam agents and biocides.",
"These formulation components are well-known in the agrochemical arts.",
"In some embodiments, the anti-freeze agent is a polyalkylene glycol, preferably propylene glycol, and when present, is present in an amount from about 5% to about 9% by weight of the total of all components in the composition.",
"In some embodiments, the anti-foam agent is an alkylcyclotetrasiloxane, preferably an octamethylcyclo-tetrasiloxane silicone emulsion, for example, DOW CORNING® AF Emulsion or DOWCORNING® ANTIFOAM C Emulsion (Dow Corning Corporation).",
"If and when present in a non-foam formulation, the anti-foam agent is present in an amount of from about 0.001% to about 1% by weight of all the components in the total formulation.",
"The preservative can be an isothiazolone or a mixture of isothiazolones, for example, KATHON® CG/ICP preservative or LEGEND® MK preservative (Rohm and Haas Corporation) or PROXEL™ BR preservative (Avecia Corporation).",
"When present, the preservative is present in an amount of from about 0.001% to about 1% by weight of the total of all components in the formulation.",
"[0046] The compositions of the present invention may also contain a pH modifier.",
"Exemplary pH ranges suitable for the present compositions include about 4-8, 4-7, 5-6, and 6-7, which includes any pH in the range of from: pH 3.5 to 3.9;",
"4.0 to 4.4;",
"pH 4.5 to 5.4;",
"pH 5.5 to pH 6.4;",
"pH 6.5 to pH 7.4.",
"[0047] In another embodiment, formulations encompass a combination of the compositions according to the present invention with liquid fertilizers to be applied in one application in a single piece of equipment.",
"One application of such a combination or formulation provides nutrients for the plant growth, while eliminating or controlling unwanted insects that can also affect the health and vitality of the desirable plants.",
"Accordingly, the composition of the present invention may also contain a liquid fertilizer.",
"In some embodiments, the liquid fertilizer is aqueous-based.",
"In some embodiments, the liquid fertilizer is present in a concentration of about 95.0% by weight to about 99.99% by weight based on the total weight of all components in the composition.",
"[0048] According to the present invention invention carrier system is an acceptable agricultural carrier and may be a liquid, a powder, in spray or foam form to allow delivery of agriculturally effective amounts of the diamide insecticides.",
"In at least embodiments that tetraniliprole is the diamide insecticide alone or in combination with one or more plant protection agents, the carrier system may be in the form of a suspension concentrate.",
"Various methods are known to prepare a SC formulation.",
"An exemplary procedure is provided in U.S. Pat. No. 9,253,981, the entire disclosure of which is hereby incorporated by reference.",
"The SC formulation may contain additional components such as a surfactant, an antifoam agent, a preservative, a thickener, water, and a suspending agent.",
"Water is used as a diluent and preferably is purified water, for example, deionized or distilled water, and is present in an amount that would dilute the active ingredient to a desired concentration.",
"[0049] Another aspect of the invention provides a method for controlling rootworms including NCR, WCRW, and SCRW at all stages of their lifecycle, egg, larva, pupa and adult form in plants and crops using the compositions of the present invention.",
"In at least one embodiment, controlling infestation of rootworm in the corn crop can be accomplished in any soil pH.",
"In one embodiment, the soil of the area to be protected from rootworm infestation may posses a pH in the range of from about pH 4 to about pH 9, which includes a pH in the range of from 3.5 to 9.4, or a pH of: about pH 4, about pH 5, about pH 6, about pH 7, about pH 8, or about pH 9.",
"The method includes the step of applying to a plant or soil an effective amount of diamide insecticide including, but not limited to, flubendiamide, the phthalamide compounds (R)-3-Chlor-N1-{2-methyl-4-[1,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid and (S)-3-Chlor-N1-{2-methyl-441,2,2,2-tetrafluor-1-(trifluormethyl)ethyl]phenyl}-N2-(1-methyl-2-methylsulfonylethyl)phthalamid, chloranthraniliprole, cyanthraniliprole and tetraniliprole.",
"In one embodiment, the composition may contain essentially just tetraniliprole as the sole active ingredient or may include at least one plant protection agent.",
"[0050] The method of the present invention can be used in pest-infested areas.",
"However, it is also suitable for pest prevention purposes.",
"The pests to be controlled may inhabit various places, including for example, rice paddies, fields, tea plantations, orchards, non-plant lands, houses, nursery trays or nursery boxes, nursery soil and nursery mats, and the like in the soil or at the foliage.",
"Accordingly, the compositions can be applied in different means and forms depending on specific needs to control pests.",
"For example, both direct spray and foliar applications can effectively control the egg production on the plant.",
"Certainly, the method of the present invention is by no means limited to plant foliage application;",
"other processes such as soil treatment and seed disinfection are also contemplated within the scope of the present invention.",
"In one embodiment, the targeted pests are any WCRW and SCRW and their adult forms.",
"[0051] Prior to application, the concentrations of the compositions may be readjusted.",
"For example, tetraniliprole and the plant protection agent may account for about 0.0005 to 40% by weight in the composition.",
"Other exemplary ranges include about 0.05 to about 10%, about 0.1 to about 10%, about 0.5 to about 10%, about 1 to about 10%, and about 1 to about 5%.",
"[0052] In certain embodiments, tetraniliprole and the plant protection agent may be applied at a rate ranging from about 1 to 20 gallons per acre.",
"Non-limiting examples include about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8 and about 9 gallons per acre.",
"[0053] As described above, tetraniliprole and the plant protection agent may be mixed together and applied in the same formulation.",
"Alternatively, tetraniliprole and the plant protection agent can be applied sequentially.",
"The length of the interval between the applications depends on factors such as the target pest and concentration of the ingredients and can be determined by one of ordinary skill in the art without undue experimentation.",
"[0054] The plants to be protected by the compositions of the present invention include, for example, agricultural crops, fruit trees and trees other than fruit trees, grass crops, and weeds.",
"The plants can be, for example, floricultural plants, and ornamentals.",
"Examples of agricultural crops include, but are not limited to, corn, peanut, alfalfa, rice, wheat, barley, rye, oats, sorghum, cotton, soybean, pin-nuts, buckwheat, sugar beet, rapeseed, sunflower, sugar cane, tobacco, etc.",
", vegetables;",
"Solanaceae vegetables (eggplant, tomato, pin-Man, peppers, potatoes, etc.), Cucurbitaceae vegetables (cucumber, pumpkin, Zucchi-two, watermelon, melon, etc.), cruciferous vegetables (radish, turnip, horseradish, co-Rurabi, Chinese cabbage, cabbage, mustard, broccoli-, cauliflower-, etc.), Asteraceae vegetables (burdock, garland chrysanthemum , A-Ticho-clause, lettuce, etc.), Liliaceae vegetables (leek, onion, garlic, asparagus), Umbelliferae vegetables (carrot, parsley, celery, parsnip, etc.), Chenopodiaceae vegetables (spinach, Swiss chard, etc.), Labiatae vegetables ( perilla , mint, basil, etc.), strawberry, sweet potato, yam, taro, etc.",
", flowers, and foliage plants.",
"Examples of fruit trees include pome fleshy fruits (apple, pear, Japanese pear, quince, quince, etc.), stone fruit (peach, plum, nectarine, plum, cherry, apricot, pull-down, etc.), citrus (satsuma mandarin, orange, lemon, lime, gray-Pufuru-Tsu, etc.), Kenhate-rui (chestnut, walnut, hazel, A-Monde, pistachio, cashew-nuts, macadamia nuts, etc.), berries, grape, persimmon, Cage-parts, loquat, banana, co-Non-, date palm, and coconut.",
"Examples of trees other than fruit trees include, but are not limited to, tea, mulberry, flowers and trees, street trees (ash, birch, dogwood, Yu-Cali, ginkgo, lilac, maple, oak, poplar, Cercis chinensis , SEAL, sycamore, zelkova Kurobe, fir, hemlock, juniper, pine, spruce, yew), and the like.",
"[0055] When and if employed with a liquid fertilizer, a hydrated aluminum-magnesium silicate may be used in the composition according to the present invention, preferably selected from montmorillonite and attapulgite.",
"Such compositions may further include phosphate ester dispersants selected from a nonyl phenol phosphate ester and a tridecyl alcohol ethoxylated phosphate potassium salt.",
"The dispersant or dispersants are preferably present in a total concentration of from about 0.02% by weight to about 20% by weight based upon the total weight of all components in the composition.",
"[0056] In one embodiment, the compositions of the present claims are superior in controlling rootworms as compared to diamide standards such as Exirel® (cyantraniliprole) and Coragen® when applied as a soil treatment against all stages and types of rootworms, particularly SCRW and WCRW larvae.",
"In one embodiment, the tetraniliprole SC formulation of the present invention at ranges between 150 ppm to 250 ppm, preferably 200 to 225 pm and more preferably at 213.8 ppm, provided more than 90% control to larvae and provided statistically greater control compared to all rates of Exirel (cyantraniliprole).",
"In another embodiment, the compositions according to the present invention against WCRW, at ranges between 150 ppm to 250 ppm, preferably 200 to 225 pm and more preferably at 213.8 ppm, provide more than 92% control and statistically outperformed Exirel at similar rate and was further numerically greater than Exirel and Coragen® (chlorantraniliprole) against rootworms.",
"[0057] In another embodiment, the compositions of the present invention were superior in controlling rootworms when applied foliarly to infested leafs with adult beetles of Diabrotica virgifera virgifera .",
"In another embodiment, compositions according to the present invention controlled rootworm larve in natural ambient condition regardless of differing water pHs 6, 7, or 8.",
"In at least one embodiment, the composition is a tetratraniliprole SC formulation.",
"[0058] In another embodiment, soil treated with the formulations of the present invention containing a diamide compound provided ≧90, 95, or 98% control of 1 st and/or 2 nd instar NCR, SCRW, WCRW larvae at 64 day after treatment (DAT).",
"In at least another embodiment, the diamide compound and bifenthrin administered in combination or sequentially provided more than ≧90, 95, or 98% control of 2 nd instar SCRW, WCRW larvae at 64 day after treatment DAT.",
"In another embodiment, the diamide compound is tetratraniliprole.",
"[0059] In at least one embodiment, the present invention contains: (1) between about 1% to about 35% by weight of tetraniliprole;",
"(2) between about about 1% to about 35% by weight of the plant protecting agent, (3) between about 1% to about 20% by weight of hydrated aluminum-magnesium silicate, and optionally (4) between about 0.2% to about 20% by weight of at least one dispersant selected from the group consisting of a sucrose ester, a lignosulfonate, an alkylpolyglycoside, a naphthalenesulfonic acid formaldehyde condensate and a phosphate ester.",
"[0060] In another embodiment, methods of using such formulations are described to provide ≧90, 95, or 98% control of 1 st and/or 2 nd instar NCR, SCRW, or WCRW larvae at 64 days after treatment (DAT).",
"In at least another embodiment, the administration of tetraniliprole and bifentrin in combination or sequentially provided more than ≧90, 95, 98% control of 2 nd instar SCRW, WCRW larvae at 64 DAT.",
"[0061] In another embodiment, the present invention may be in the form of a foamable formulation.",
"Certain embodiments include stable, aqueous compositions suitable for the generation of air foams in a suitable system to provide in furrow or in situ treatment.",
"As a result in at least one embodiment, the tetraniliprole SC formulation according to the present invention is of such consistency and flowability to generate foam when applied directly in-furrow to the seeds or if needed to form an in situ product.",
"[0062] The foamable formulations of the present disclosure include at least one active ingredient including traniliprole, at least one foaming agent, and at least one foam stabilizer.",
"It is recognized that the foamable formulations may include more than one active ingredient, foaming agent and/or foam stabilizer.",
"They may be prepared and used without dilution, or they may be diluted with water before use.",
"The formulation may be diluted by mixing with water in the storage tank on the tractor (“tank mixing”), in these embodiments the formulation can be configured such that the mixture will remain stable upon mixing (i.e. introducing water to the formulation).",
"[0063] Alternatively, the formulation can be configured such that the mixture will require agitation prior to foaming, wherein the agitation can be provided by a mechanical mixture member (not shown) located within the tank.",
"Additionally or alternatively, the mixing motion can be provided by the vibration and oscillation induced by normal operation of the tractor over the terrain.",
"In other embodiments, mixing the formulation with water can occur within the line while it is being pumped to the foaming chamber.",
"In an exemplary embodiment, the mixing can occur at a location upstream of the discharge or ejection nozzle(s).",
"[0064] In at least one embodiment, the tank mix chemical formulation has a suitable viscosity to allow the active ingredient in the foamable formulation to be delivered at a range of from 0.75-4.00 lbs a.i./gallon, and preferably from 0.75-2.00 lbs a.i./gallon.",
"In at least one embodiment, the viscosity of the formulation is adjusted to the speed of the apparatus to provide optimal foaming at a range of speeds including approximately 4-16 ounces of chemical formulation per acre, and 24-64 ounces of water per acre and a ground speed ranging from 2-7 miles per hour.",
"In at least one embodiment, the present invention provides the delivery of the chemical formulation with at least 0.75 lbs a.i./gallon to be delivered at a rate of at least 0.25 gallons/acre.",
"In at least one embodiment, the tetratranilipole containing formulation is administered at a rate of about 5 to about 100 g ai/ha or about 7.5 to about 60 g ai/ha.",
"Another aspect of the instant invention provides a foamable formulation with an expansion factor of at least 30, 40, 50, or 60.",
"[0065] Suitable foam stabilizers act to stabilize the foam generated from the liquid, foamable formulation.",
"Examples of suitable foam stabilizers include, but are not limited to, glycerine, Kelzan, carrageenan, xanthan gum, guar gum, gum Arabic, gum tragacanth, polyox, alginin, and sodium alginate.",
"Glycerine and Kelzan are particularly preferred.",
"The total concentration of foam stabilizers in the formulation will be dependent on the foaming agents used, and may comprise between 0.1% and 15% of the total formulation, preferably 1-14%, more preferably 7-12%.",
"[0066] The foamable formulations of the present invention may also include dispersants, and/or preservatives.",
"Suitable dispersants include, but are not limited to, nonionic and/or ionic substances, for example from the classes of the alcohol-POE and/or -POP ethers, acid and/or POP POE esters, alkylaryl and/or POP POE ethers, fat and/or POP POE adducts, POE- and/or POP-polyol derivatives, POE- and/or POP-sorbitan or -sugar adducts, alkyl or aryl sulfates, alkyl- or arylsulfonates and alkyl or aryl phosphates or the corresponding PO-ether adducts, and mixtures thereox.",
"Alkyl polyglucosides and phosphate esters are preferred dispersants.",
"[0067] Suitable preservatives include but are not limited to C 12 to C 15 alkyl benzoates, alkyl p-hydroxybenzoates, aloe vera extract, ascorbic acid, benzalkonium chloride, benzoic acid, benzoic acid esters of C 9 to C 15 alcohols, butylated hydroxytoluene, butylated hydroxyanisole, tert-butylhydroquinone, castor oil, cetyl alcohols, chlorocresol, citric acid, cocoa butter, coconut oil, diazolidinyl urea, diisopropyl adipate, dimethyl polysiloxane, DMDM hydantoin, ethanol, ethylenediaminetetraacetic acid, fatty acids, fatty alcohols, hexadecyl alcohol, hydroxybenzoate esters, iodopropynyl butylcarbamate, isononyl iso-nonanoate, jojoba oil, lanolin oil, mineral oil, oleic acid, olive oil, parabens, polyethers, polyoxypropylene butyl ether, polyoxypropylene cetyl ether, potassium sorbate, propyl gallate, silicone oils, sodium propionate, sodium benzoate, sodium bisulfite, sorbic acid, stearic fatty acid, sulfur dioxide, vitamin E, vitamin E acetate and derivatives, esters, salts and mixtures thereof.",
"Preferred preservatives include sodium o-phenylphenate, 5-chloro-2-methyl-4-isothiazolin-3-one, 2-methyl-4-isothiazolin-3-one, and 1,2-benisothiazolin-3-one.",
"[0068] The compositions and methods of the present invention are further illustrated by the examples below.",
"These examples serve only to illustrate the invention and should not be interpreted as limiting the scope of the invention in any way, since further modifications encompassed by the disclosed invention will be apparent to those skilled in the art.",
"All such modifications are deemed to be within the scope of the invention as defined in the present specification and claims.",
"EXAMPLES Example 1: Determination of the Insecticidal Activity of Test Formulation in Midwestern Soil [0069] In this Example, a formulation according to the present invention provided greater control to 2 nd instar SCRW and WCRW larvae compared to the commercially available diamide standards, Exirel® (cyantraniliprole) and Coragen (chlorantraniliprole), when applied as a soil treatment.",
"Methodology [0070] In order to induce seed germination prior to test initiation, corn seed was submerged in water for 12 h and then placed between layers of moistened paper towel for 48 h ( FIG. 1A ).",
"Plastic Dart® containers (1 oz.",
"/30 ml) were utilized for the assay ( FIGS. 1C-D ).",
"Treatments included Test Formula (tetraniliprole 200 SC formulation), Rugby® (cadusafos), and chlorantraniliprole.",
"A 60 g ai/ha foliar rate applied at a volume of 30 GPA which equates to 213.8 ppm.",
"If this application rate was condensed into a 6″ T-ban application that assumed a 30″ row spacing, the ppm rate would increase to 1069 ppm (213.8 ppm×5);",
"thus, three rates were selected for all experimental and standard treatments (213.8, 534, and 1069 ppm).",
"[0071] Dilutions of Test Formula (Table 1) were mixed into dry, sifted, Midwestern soil ( FIG. 1B ), from Wyoming, Ill.",
", by adding 49.5 mLs of solution into 330 g of soil and equated to approximate 15% soil moisture value;",
"soil clumped when pinched.",
"[0072] An estimated 0.75 cm of treated soil was placed into the bottom of each container, two germinated corn seeds were placed onto the soil, and then the arenas were capped with a lid until rootworms were infested ( FIG. 1C-D ).",
"Using a fine tipped paint brush, 5 larvae (2 nd instar) of each rootworm species (SCRW and WCRW) were transferred onto the soil of each replicate ( FIG. 1E ), covered with approximately 1.75 cm of treated soil, and capped ( FIG. 1F ).",
"[0073] There were 7 replicates and 35 larvae per treatment.",
"Arenas containing soil, corn, and larvae were transferred into the Insectary room (≈23° C., 0 L:24 D) and evaluated 6 days later for the presence of living SCRW and WCRW larvae.",
"Larvae not recovered within each arena were considered dead.",
"Longest root for each seed was recorded.",
"All data was analyzed by ANOVA/GLM with an alpha of 0.1 (Minitab 16.0).",
"Data points having the same letter within each column are not significantly different and were assessed using ANOVA: GLM (α=0.1) (Table 1).",
"The results are depicted in Table 1 below: [0000] TABLE 1 Rates Tested Rates Tested WRCW SCRW Treatment (ppm) (g ai/ha) % Control % Control Test Formula 213.8 60 94.3ab 91.4a Test Formula 534 150 100a 100a Test Formula 1,069 300 100a 100a Exirel 213.8 60 2.96f 8.6c Exirel 534 150 74.3 bc 22.9c Exirel 1069 300 86.6ab 45.7b Coragen 213.8 60 54.3cd 11.4c Coragen 534 150 25.7ef 8.6c Coragen 1,069 300 34.3de 17.1c Untreated UTC — 11.4ef 5.7c * Conversion from g ai/ha to ppm is based upon an application volume of 30 GPA (Galloons per Acre).",
"Note: Values in each column that have the same letter are not statistically different when analyzed at a 90% CI, ANOVA, GLM.",
"[0074] As indicated in the Table 1, in a rate to rate comparison, Test Formula provided greater control to 2 nd instar SCRW and WCRW larvae compared to the diamide standards, Exirel and Coragen, when applied as a soil treatment.",
"Coragen did not provide adequate control to rootworm larvae at any rate tested.",
"Against SCRW, Test Formula at 213.8 ppm (91.4% a) provided statistically greater control to 2 nd instar larvae compared to all rates of Exirel.",
"Against WCRW, Test Formula at 213.8 ppm (94.3% control) statistically outperformed Exirel at 213.8 ppm (2.9%) and was numerically greater than Exirel at 534 (74.3% bc).",
"All surviving larvae within Test Formula treated soil (213.8 ppm) were controlled, stunted, had not grown, and differed from all other surviving larvae within other treatments and rates.",
"Conclusion [0075] In conclusion, against SCRW, Test Formula at 213.8 ppm provided some 91.4% control to larvae and provided statistically greater control compared to all rates of cyantraniliprole.",
"Against WCRW, Test Formula at 213.8 ppm provided 94.3% control, and statistically outperformed cyantraniliprole.",
"In fact, Test Formula of the present invention outperformed cyantraniliprole at 535 ppm.",
"Example 2 [0076] In this example, Test Formula was compared with Belt®, Coragen®, and Exirel® in both direct spray and foliar applications against SCRW and WCRW.",
"The results indicated that the Test Formula provided greater control to SCRW and WCRW adults (direct contact and feeding).",
"In addition, against SCRW and WCRW adults, Test Formula was more effective than Belt, Coragen, and Exirel in both direct spray and foliar applications against Southern and Western corn rootworm adults (SCRW+WCRW).",
"Methodology [0077] Direct Spray: Three replicates of five adult beetles (n=15) were placed into 12 oz.",
"Styrofoam containers on the day of application.",
"Both southern and western corn rootworms (SCRW and WCRW) were evaluated in the bioassay.",
"Treatments and rates are listed in Table 1 and were applied using a DeVilbiss sprayer in accordance with SOP 529.00 with the deviation of beetles being sprayed at 40 p.s.i. Beetles were immediately transferred to clean containers and provisioned with a water source and a clipped cucumber leaf.",
"At 2 Days After Administeration (DAA), mortality and % feeding damage were assessed.",
"Because leaves varied in size, a single untreated check leaf was used as a reference to compare to all other replicates.",
"After the initial assessment of feeding damage, the leaf was discarded and a freshly cut, untreated cucumber leaf was placed back into each arena.",
"At 4 DAA, mortality was recorded.",
"[0078] Foliar Spray: Four leaf staged cucumber plants were trimmed down to the two youngest leaves, the upper and lower leaves sprayed with the DeVilbiss at 40 p.s.i., and placed in the drying hood until dry.",
"A single leaf was cut and placed over the water source within a 12 oz.",
"Styrofoam container.",
"Scissors were cleaned with 70% EtOH between treatments.",
"Three replicates of five adult beetles (n=15) were infested onto the leaf of each container.",
"Both southern and western corn rootworms (SCRW and WCRW) were evaluated in the bioassay.",
"Assessment timing and methods were synonymous to the direct spray component of the assay.",
"[0079] The results of the direct spray applications are depicted in Table 2 below: [0000] TABLE 2 DIRECT SPRAY Avg % Control to SCRW Avg % Control to WCRW % Feeding Damage at 2DAA Treatment Rate (g ai/ha) 2DAA 4DAA 2DAA 4DAA SCRW WCRW Exirel 7.5 13.3c 13.3b 13.3c 40.0bcde 27.7abcd 21.7cd 15 6.7c 6.7b 0.0c 13.3de 9.0cde 7.7de 30 0.0c 8.3b 13.3c 20.0cde 10.7bcde 7.3de 60 6.7c 20.0b 0.0c 26.7cde 3.3de 2.0e Coragen 7.5 0.0c 0.0b 6.7c 6.7e 36.7a 40.0abc 15 13.3c 13.3b 0.0c 8.3de 35.0ab 26.7bc 30 0.0c 6.7b 0.0c 13.3de 38.3a 31.7abc 60 0.0c 0.0b 0.0c 13.3de 31.7abc 36.7abc Belt 7.5 6.7c 6.7b 0.0c 6.7e 36.7a 45.0ab 15 8.3c 8.3b 30.0bc 48.3bcde 36.7a 30.0abc 30 0.0c 0.0b 6.7c 6.7e 41.7a 46.7a 60 0.0c 0.0b 0.0c 20.0cde 40.0a 38.3abc Brigade 11 100.0a 100.0a 100.0a 78.3ab 0.0e 0.0e 22 100.0a 100.0a 100.0a 100.0a 0.0e 0.0e 44 100.0a 100.0a 100.0a 100.0a 0.0e 0.0e 88 100.0a 100.0a 100.0a 100.0a 0.0e 0.0e Test Formula 7.5 13.3c 86.7a 13.3c 46.7bcd 0.0e 1.3e 15 48.3b 93.3a 0.0c 56.7bc 1.7e 1.3e 30 65.0b 93.3a 26.7bc 40.0bcde 0.3e 1.3e 60 65.0b 100.0a 58.3b 71.7ab 0.3e 0.0e UTC — 0.0c 0.0b 13.3c 20.0cde 50.0a 33.3abc Note: Statistical analysis (GLM/ANOVA;",
"CI = 90%) compared differences within each individual column [0080] The results of the foliar spray applications are depicted in Table 3 below: [0000] TABLE 3 Foliar Avg % Control to SCRW Avg % Control to WCRW % Feeding Damage at 2DAA Treatment Rate (g ai/ha) 2DAA 4DAA 2DAA 4DAA SCRW WCRW Exirel 7.5 6.7c 6.7c 6.7d 20.0bc 9.3cde 10.0efg 15 0.0c 0.0c 20.0cd 33.3bc 7.3de 8.0efg 30 0.0c 0.0c 0.0d 13.3c 5.3de 8.3efg 60 5.6c 6.7c 6.7d 25.6bc 3.7e 6.3efg Coragen 7.5 5.6c 5.6c 6.7d 13.3c 16.7cde 31.7abc 15 0.0c 8.3c 0.0d 20.6bc 25.0bcd 21.7cde 30 0.0c 0.0c 20.0cd 46.7bc 11.0cde 13.0defg 60 0.0c 0.0c 20.0cd 26.7bc 16.7cde 20.0cdef Belt 7.5 0.0c 0.0c 0.0d 24.4bc 28.3abc 46.7a 15 0.0c 0.0c 6.7d 13.3c 41.7ab 31.7abc 30 0.0c 6.7c 0.0d 13.3c 40.0ab 40.0ab 60 0.0c 0.0c 20.0cd 46.7bc 38.3ab 28.3bcd Brigade 11 100.0a 94.4ab 100.0a 60.0ab 0.0e 0.0g 22 100.0a 100.0a 100.0a 100.0a 0.0e 0.0g 44 100.0a 100.0a 100.0a 100.0a 0.0e 0.0g 88 100.0a 100.0a 100.0a 100.0a 0.0e 0.0g Test Formula 7.5 13.3c 26.7c 13.3d 26.7bc 2.7e 5.0fg 15 0.0c 20.0c 40.0bc 53.3bc 3.3e 1.3g 30 53.3b 41.7c 40.0bc 53.3bc 1.3e 2.0g 60 0.0c 47.6bc 53.3b 46.7bc 1.7e 2.0g UTC — 0.0c 0.0c 6.7d 20.0bc 46.7a 38.3ab Note: Statistical analysis (GLM/ANOVA;",
"CI = 90%) compared differences within each individual column Conclusion Direct Spray: [0081] SCRW: Against Southern corn rootworms, all rates of Test Formula (7.5 g to 60 g ai/ha) were statistically equivalent to Brigade and provided a greater level of control (86.7% to 100%) compared to the diamide standard products Exirel (8% to 20%), Coragen (0% to 13%), and Belt (0% to 8.3%) when applied directly to beetles.",
"At 2 DAA, no feeding on untreated leaves was observed on SCRW sprayed with all rates of Brigade.",
"Feeding damage by SCRW beetles treated with Test Formula ranged between 0.0% to 1.7%, was statistically lower than Coragen and Belt, and numerically reduced compared to Exirel.",
"[0082] WCRW: Western corn rootworms were less susceptible to direct applications of all treatments compared to SCRW;",
"at 60 g ai/ha, Test Formula provided greater control (72%) compared to the diamide standards, Exirel, Coragen, Belt.",
"Feeding damage by WCRW beetles was similar to the SCRW data;",
"beetles treated with Test Formula had feeding damage ranging between 0.0% and 1.3%, was statistically lower than Coragen and Belt, and numerically reduced compared to Exirel.",
"Foliar Spray: [0083] SCRW: At 60 g ai/ha, Test Formula provided 48% control when sprayed to the foliage of cucumber plants compared to Exirel 7%, Coragen, 0%, and Belt, 0%.",
"When Brigade treatments were removed from the statistical evaluation within Minitab, Test Formula provided statistically improved control compared to the standard diamides.",
"Leaves treated with Test Formula had damage ranging between 1.3% and 3.3%, which was statistically lower than Belt, and numerically reduced compared to Coragen and Exirel.",
"The amount of feeding damage was similar to the direct spray beetle component of the assay.",
"Treated leaves were removed at 2 DAA and replaced with untreated leaves;",
"mortality would have likely continued to increase if the beetles remained on treated foliage.",
"[0084] WCRW: Similar mortality was observed between WCRW and SCRW infested upon Test Formula treated foliage.",
"Accordingly the Test Formula provided 47% control vs.",
"Exirel (27%), Coragen (27%), Belt (47%).",
"The untreated check WCRW adults had 20% mortality at 4 DAA, had the same mortality as the direct spray WCRW untreated checks, but were different cohorts.",
"Brigade at the lowest tested rate (11 g ai/ha) had 40% recovery between 2 DAA and 4 DAA (60% mortality).",
"Untreated check mortality, coupled with the low number of beetles per treatment (N=15), likely prevented statistical separation between treatments.",
"[0085] In conclusion, in both direct spray and foliar applications Test Formula provided statistically improved control compared to the standard product Belt and numerical and/or statically greater control compared to Coragen and Exirel.",
"Example 3 [0086] In this example, the activity of Test Formula treatment applied to Midwestern soil had extended residual activity against Diabrotica virgifera virgifera.",
"Methodology [0087] Dilutions of Test Formula were mixed into dry, sifted, Midwestern soil ( FIG. 1B ), from Wyoming, Ill.",
", by adding 300 ml of solution into 2000 g of soil and equated to approximate 15% soil moisture value;",
"soil clumped when pinched.",
"Treated soil was maintained in 3″ pots (8 pots per treatment) within greenhouse.",
"Pots were watered from above one time per day to maintain soil at approximately 15% moisture.",
"[0088] An estimated 0.75 cm of treated soil was placed into the bottom of each container, two germinated corn seeds were placed onto the soil, and then the arenas were capped with a lid until rootworms were infested ( FIG. 1C-D ).",
"Using a fine tipped paint brush, 5 larvae (2 nd instar) of each rootworm species (SCRW and WCRW) were transferred onto the soil of each replicate ( FIG. 1E ), covered with approximately 1.75 cm of treated soil, and capped ( FIG. 1F ).",
"[0089] There were 8 replicates and 40 larvae per treatment.",
"Arenas containing soil, corn, and larvae were transferred into the Insectary room (≈23° C., 0 L:24 D) and evaluated 6 days later for the presence of living SCRW and WCRW larvae.",
"Larvae not recovered within each arena were considered dead.",
"All data was analyzed by ANOVA/GLM with an alpha of 0.1 (Minitab 16.0).",
"Data points having the same letter within each column are not significantly different and were assessed using ANOVA: GLM (α=0.1).",
"The results are depicted in Table 4 below: [0000] TABLE 4 In-furrow Rates Application 2nd instar WCRW: Tested Rate* % Mortality Treatment (ppm) (g ai/ha) 14DAT 28DAT 43DAT Test Formula 66.8 3.75 92.5 a 97.5 a 82.5 b Test Formula 133.6 7.5 97.5 a 100 a 90 ab Test Formula 267.3 15 100 a 100 a 100 a Test Formula 534.5 30 100 a 100 a 97.5 a Test Formula 1069 60 100 a 100 a 97.5 a Capture LFR 3,977 223.2 100 a 100 a 100 a Rugby 1,069 60 100 a 100 a 100 a Untreated UTC 10 b 2.5 b 2.5 c *rates calculated based upon a 6″ T-ban with a 30″ row spacing same letters within a column are not significantly different (ANOVA, CI 90%) Conclusion [0090] Test Formula applied to soil maintained in fluctuating ambient conditions within the greenhouse at rates of ≧15 g ai/ha provided 97.5 to 100% control out to 43 DAT.",
"The efficacy provided by the 2 lower rates of Test Formula were beginning to diminish at this time point.",
"The lowest rate tested (3.75 g ai/ha) provided statistically reduced control (83% b) at 43 DAT.",
"This break in treatment efficacy suggests that the product will ultimately break down in soil within a field setting.",
"Example 4 [0091] Soil treated with a formulation according to the present invention and maintained outdoors was evaluated for activity for WCRW larvae.",
"[0092] The efficacy of the formulation of the present invention on control of rootworm larve was evaluated after it was applied to soil and maintained in natural ambient condition and was subjected to differing water pHs (6, 7, and 8) applied daily to soil.",
"Methodology [0093] A solution of the Test Formula A was prepared by making dilutions in water to form a solution.",
"Dry, Midwestern soil was brought up to 15% moisture with treatment solutions (Table 5).",
"Buckets of treated soil were carted outside daily between Monday and Friday and exposed to direct sunlight.",
"Carts were not wheeled out on days that forecasted precipitation.",
"At the end of each day, soil buckets were brought back into the laboratory, weighed, the appropriate amount of water added to the soil to bring it back up to 15% moisture, and covered overnight;",
"daily records of weights and amount of water added to each bucket was recorded.",
"The deionized water (dH 2 O) had a pH of approximately 5.0 and was altered with 0.5M KOH to a final pH of 6, 7, and 8.",
"[0094] At 30 DAT, 42 DAT, 57 DAT, and 85 DAT, 2 nd instar WCRW larvae were infested into treated soil containing and germinating corn seed and evaluated 6 days after infestation (6 DAI) for percent control and larval stunting.",
"There were 6 replicates per infestation date with 5 larvae per replicate (n=30).",
"Treatments applied to dry Midwestern soil for assessment of residual WCRW included Test Formula at 67, 267, and 1,069 ppm, Capture LFR at 1988.5 and 3,977 ppm.",
"[0095] Table 5 below provides the mortality rates of 2 nd instar WCRW larvae infested into treated soil exposed to direct sunlight at 85 days after treatment.",
"[0000] No Dead per replicate Rate (n = 5) at 85 DAT Avg % Treatment (ppm) pH 1 2 3 4 5 6 Mortality Test 67 6 5 5 5 4 5 5 96.67 a Formula Test 67 7 4 5 4 4 5 4 86.67 a Formula Test 67 8 3 4 5 5 4 5 86.67 a Formula Capture 1988.5 7 5 5 5 5 5 5 100.0 a LFR Untreated — 7 1 0 0 1 2 0 13.33 b Check Note: same letters within a column are not significantly different when analyzed via ANOVA: GLM (α = 0.1) [0096] All three rates of tetraniliprole Test Formula as shown in Table 5 above, provided 100% control up to 42 DAT.",
"The lowest rate of tetraniliprole (67 ppm) was further assessed at 57 DAT and 85 DAT.",
"No statistical difference in the level of WCRW control was detected between tetraniliprole treated soil kept at 15% moisture using pH (6, 7, or 8) altered, deionized water (Table 5).",
"At 57 DAT and 85 DAT, all surviving larvae recovered from Test Formula treated soil were severely stunted compared to the non-treated check ( FIG. 2 ).",
"At 85 DAT, Test Formula treated soil that had moisture maintained with water at a pH of 6 provided 97% control but was not significantly different from pH 7 or pH 8.",
"Conclusion [0097] A solution containing tetraniliprole at 67 ppm (3.75 g ai/ha) was incorporated into Midwestern soil (15% moisture) and maintained outdoors provided control to WCRW larvae.",
"This amount of tetraniliprole was equivalent to Capture LFR (α=0.1).",
"Soil of each treatment was manipulated daily with water at pH 6, 7, or 8.",
"A tetraniliprole containing formulation according to the present invention provided ≧87% control with all surviving larvae being severely stunted compared to the non-treated check Example 5: Efficacy of Test Formula Treated Soil Against WCRW Larvae [0098] In this example residual activity and stability of tetraniliprole test treatments within microbially active Midwestern soil against 2 nd nymphal stage WCRW- Diabrotica virgifera virgifera was assessed in corn field and further compared to Capture LFR and Rugby.",
"Methodology [0099] In order to induce seed germination prior to test initiation, corn seed was submerged in water for 12 h and then placed between layers of moistened paper towel for 72 h. Plastic Dart® containers (1 oz/30 ml) were utilized for the assay.",
"Treatments included tetraniliprole Test Formula according to the present invention, Capture LFR® (bifenthrin), and Rugby® (cadusafos).",
"A 60 g ai/ha foliar rate applied at a volume of 30 GPA equates to 213.8 ppm.",
"If this application rate was condensed into a 6″ T-band application that assumed a 30″ row spacing, the ppm rate would increase to 1069 ppm (213.8 ppm×5).",
"Five rates were selected for the experimental treatment (Test Formula) and compared to a single rate of two standard treatments (Capture LFR and Rugby).",
"Treatment solutions (Table 4) were mixed into dry, sifted, Midwestern soil, from Wyoming, Ill.",
", by adding 300 mLs of solution into 2000 g of soil and equates to approximate 15% soil moisture value;",
"soil clumped when pinched.",
"[0100] An estimated 0.75 cm of treated soil was placed into the bottom of each container, one germinated corn seed was placed onto the soil, and then the arenas were capped with a lid until rootworms were infested.",
"Corn was covered with approximately 1.75 cm of treated soil.",
"Using a fine tipped paint brush, 5 WCRW larvae (2 nd instar) were transferred onto the soil of each replicate and then capped.",
"There were 8 replicates and 40 larvae per treatment.",
"Arenas containing soil, corn, and larvae were transferred into the Insectary room (≈23° C., 0 L:24 D) and evaluated 6 days later for the presence of living larvae.",
"Larvae not recovered within each arena were considered dead.",
"Additional treated soil was maintained within a 5 gallon bucket, covered with aluminum soil, and weights recorded.",
"Additional water was added every Monday in order to maintain a 15% soil moisture level.",
"[0101] All mortality data was analyzed by ANOVA/GLM with an alpha of 0.1 (Minitab 16.0).",
"Data points having the same letter within each column are not significantly different and were assessed using the Tukey Method (Table 5).",
"[0102] At 0 DAT: tetraniliprole treated soil at 30 and 60 g ai/ha provided 97.5% control to 2 nd instar WCRW.",
"This bioassay confirms the activity of tetraniliprole against rootworms as shown in Example 1.",
"Stunted larvae were detected in all tetraniliprole treated soils compared to the untreated check.",
"At the lowest rate tested (3.75 g aiha), larvae were approximately half the size as the untreated check;",
"a single, drastically stunted larvae were found at the two highest rates tested.",
"Protection to the root and shoot system of corn was evident with all tetraniliprole treated soils ( FIG. 3 ).",
"The lowest two rates of tetraniliprole (3.75 g and 7.5 g ai/ha) were not infested at 14 DAT due to rates providing <80% control at 0 DAT.",
"[0103] At 14 DAT: The 15 g ai/ha rate of tetraniliprole formulation according to the present invention provided greater control at 14 DAT compared to 0 DAT.",
"Those of ordinary skill in the art would understand that the lower rates (3.75 and 7.5 g ai/ha) at residual evaluation dates would be as effective in future assays.",
"[0104] At 28, 50, and 64 DAT: All soil treatments remaining in the bioassay provided ≧95% control out to 64 DAT (Table 6).",
"[0000] TABLE 6 Mortality of 2 nd instar WCRW after 144 h within treated soil.",
"In-furrow Application 2nd instar WCRW: Rates Tested Rate* % Mortality Treatment (ppm) (g ai/ha) 0 DAT 14 DAT 28 DAT 50 DAT 64 DAT Test Formula 66.8 3.75 57.5 c — — — — Test Formula 133.6 7.5 77.5 bc — — — — Test Formula 267.3 15 87.5 ab 95.0 a 100.0 a 100.0 a 95.0 a Test Formula 534.5 30 97.5 ab 100.0 a 100.0 a 100.0 a 95.0 a Test Formula 1069 60 97.5 ab 100.0 a 100.0 a 100.0 a 100.0 a Capture LFR 3,977 223.2 100.0 a 100.0 a 100.0 a 100.0 a 100.0 a Rugby 1,069 60 100.0 a 100.0 a 100.0 a 100.0 a 100.0 a Untreated UTC 2.5 d 0.0 b 7.5 b 0 b 17.5 b *rates calculated based upon a 6″ T-ban with a 30″ row spacing —treated soil not infested after 0 DAT Note: rows having the same letter are not significanly different when analyzed via ANOVA: GLM (a = 0.1) Conclusion [0105] Tetraniliprole treated Midwestern soil (15, 30, 60 g ai/ha) maintained in the lab at a 15% moisture level provides ≧95% control to 2 nd instar WCRW larvae at 64 DAT.",
"Both Capture LFR® (bifenthrin) and Rugby® (cadusafos) provided 100% mortality.",
"[0106] While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred compositions and methods can be used and that it is intended that the invention can be practiced otherwise than as specifically described herein.",
"Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the claims that follow."
] |
FIELD OF THE INVENTION
The present invention pertains to the fabrication of semiconductor devices and more specifically to improved methods of forming contact metal during semiconductor device fabrication.
BACKGROUND OF THE INVENTION
In the semiconductor field it is common to place contact metal on semiconductor device by evaporation. In semiconductor devices having a mesa structure, a metal contact is generally placed at the top and bottom of the mesa. Typically, contact isolation is required between the top and bottom of the mesa. Isolating contacts can be difficult and time consuming, and is commonly achieved through multiple evaporations. Even when the mesa walls are near vertical, a small amount of metal can be deposited on the sidewalls. This small amount of deposited metal is sufficient to act as a short between top and bottom contact metal.
Therefore, to prevent the formation of shorts, conventional lithographic techniques are employed to define top and bottom contact regions. A plurality of steps are required, including forming a mask using lithographic techniques. During the etching and/or mask removal processes, the material of the semiconductor device has a high likelihood of being contaminated by the etchant, which contamination greatly reduces the life of the device, the operating characteristics of the device, and the reliability of the device. Further, the etching process severely damages semiconductor material adjacent the etched areas which further reduces life, operating characteristics, and reliability. Also, etching processes are very time consuming and difficult to perform.
In addition to the etching problems, the lithographic processes require many interspersed growing, masking and etching steps which greatly complicate and lengthen the process. For example, when metal is deposited, the wafers must be placed in a processing chamber. Each time the wafer must be etched and/or masked, it must be removed from the chamber, resulting in large amounts of preparation time for each step. Also, each time wafers are removed from a chamber and subsequently replaced, the opening and preparation of the chamber (as well as the processing of the wafer) is an opportunity for additional impurities and contaminants to be introduced to the wafer.
Accordingly, it would be highly desirable to provide a single step process for forming metal contacts on the top and bottom of a mesa.
It is a purpose of the present invention to provide a method for forming metal contacts on the top and bottom of a mesa without the use of lithography.
It is another purpose of the present invention to provide a method for forming metal contacts on the top and bottom of a mesa during the fabrication of semiconductor devices which does not require removal of the substrate from the processing chamber.
It is a further purpose of the present invention to provide a method for forming metal contacts on the top and bottom of a mesa during the fabrication of semiconductor devices which is much simpler and includes less chance of contamination of the devices.
SUMMARY OF THE INVENTION
The above problems and others are at least partially solved and the above purposes and others are realized in a method of forming isolated metal contacts during fabrication of semiconductor devices including blanket forming contact metal on a semiconductor device having a mesa structure with a first layer overlying an upper surface, a second layer overlying a lower surface and a third, substantially thinner layer overlying the sidewall therebetween. The contact metal is blanket oxidized using deep ultra violet light until the third layer is substantially completely oxidized thereby electrically isolating the first layer from the second layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings, in which:
FIG. 1 is a simplified sectional view of a mesa structure of a semiconductor device with contact metal formed thereon in accordance with the present invention; and
FIG. 2 is a simplified sectional view of the mesa structure of FIG. 1 with electrically isolated contacts.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is directed to FIG. 1 which illustrates a semiconductor device 10 having a mesa structure 12. Semiconductor device 10 is not illustrated in detail, other than including mesa structure 12 having an upper surface 13, a lower surface 14, and a sidewall 15 extending therebetween in a substantially upright orientation. Other details are not included as they are not relevant to the present invention. However, it will be understood that semiconductor device 10 can include a great many various structures and layers used in semiconductor devices well known to those skilled in the art and employed with a mesa structure, such as FETs.
Many semiconductor devices require metal contacts which are isolated from one another, such as in gate, source and drain, etc. In the present embodiment, contact metal is blanket deposited over the entire mesa structure forming a layer 17 overlying upper surface 13, a layer 18 overlying lower surface 14 and a layer 19 overlying sidewall 15. This process is preferably performed in a single step by evaporation. As will be readily understood, layers 17 and 18 will be substantially uniform and have a thickness of approximately 1000 Å. It will also be understood that layers 17 and 18 may be thinner or thicker as required to provide a good contact. Layer 19 will be substantially thinner than layers 17 and 18, as sidewall 15 is substantially upright between surfaces 13 and 14. Because sidewall 15 is upright, less contact material is deposited thereon. Some contact metal will deposit on sidewall 15 even when near vertical. Layer 19 is preferably in the range of approximately 10-20 Å thick.
The contact metal used is selected from III-V materials. In this specific embodiment, aluminum is employed as the contact metal. III-V material such as aluminum is employed because it has been found to oxidize under deep ultra violet radiation in the presence of oxygen. Oxygen may be supplied in a pure form or air such as the ambient atmosphere.
Turning now to FIG. 2, in a preferred embodiment semiconductor device 10 and mesa structure 12 are exposed to an ultraviolet source in ambient conditions (air), i.e. no special chamber, etc., to expose the contact metal (aluminum) to a combination of ultraviolet rays and ozone. The UV-ozone process grows a dense layer of oxide on III-V material such as aluminum by converting the aluminum to aluminum oxide. The term "deep ultraviolet" refers to light in the ultraviolet range, generally with a wavelength in the range of 180 to 250 nanometers. In the present specific example, it is believed that the 185 nm light generates ozone due to optical excitation. Therefore, excitation wavelength that is most suitable for efficient ozone generation is also the most efficient to use, although virtually any ultraviolet light will produce the desired result. The exposure to light can be performed in an aligner or stepper to define sharp features or, as in the present embodiment, performed under a lamp to provide a blanket oxidation of the III-V material.
Because blanket oxidation is used, the contact metal of layers 17, 18 and 19 will oxidize at a substantially uniform rate. Since layer 19 is substantially thinner than layers 17 and 18, it can be substantially entirely converted into an insulator layer 20, such as aluminum oxide, while leaving the majority of layers 17 and 18 in the original form with a thin layer 22 and 23 of oxide formed thereon. Thus, layers 17 and 18 are effectively isolated from each other by aluminum oxide layer 20, an insulator. It has been found that not only are the contacts isolated, but device performance is also enhanced. For example, the UV oxide could oxidize the top surface of GaAs, particularly in the gate region of a FET, and reduce leakage current. This happens by the growth of the oxide as Ga 2 O 3 and the resultant tying of the dangling bonds on the surface. If the surface layer contains carbon, the surface oxidation process will prevent leakage current or other effects that might hurt device performance.
Thus, a single step process for forming isolated metal contacts on an upper surface and a lower surface of a mesa is provided. The method of forming metal contacts on the upper surface and lower surface of a mesa during the fabrication of semiconductor devices does not use of lithography and also does not require removal of the substrate from the processing chamber. Thus a much simpler method for forming metal contacts on the top and bottom of a mesa during the fabrication of semiconductor devices is provided, and one which includes less chance of contamination of the devices.
While I have shown and described specific embodiments of the present invention, further modifications and improvements will occur to those skilled in the art. I desire it to be understood, therefore, that this invention is not limited to the particular forms shown and I intend in the appended claims to cover all modifications that do not depart from the spirit and scope of this invention. | A method of forming isolated metal contacts during fabrication of semiconductor devices including blanket forming contact metal on a semiconductor device having a mesa structure with a first layer overlying an upper surface, a second layer overlying a lower surface and a third, substantially thinner layer overlying the sidewall therebetween. The contact metal is blanket oxidized using deep ultra violet light until the third layer is substantially completely oxidized thereby electrically isolating the first layer from the second layer. | Summarize the key points of the given patent document. | [
"FIELD OF THE INVENTION The present invention pertains to the fabrication of semiconductor devices and more specifically to improved methods of forming contact metal during semiconductor device fabrication.",
"BACKGROUND OF THE INVENTION In the semiconductor field it is common to place contact metal on semiconductor device by evaporation.",
"In semiconductor devices having a mesa structure, a metal contact is generally placed at the top and bottom of the mesa.",
"Typically, contact isolation is required between the top and bottom of the mesa.",
"Isolating contacts can be difficult and time consuming, and is commonly achieved through multiple evaporations.",
"Even when the mesa walls are near vertical, a small amount of metal can be deposited on the sidewalls.",
"This small amount of deposited metal is sufficient to act as a short between top and bottom contact metal.",
"Therefore, to prevent the formation of shorts, conventional lithographic techniques are employed to define top and bottom contact regions.",
"A plurality of steps are required, including forming a mask using lithographic techniques.",
"During the etching and/or mask removal processes, the material of the semiconductor device has a high likelihood of being contaminated by the etchant, which contamination greatly reduces the life of the device, the operating characteristics of the device, and the reliability of the device.",
"Further, the etching process severely damages semiconductor material adjacent the etched areas which further reduces life, operating characteristics, and reliability.",
"Also, etching processes are very time consuming and difficult to perform.",
"In addition to the etching problems, the lithographic processes require many interspersed growing, masking and etching steps which greatly complicate and lengthen the process.",
"For example, when metal is deposited, the wafers must be placed in a processing chamber.",
"Each time the wafer must be etched and/or masked, it must be removed from the chamber, resulting in large amounts of preparation time for each step.",
"Also, each time wafers are removed from a chamber and subsequently replaced, the opening and preparation of the chamber (as well as the processing of the wafer) is an opportunity for additional impurities and contaminants to be introduced to the wafer.",
"Accordingly, it would be highly desirable to provide a single step process for forming metal contacts on the top and bottom of a mesa.",
"It is a purpose of the present invention to provide a method for forming metal contacts on the top and bottom of a mesa without the use of lithography.",
"It is another purpose of the present invention to provide a method for forming metal contacts on the top and bottom of a mesa during the fabrication of semiconductor devices which does not require removal of the substrate from the processing chamber.",
"It is a further purpose of the present invention to provide a method for forming metal contacts on the top and bottom of a mesa during the fabrication of semiconductor devices which is much simpler and includes less chance of contamination of the devices.",
"SUMMARY OF THE INVENTION The above problems and others are at least partially solved and the above purposes and others are realized in a method of forming isolated metal contacts during fabrication of semiconductor devices including blanket forming contact metal on a semiconductor device having a mesa structure with a first layer overlying an upper surface, a second layer overlying a lower surface and a third, substantially thinner layer overlying the sidewall therebetween.",
"The contact metal is blanket oxidized using deep ultra violet light until the third layer is substantially completely oxidized thereby electrically isolating the first layer from the second layer.",
"BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings, in which: FIG. 1 is a simplified sectional view of a mesa structure of a semiconductor device with contact metal formed thereon in accordance with the present invention;",
"and FIG. 2 is a simplified sectional view of the mesa structure of FIG. 1 with electrically isolated contacts.",
"DESCRIPTION OF THE PREFERRED EMBODIMENT Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is directed to FIG. 1 which illustrates a semiconductor device 10 having a mesa structure 12.",
"Semiconductor device 10 is not illustrated in detail, other than including mesa structure 12 having an upper surface 13, a lower surface 14, and a sidewall 15 extending therebetween in a substantially upright orientation.",
"Other details are not included as they are not relevant to the present invention.",
"However, it will be understood that semiconductor device 10 can include a great many various structures and layers used in semiconductor devices well known to those skilled in the art and employed with a mesa structure, such as FETs.",
"Many semiconductor devices require metal contacts which are isolated from one another, such as in gate, source and drain, etc.",
"In the present embodiment, contact metal is blanket deposited over the entire mesa structure forming a layer 17 overlying upper surface 13, a layer 18 overlying lower surface 14 and a layer 19 overlying sidewall 15.",
"This process is preferably performed in a single step by evaporation.",
"As will be readily understood, layers 17 and 18 will be substantially uniform and have a thickness of approximately 1000 Å.",
"It will also be understood that layers 17 and 18 may be thinner or thicker as required to provide a good contact.",
"Layer 19 will be substantially thinner than layers 17 and 18, as sidewall 15 is substantially upright between surfaces 13 and 14.",
"Because sidewall 15 is upright, less contact material is deposited thereon.",
"Some contact metal will deposit on sidewall 15 even when near vertical.",
"Layer 19 is preferably in the range of approximately 10-20 Å thick.",
"The contact metal used is selected from III-V materials.",
"In this specific embodiment, aluminum is employed as the contact metal.",
"III-V material such as aluminum is employed because it has been found to oxidize under deep ultra violet radiation in the presence of oxygen.",
"Oxygen may be supplied in a pure form or air such as the ambient atmosphere.",
"Turning now to FIG. 2, in a preferred embodiment semiconductor device 10 and mesa structure 12 are exposed to an ultraviolet source in ambient conditions (air), i.e. no special chamber, etc.",
", to expose the contact metal (aluminum) to a combination of ultraviolet rays and ozone.",
"The UV-ozone process grows a dense layer of oxide on III-V material such as aluminum by converting the aluminum to aluminum oxide.",
"The term "deep ultraviolet"",
"refers to light in the ultraviolet range, generally with a wavelength in the range of 180 to 250 nanometers.",
"In the present specific example, it is believed that the 185 nm light generates ozone due to optical excitation.",
"Therefore, excitation wavelength that is most suitable for efficient ozone generation is also the most efficient to use, although virtually any ultraviolet light will produce the desired result.",
"The exposure to light can be performed in an aligner or stepper to define sharp features or, as in the present embodiment, performed under a lamp to provide a blanket oxidation of the III-V material.",
"Because blanket oxidation is used, the contact metal of layers 17, 18 and 19 will oxidize at a substantially uniform rate.",
"Since layer 19 is substantially thinner than layers 17 and 18, it can be substantially entirely converted into an insulator layer 20, such as aluminum oxide, while leaving the majority of layers 17 and 18 in the original form with a thin layer 22 and 23 of oxide formed thereon.",
"Thus, layers 17 and 18 are effectively isolated from each other by aluminum oxide layer 20, an insulator.",
"It has been found that not only are the contacts isolated, but device performance is also enhanced.",
"For example, the UV oxide could oxidize the top surface of GaAs, particularly in the gate region of a FET, and reduce leakage current.",
"This happens by the growth of the oxide as Ga 2 O 3 and the resultant tying of the dangling bonds on the surface.",
"If the surface layer contains carbon, the surface oxidation process will prevent leakage current or other effects that might hurt device performance.",
"Thus, a single step process for forming isolated metal contacts on an upper surface and a lower surface of a mesa is provided.",
"The method of forming metal contacts on the upper surface and lower surface of a mesa during the fabrication of semiconductor devices does not use of lithography and also does not require removal of the substrate from the processing chamber.",
"Thus a much simpler method for forming metal contacts on the top and bottom of a mesa during the fabrication of semiconductor devices is provided, and one which includes less chance of contamination of the devices.",
"While I have shown and described specific embodiments of the present invention, further modifications and improvements will occur to those skilled in the art.",
"I desire it to be understood, therefore, that this invention is not limited to the particular forms shown and I intend in the appended claims to cover all modifications that do not depart from the spirit and scope of this invention."
] |
BACKGROUND OF THE INVENTION
In our U.S. Pat. Nos. 3,773,925 and 3,780,173, we have described and claimed a new antibiotic, which we have called partricin, and its methyl ester.
Partricin is a polyenic antibiotic and, more precisely, is a heptaenic substance which can be obtained by fermentation of a new strain of Streptomyces aureofaciens, filed at the United States Department of Agriculture, Agricultural Research Services, Northern Utilisation Research and Development Division, Peoria (USA), which has been assigned the number NRRL 3878. This antibiotic exhibits a marked antifungal activity, particularly against certain pathogenic strains of Candida albicans, and also has a marked anti-protozoal activity, especially against Trichomonas vaginalis.
The partricin methyl ester is obtained by treating a solution of partricin in an appropriate organic solvent with a slight excess of diazomethane, in order to prevent the possible formation of products with higher degrees of reaction, and then leaving the reaction mixture to stand for a few hours (or at least until the evolution of nitrogen has ceased, this being proof that the reaction has taken place). The reaction product is then precipitated by adding an appropriate solvent. This semi-synthetic antibiotic, partricin methyl ester, also exhibits a marked antifungal activity, especially against certain pathogenic strains of Candida albicans and against protozoa, i.e. Trichomonas. It also has the advantage over the parent antibiotic, partricin, of having a reduced degree of toxicity.
Both these antibiotics are, however, practically insoluble in water; in our above-mentioned United States Patent Specifications, in relation to the toxocological properties of partricin and methyl partricin, we mentioned their therapeutic use for many human and animal diseases caused by fungi and protozoa. We described the use of these antibiotics by topical application in the form of ointments, liniments or creams for dermatological purposes, or in the form of inserts or suppositories (effervescent or ordinary) for endovaginal use against mycoses and protozoal infections. Furthermore, because of their low solubility in water, we indicated, for general use, the administration thereof by the oral route only for combating mycotic or protozoal intestinal infections: since these antibiotics are not absorbed, they can only exert their activity in the intestines.
Literature, however, amply describes infections of a generalised mycotic or protozoal type (for example pulmonary mycosis) in which, obviously, administration by the topical route would be ineffective.
The two new polyenic antibiotics have a good solubility in dimethyl sulphoxide, dimethyl acetamide and pyridine (i.e. in solvents not used in the therapeutic field for parenteral administration), whereas they are practically insoluble in water and in the common organic solvents. As we have already mentioned, their insolubility in water constitutes a marked limitation.
Therefore, it is an object of the present invention to render partricin and partricin methyl ester water-soluble so as to permit administration thereof by the parenteral or oral route and to guarantee blood antibiotic levels which are high enough to combat generalised mycotic or protozoal infections. Furthermore, this water-solubilisation is to be obtained without impairing the anti-fungal and antiprotozoal activity of partricin and methyl partricin.
During our researches we have found that certain anionic and cationic surfactants, for example the nontoxic salts of sulphated aliphatic hydrocarbons, such as sodium lauryl sulphate and sodium tetradecyl sulphate, as well as benzalkonium chlorides and the like are able to make partricin, as well as partricin methyl ester, soluble in water. Of all the surfactants which we have tested, sodium lauryl sulphate shows the best water-solubilising properties.
SUMMARY OF THE INVENTION
Thus, according to the present invention, there is provided a water-soluble pharmaceutical composition, comprising partricin and/or partricin methyl ester in admixture with at least one anionic and/or cationic surfactant.
DETAILED DESCRIPTION OF THE INVENTION
The solubility in water of partricin and the partricin methyl ester in the presence of the surfactant depends upon the physical form of the antibiotic, maximum solubility being obtained when the active substance is in an amorphous form. This is obtained by dissolving the antibiotic in dimethyl sulphoxide and precipitating it with water or, in the case of partricin, by dissolving it in a 1:1 mixture of water and acetone at pH 11 obtained by adding triethylamine and precipitating the partricin by lowering the pH to about 5 by adding hydrochloric acid.
The solubility in water of partricin increases with the increase of the concentration of sodium lauryl sulphate, up to a maximum concentration of surfactant of 3%.
In the case of partricin methyl ester, too, the higher is the concentration of the surfactant, the higher is the solubility in water, up to a maximum concentration of 4% of sodium lauryl sulphate.
Since the solubility in water of the two antibiotics does not increase proportion-wise with the concentration in surfactant, the antibiotic/surfactant weight ratio which gives hydrosoluble compounds with the highest microbiological activity is preferably about 1 to 10, more preferably about 1 to 5 and most preferably about 1 to 2.
The antibiotic/surfactant complexes thus solubilised can be isolated from their aqueous solution by lyophilisation or by precipitation with, for example, sodium chloride. The complexes thus obtained are very soluble in water and in dimethyl sulphoxide but are practically insoluble in acetone, ether and lower alcohols.
It is interesting to note that the ultra-violet spectra of the solutions in dimethyl sulphoxide and ethanol of the hydrosoluble compounds have the same behaviour as those of the starting partricin and methyl ester thereof in the same solvents, whereas the ultra-violet spectra of the aqueous solutions of the hydrosoluble products have a much different behaviour.
The aqueous solutions of the antibiotic/surfactant complexes are physically stable.
Solutions of methyl partricin/sodium lauryl sulphate at concentrations of 2000 γ/ml activity kept at +4°C. for 24 hours, do not show any loss of microbiological activity, while the solutions of partricin/sodium lauryl sulphate are microbiologically less stable.
The following Examples are given for the purpose of illustrating the present invention:
EXAMPLE 1
3 g. crystalline partricin methyl ester (1 mg = 1000 Units) are dissolved in 60 ml. dimethyl sulphoxide; after stirring for 10 minutes, the solution is poured into 360 ml. water, containing 0.5% by weight sodium chloride, to precipitate the partricin methyl ester.
The amorphous precipitate thus obtained is filtered on a porous filter G 4 and washed with water; the wet product is then suspended in 30 ml. water and added to 270 ml. water containing 6 g. sodium lauryl sulphate.
After stirring for about 1 hour, solution is complete. The dissolved product can be isolated:
a. by lyophilisation, or
b. by adding to the solution 10% by weight sodium chloride.
The precipitate obtained is filtered and dried, thus yielding 8.8 g. of product which is soluble in water and has an activity of 320 Units/mg.
EXAMPLE 2
5 g. crystalline partricin (1 mg = 1000 Units) are dissolved in 100 ml. dimethyl sulphoxide. The resulting solution is poured into 600 ml. of a 0.5% by weight aqueous solution of sodium chloride to precipitate the partricin which is filtered off and washed with water. The precipitate is suspended in 50 ml. water and added to 450 ml. water containing 10 g. sodium lauryl sulphate.
The suspension is stirred for about one hour until solution is complete. The product can be obtained in a solid form by:
a. lyophilisation, or
b. adding to the solution 75 g. sodium chloride, filtering and drying the precipitate in a vacuum at 40°C.
Yield: 14.6 g. of hydrosoluble product with an activity of 280 Units/mg.
EXAMPLE 3
2 g. Partricin are dissolved in 40 ml. dimethyl sulphoxide; the solution is slowly poured into 240 ml. water, containing 0.5% by weight of sodium chloride to precipitate the partricin. The amorphous precipitate thereby obtained is filtered off, washed with water and resuspended in 20 ml. water. The suspension obtained is poured into 180 ml. water containing 6 g. sodium tetradecyl sulphate. After stirring for 1 hour, the product is filtered and lyophilised.
EXAMPLE 4
3 g. Methyl partricin are dissolved in 60 ml. dimethyl sulphoxide; the solution is slowly poured into 360 ml. water, containing 0.5% by weight sodium chloride to precipitate the methyl partricin. An amorphous precipitation is obtained, which is filtered off and suspended in 30 ml. water. The fine suspension obtained is added to 270 ml. water containing 9 g. sodium tetradecyl sulphate. After stirring for one hour, it is filtered and lyophilised.
EXAMPLE 5
1 g. Partricin is dissolved in 20 ml. dimethyl sulphoxide. The solution is poured into 120 ml. water containing 0.5% by weight sodium chloride. The amorphous precipitate is filtered off, washed with water and suspended in 10 ml. water. The suspension is added to 100 ml. water containing 4 g. 50% benzalkonium chloride. After stirring for one hour, it is filtered and lyophilised.
EXAMPLE 6
Example 5 is repeated but using the methyl ester of partricin.
EXAMPLE 7
4 g. Partricin are suspended in 240 ml. acetone/water (1:1). Triethylamine is added to adjust the pH to 11 and the mixture then stirred for 30 minutes. After filtration, the filtrate is adjusted cautiously and with external cooling to pH 5 by adding concentrated hydrochloric acid. The amorphous precipitate obtained is filtered off, washed with water and suspended in 40 ml. water. The suspension is poured into 350 ml. water containing 8 g. sodium lauryl sulphate. After stirring for one hour, it is filtered and lyophilised or is precipitated with sodium chloride.
The present invention also provides pharmaceutical compositions, which can be administered orally or parenterally, which additionally contain a solid or liquid pharmaceutical carrier.
Solid compositions for oral, rectal or vaginal administration include compressed tablets, effervescent tablets, pills, dispersible powders, capsules, granules and suppositories. In such solid compositions, the active material complex is admixed with at least one inert diluent, such as calcium carbonate, starch, alginic acid or lactose. The compositions may also comprise, as is normal practice, additional substances other than inert diluents, for example, lubricating agents, such as magnesium stearate.
Liquid compositions for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs containing inert diluents commonly used in the art, such as water and liquid paraffin. Besides inert diluents, such compositions may also comprise adjuvants, such as wetting and suspension agents and sweetening and flavouring agents.
The compositions according to the present invention, for oral administration, include capsules of absorbable material, such as gelatine, containing the active material, with or without the addition of diluents or excipients.
Preparations according to the present invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions or emulsions. Examples of non-aqueous solvents or suspending media include propylene glycol, polyethylene glycol, vegetable oils, such as olive oil, and injectable organic esters, such as ethyl oleate. These compositions may also contain adjuvants, such as wetting, emulsifying and dispersing agents. They may be sterilised, for example, by filtration through bacteria-retaining filters, by incorporation into the compositions of sterilising agents, by irradiation or by heating. They may also be produced in the form of sterile solid compositions, which can be dissolved in sterile water or some other sterile injectable medium immediately before use.
The percentage of active complex in the compositions of the present invention may be varied, it being necessary that it should constitute a proportion such that a suitable dosage for the desired therapeutic effect shall be obtained. In the case of dosage units for oral administration, each unit can contain up to 2 g. of partricin or up to 3 g. of partricin methyl ester. In the case of compositions for topical, vaginal or rectal administration, the content of complex can be up to about 0.06% by weight.
Examples of pharmaceutical compositions containing the polyene antibiotic include the following:
EXAMPLE 8
Ointment
Composition:
the product of Example 1 0.5 g.alcoholic fats 60 g.lanolin 15 g.polyethylene glycol 1540 monostearate ad 100 g.
EXAMPLE 9
Liniment
Composition:
the product of Example 3 0.5 g.dimethylacetamide 5 g.anhydrous lanolin 15 g.cetyl alcohol 30 g.oleyl alcohol 15 g.sorbitan trioleate 10 g.polyethylene glycol 1540 monostearate 24 g.
EXAMPLE 10
Vaginal suppositories
each vaginal suppository contains:
the product of Example 7 5 mg.dimethyl acetamide 50 mg.polyethylene glycol 1540 monostearate 1.35 g.cetyl alcohol 0.500 g.
EXAMPLE 11
Vaginal suppositories
each vaginal suppository contains:
the product of Example 1 25 mg.dimethyl acetamide 50 mg.polyethylene glycol 1540 monostearate 1.35 g.cetyl aLcohol 0.500 g.
The pharmaceutical compositions illustrated in Examples 8 to 11 above show valuable anti-fungal and anti-protozoal activity when administered to humans. | The present invention provides a water-soluble pharmaceutical composition, comprising partricin and/or partricin methyl ester in admixture with at least one anionic and/or cationic surfactant. | Summarize the information, clearly outlining the challenges and proposed solutions. | [
"BACKGROUND OF THE INVENTION In our U.S. Pat. Nos. 3,773,925 and 3,780,173, we have described and claimed a new antibiotic, which we have called partricin, and its methyl ester.",
"Partricin is a polyenic antibiotic and, more precisely, is a heptaenic substance which can be obtained by fermentation of a new strain of Streptomyces aureofaciens, filed at the United States Department of Agriculture, Agricultural Research Services, Northern Utilisation Research and Development Division, Peoria (USA), which has been assigned the number NRRL 3878.",
"This antibiotic exhibits a marked antifungal activity, particularly against certain pathogenic strains of Candida albicans, and also has a marked anti-protozoal activity, especially against Trichomonas vaginalis.",
"The partricin methyl ester is obtained by treating a solution of partricin in an appropriate organic solvent with a slight excess of diazomethane, in order to prevent the possible formation of products with higher degrees of reaction, and then leaving the reaction mixture to stand for a few hours (or at least until the evolution of nitrogen has ceased, this being proof that the reaction has taken place).",
"The reaction product is then precipitated by adding an appropriate solvent.",
"This semi-synthetic antibiotic, partricin methyl ester, also exhibits a marked antifungal activity, especially against certain pathogenic strains of Candida albicans and against protozoa, i.e. Trichomonas.",
"It also has the advantage over the parent antibiotic, partricin, of having a reduced degree of toxicity.",
"Both these antibiotics are, however, practically insoluble in water;",
"in our above-mentioned United States Patent Specifications, in relation to the toxocological properties of partricin and methyl partricin, we mentioned their therapeutic use for many human and animal diseases caused by fungi and protozoa.",
"We described the use of these antibiotics by topical application in the form of ointments, liniments or creams for dermatological purposes, or in the form of inserts or suppositories (effervescent or ordinary) for endovaginal use against mycoses and protozoal infections.",
"Furthermore, because of their low solubility in water, we indicated, for general use, the administration thereof by the oral route only for combating mycotic or protozoal intestinal infections: since these antibiotics are not absorbed, they can only exert their activity in the intestines.",
"Literature, however, amply describes infections of a generalised mycotic or protozoal type (for example pulmonary mycosis) in which, obviously, administration by the topical route would be ineffective.",
"The two new polyenic antibiotics have a good solubility in dimethyl sulphoxide, dimethyl acetamide and pyridine (i.e. in solvents not used in the therapeutic field for parenteral administration), whereas they are practically insoluble in water and in the common organic solvents.",
"As we have already mentioned, their insolubility in water constitutes a marked limitation.",
"Therefore, it is an object of the present invention to render partricin and partricin methyl ester water-soluble so as to permit administration thereof by the parenteral or oral route and to guarantee blood antibiotic levels which are high enough to combat generalised mycotic or protozoal infections.",
"Furthermore, this water-solubilisation is to be obtained without impairing the anti-fungal and antiprotozoal activity of partricin and methyl partricin.",
"During our researches we have found that certain anionic and cationic surfactants, for example the nontoxic salts of sulphated aliphatic hydrocarbons, such as sodium lauryl sulphate and sodium tetradecyl sulphate, as well as benzalkonium chlorides and the like are able to make partricin, as well as partricin methyl ester, soluble in water.",
"Of all the surfactants which we have tested, sodium lauryl sulphate shows the best water-solubilising properties.",
"SUMMARY OF THE INVENTION Thus, according to the present invention, there is provided a water-soluble pharmaceutical composition, comprising partricin and/or partricin methyl ester in admixture with at least one anionic and/or cationic surfactant.",
"DETAILED DESCRIPTION OF THE INVENTION The solubility in water of partricin and the partricin methyl ester in the presence of the surfactant depends upon the physical form of the antibiotic, maximum solubility being obtained when the active substance is in an amorphous form.",
"This is obtained by dissolving the antibiotic in dimethyl sulphoxide and precipitating it with water or, in the case of partricin, by dissolving it in a 1:1 mixture of water and acetone at pH 11 obtained by adding triethylamine and precipitating the partricin by lowering the pH to about 5 by adding hydrochloric acid.",
"The solubility in water of partricin increases with the increase of the concentration of sodium lauryl sulphate, up to a maximum concentration of surfactant of 3%.",
"In the case of partricin methyl ester, too, the higher is the concentration of the surfactant, the higher is the solubility in water, up to a maximum concentration of 4% of sodium lauryl sulphate.",
"Since the solubility in water of the two antibiotics does not increase proportion-wise with the concentration in surfactant, the antibiotic/surfactant weight ratio which gives hydrosoluble compounds with the highest microbiological activity is preferably about 1 to 10, more preferably about 1 to 5 and most preferably about 1 to 2.",
"The antibiotic/surfactant complexes thus solubilised can be isolated from their aqueous solution by lyophilisation or by precipitation with, for example, sodium chloride.",
"The complexes thus obtained are very soluble in water and in dimethyl sulphoxide but are practically insoluble in acetone, ether and lower alcohols.",
"It is interesting to note that the ultra-violet spectra of the solutions in dimethyl sulphoxide and ethanol of the hydrosoluble compounds have the same behaviour as those of the starting partricin and methyl ester thereof in the same solvents, whereas the ultra-violet spectra of the aqueous solutions of the hydrosoluble products have a much different behaviour.",
"The aqueous solutions of the antibiotic/surfactant complexes are physically stable.",
"Solutions of methyl partricin/sodium lauryl sulphate at concentrations of 2000 γ/ml activity kept at +4°C.",
"for 24 hours, do not show any loss of microbiological activity, while the solutions of partricin/sodium lauryl sulphate are microbiologically less stable.",
"The following Examples are given for the purpose of illustrating the present invention: EXAMPLE 1 3 g. crystalline partricin methyl ester (1 mg = 1000 Units) are dissolved in 60 ml.",
"dimethyl sulphoxide;",
"after stirring for 10 minutes, the solution is poured into 360 ml.",
"water, containing 0.5% by weight sodium chloride, to precipitate the partricin methyl ester.",
"The amorphous precipitate thus obtained is filtered on a porous filter G 4 and washed with water;",
"the wet product is then suspended in 30 ml.",
"water and added to 270 ml.",
"water containing 6 g. sodium lauryl sulphate.",
"After stirring for about 1 hour, solution is complete.",
"The dissolved product can be isolated: a. by lyophilisation, or b. by adding to the solution 10% by weight sodium chloride.",
"The precipitate obtained is filtered and dried, thus yielding 8.8 g. of product which is soluble in water and has an activity of 320 Units/mg.",
"EXAMPLE 2 5 g. crystalline partricin (1 mg = 1000 Units) are dissolved in 100 ml.",
"dimethyl sulphoxide.",
"The resulting solution is poured into 600 ml.",
"of a 0.5% by weight aqueous solution of sodium chloride to precipitate the partricin which is filtered off and washed with water.",
"The precipitate is suspended in 50 ml.",
"water and added to 450 ml.",
"water containing 10 g. sodium lauryl sulphate.",
"The suspension is stirred for about one hour until solution is complete.",
"The product can be obtained in a solid form by: a. lyophilisation, or b. adding to the solution 75 g. sodium chloride, filtering and drying the precipitate in a vacuum at 40°C.",
"Yield: 14.6 g. of hydrosoluble product with an activity of 280 Units/mg.",
"EXAMPLE 3 2 g. Partricin are dissolved in 40 ml.",
"dimethyl sulphoxide;",
"the solution is slowly poured into 240 ml.",
"water, containing 0.5% by weight of sodium chloride to precipitate the partricin.",
"The amorphous precipitate thereby obtained is filtered off, washed with water and resuspended in 20 ml.",
"water.",
"The suspension obtained is poured into 180 ml.",
"water containing 6 g. sodium tetradecyl sulphate.",
"After stirring for 1 hour, the product is filtered and lyophilised.",
"EXAMPLE 4 3 g. Methyl partricin are dissolved in 60 ml.",
"dimethyl sulphoxide;",
"the solution is slowly poured into 360 ml.",
"water, containing 0.5% by weight sodium chloride to precipitate the methyl partricin.",
"An amorphous precipitation is obtained, which is filtered off and suspended in 30 ml.",
"water.",
"The fine suspension obtained is added to 270 ml.",
"water containing 9 g. sodium tetradecyl sulphate.",
"After stirring for one hour, it is filtered and lyophilised.",
"EXAMPLE 5 1 g. Partricin is dissolved in 20 ml.",
"dimethyl sulphoxide.",
"The solution is poured into 120 ml.",
"water containing 0.5% by weight sodium chloride.",
"The amorphous precipitate is filtered off, washed with water and suspended in 10 ml.",
"water.",
"The suspension is added to 100 ml.",
"water containing 4 g. 50% benzalkonium chloride.",
"After stirring for one hour, it is filtered and lyophilised.",
"EXAMPLE 6 Example 5 is repeated but using the methyl ester of partricin.",
"EXAMPLE 7 4 g. Partricin are suspended in 240 ml.",
"acetone/water (1:1).",
"Triethylamine is added to adjust the pH to 11 and the mixture then stirred for 30 minutes.",
"After filtration, the filtrate is adjusted cautiously and with external cooling to pH 5 by adding concentrated hydrochloric acid.",
"The amorphous precipitate obtained is filtered off, washed with water and suspended in 40 ml.",
"water.",
"The suspension is poured into 350 ml.",
"water containing 8 g. sodium lauryl sulphate.",
"After stirring for one hour, it is filtered and lyophilised or is precipitated with sodium chloride.",
"The present invention also provides pharmaceutical compositions, which can be administered orally or parenterally, which additionally contain a solid or liquid pharmaceutical carrier.",
"Solid compositions for oral, rectal or vaginal administration include compressed tablets, effervescent tablets, pills, dispersible powders, capsules, granules and suppositories.",
"In such solid compositions, the active material complex is admixed with at least one inert diluent, such as calcium carbonate, starch, alginic acid or lactose.",
"The compositions may also comprise, as is normal practice, additional substances other than inert diluents, for example, lubricating agents, such as magnesium stearate.",
"Liquid compositions for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs containing inert diluents commonly used in the art, such as water and liquid paraffin.",
"Besides inert diluents, such compositions may also comprise adjuvants, such as wetting and suspension agents and sweetening and flavouring agents.",
"The compositions according to the present invention, for oral administration, include capsules of absorbable material, such as gelatine, containing the active material, with or without the addition of diluents or excipients.",
"Preparations according to the present invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions or emulsions.",
"Examples of non-aqueous solvents or suspending media include propylene glycol, polyethylene glycol, vegetable oils, such as olive oil, and injectable organic esters, such as ethyl oleate.",
"These compositions may also contain adjuvants, such as wetting, emulsifying and dispersing agents.",
"They may be sterilised, for example, by filtration through bacteria-retaining filters, by incorporation into the compositions of sterilising agents, by irradiation or by heating.",
"They may also be produced in the form of sterile solid compositions, which can be dissolved in sterile water or some other sterile injectable medium immediately before use.",
"The percentage of active complex in the compositions of the present invention may be varied, it being necessary that it should constitute a proportion such that a suitable dosage for the desired therapeutic effect shall be obtained.",
"In the case of dosage units for oral administration, each unit can contain up to 2 g. of partricin or up to 3 g. of partricin methyl ester.",
"In the case of compositions for topical, vaginal or rectal administration, the content of complex can be up to about 0.06% by weight.",
"Examples of pharmaceutical compositions containing the polyene antibiotic include the following: EXAMPLE 8 Ointment Composition: the product of Example 1 0.5 g.alcoholic fats 60 g.lanolin 15 g.polyethylene glycol 1540 monostearate ad 100 g. EXAMPLE 9 Liniment Composition: the product of Example 3 0.5 g.dimethylacetamide 5 g.anhydrous lanolin 15 g.cetyl alcohol 30 g.oleyl alcohol 15 g.sorbitan trioleate 10 g.polyethylene glycol 1540 monostearate 24 g. EXAMPLE 10 Vaginal suppositories each vaginal suppository contains: the product of Example 7 5 mg.",
"dimethyl acetamide 50 mg.",
"polyethylene glycol 1540 monostearate 1.35 g.cetyl alcohol 0.500 g. EXAMPLE 11 Vaginal suppositories each vaginal suppository contains: the product of Example 1 25 mg.",
"dimethyl acetamide 50 mg.",
"polyethylene glycol 1540 monostearate 1.35 g.cetyl aLcohol 0.500 g. The pharmaceutical compositions illustrated in Examples 8 to 11 above show valuable anti-fungal and anti-protozoal activity when administered to humans."
] |
BACKGROUND OF INVENTION
[0001] Professional cutting boards for food preparation lack optimum means for, at least, (a) control of food for accurate manual slicing in various directions for proper preparation and pleasing presentation; (b) proper collection of food juices generated during slicing for disposal or reuse; and (c) positive ventilation of the immediate slicing area to minimize a food preparer's exposure to airborne irritants. It is the object of the invention to provide these means. Further objects and advantages will become evident as described in more detail below.
BRIEF DESCRIPTION OF THE INVENTION
[0002] The instant invention is a rigid, flat, elongate cutting board made of material suitable to back the manual cutting of food, that is, to provide a durable and easily-cleaned surface that is compatible with knife blades. At least a portion of the cutting surface is provided with a printed or inlaid grid pattern as an aid to cutting reproducible thicknesses of foods items.
[0003] Vertical holes are drilled through the board at the intersection of the grid lines to permit drainage of food juices through the board into a tray optionally mounted below the board. A vertical rigid food guide and a vertical rigid knife guard are also provided, each having dowels depending therefrom which can be inserted into the top openings of the vertical holes for support.
[0004] The cutting board is also provided with means for holding the base of a blower, in a plurality of orientations that allow the blower to blow air directly across the food as it is being cut and away from the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of the preferred embodiment of the instant invention as viewed from above the right side of the invention.
[0006] FIG. 2 is both a rear end view and a front end view of the preferred embodiment.
[0007] FIG. 3 is a perspective view of the preferred embodiment as viewed from below the right side of the invention.
[0008] FIG. 4 is a right side view of the preferred embodiment.
[0009] FIG. 5 depicts a typical use of the preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Referring now to the drawings, in which like elements are represented by like indicia in each drawing, FIG. 1 is a perspective view of the preferred embodiment of the instant invention as viewed from above the right side 110 of the invention. A rigid, flat, elongate cutting board 1 , made of material suitable to back the manual cutting of food, has an upper surface 2 upon which to cut food, at least a portion of which is provided with a printed or inlaid grid pattern 3 as an aid to cutting reproducible thicknesses of food items.
[0011] In this embodiment, the cutting board 1 is rectangular, but in other embodiments, other shapes such as, but not limited to, oval may be used. Vertical holes, e.g., 4 , 5 , 6 , 7 , 8 , 9 and 10 are drilled through the board at the intersection of lines in the grid pattern 3 . The grid pattern shown in this embodiment is square, but in other embodiments, other patterns such as, but not limited to, triangular may be used. A vertical rigid food guide 11 and a vertical rigid knife guard 12 are also provided, each having dowels 13 , 14 , 15 , 16 and 17 depending therefrom which are gripped by the top openings of the vertical holes 4 , 5 , 6 , 7 , and 8 , respectively, for support. The number and positioning of the dowels may be changed within the scope of this invention so long as they provide secure support for the food guide 11 and the knife guard 12 when food and a knife are pressed against them.
[0012] Holes 9 and 10 and all the rest of the holes at the grid points remain open to permit drainage of food juices through the board into a tray optionally mounted below the board (see FIG. 3 ). It is important for hygiene that all of the drain holes be sufficiently large and smooth-bored for complete cleaning.
[0013] A blower 18 attached to blower support means (not visible in this view) at the front end 19 of the board 1 is aimed to blow air directly at high velocity lengthwise across the upper surface 2 . Unlike most kitchen vents, the blower 18 uses air emitting from the positive side of the blower to move air contaminated with food odors and irritants positively away from a user standing at either right side 110 or left side 111 of the board. The typical draft vent of most kitchens and some ranges is effective at moving large volumes of air from a food preparation environment, but applies negligible velocity to the air adjacent to food being cut and the person cutting the food.
[0014] In this embodiment, the blower 18 is preferably articulable vertically and horizontally so that it may be optimally aimed by the user.
[0015] The lower surface of the board is provided with a blower support means (see FIGS. 2 and 3 ) for holding the base of the blower both at the front end 19 and the rear end 112 . Placement of the blower support means at other locations along the periphery of the board are within the scope of this invention.
[0016] The food guide 11 in this embodiment is elongate both in height and in the lengthwise direction of the cutting board 1 . This is to ensure that it will resist the sidewards pressure on food by the user even if the item to be cut is large. The knife guard is elongate in height but is preferably not elongate in length because it is meant to provide a stop against horizontal motion of the knife blade without significantly constraining the width of the food being cut.
[0017] In this embodiment, both the forward food guide end 113 and the knife guard 12 are shown rounded so as not to grate on the blade of a knife, but in other embodiments either or both may be planar or multifaceted in the vertical direction.
[0018] FIG. 2 is both a rear end view and a front end view of the preferred embodiment minus the blower 18 (see FIG. 1 ). Taking FIG. 2 as a rear end view, it shows the rear end 112 of the cutting board 1 resting on a board support 20 . The board end support 20 may be one piece transverse to the length of the cutting board 1 , as shown, or it may be more than one piece so long as the cutting board 1 is stably supported on a flat surface 21 (shown in dashed lines as environmental structure). One or more resilient pads 22 may also be provided to protect the surface 21 and keep the cutting board 1 from rocking. A blower support means 23 is provided here, taking the form in this embodiment of a pair of slots 23 extending inwardly through the board end support 20 from the rear end 112 parallel to the length of the cutting board 1 . The front end view in this embodiment is identical to the rear end view with the front end indicium 19 substituted for the rear end indicium 112 .
[0019] FIG. 3 is a perspective view of the preferred embodiment as viewed from below the right side 110 of the invention. It shows the fan 18 having blower attachment means 30 attached to the blower support means 23 . In this preferred embodiment, the blower attachment means takes the form of a pair of elongate tangs inserted into the pair of slots 23 . The slots 23 may extend through the board end support 20 and into extensions 31 attached to the lower surface 32 of the cutting board 1 for rigidity of support. Note that in this embodiment, the extensions 31 are made narrow enough that they fall between adjacent rows of drain holes exemplified by drain holes 33 and 34 .
[0020] Drain holes 8 and 10 in this figure correspond with drain holes 8 and 10 in FIG. 1 , illustrating that the drain holes pass all the way through the cutting board 1 .
[0021] Other embodiments of this invention may utilize one or more alternatively-shaped slots in the board end support 20 , so dimensioned as to provide adequate support for the blower 18 without extensions 31 . It is also possible within the scope of this invention to have the slots 23 made in the front end 19 of the cutting board 1 , preferably positioned so that the corresponding blower attachment means does not obstruct any of the drain holes.
[0022] A juice collection tray 35 is provided in this preferred embodiment. It comprises a preferably square collection portion 36 surrounded by a support lip 37 . The support lip 37 cooperates with transverse support grooves 38 (only one visible in this view) so that the tray 35 may be slid in and out in the direction of the arrows A underneath the cutting board 1 . For this purpose, the depth of the collection portion 36 must be less than the vertical distance between the lower extremity of the resilient pads 22 and the lower surface 32 of the cutting board 1 . Other means for supporting the tray 35 under the cutting board 1 that are currently known in the art are within the scope of this invention.
[0023] This figure also shows a center board support 39 , the need for which depends on the length and rigidity of the cutting board 1 . Like the board end supports 20 , this support may consist alternatively within the scope of this invention as a plurality of supports. FIG. 4 is a right side view of the preferred embodiment minus the blower attachment. It shows all of the elements identified in the other figures that are visible in this view. The left side view of this embodiment is a mirror image of this right side view with the left side indicium 111 substituted for the right side indicium 110 .
[0024] FIG. 5 depicts a typical use of the preferred embodiment. The food guide 11 has been pressed downwardly into the cutting board 1 so that the dowels fit into their corresponding holes (see FIG. 1 ). Food to be sliced 50 (in this case an onion, shown in dashed lines to indicate environmental structure) has been placed against the right side 51 of the food guide 11 , and the knife guard 12 has been pressed downwardly on the opposite side of the food so that its dowel (again refer to FIG. 1 ) fits into a corresponding hole. The position of the knife guard 12 relative to the food guide 11 determines the angle of the cut. When the edge 52 of the knife 53 (again shown in dashed lines to indicate environmental structure) is placed against the food guide 11 at point 54 and against the knife guard 12 at point 55 , the knife 53 will cut the food 50 along a straight line between them.
[0025] In embodiments, the cutting board 1 may also have a cutout portion through it (not shown) which would allow waste to be pushed off the surface. Embodiments may also include a food pushing device (not shown) for pushing food forwardly between the food guide 11 and the knife guard 12 . | A cutting board for food preparation is equipped with a blower which can be mounted on the board in various positions to keep airborne irritants from the cut food away from the breathing zone of the preparer. A novel food guide and knife guard combination may be mounted on a grid of locations on the upper surface of the cutting board. The grid points have holes drilled through the board which provide a means for mounting the food guide and the knife guard as well as a means for draining juices from the cutting surface. A removable juice collection tray is mounted below the cutting board. | Identify the most important claim in the given context and summarize it | [
"BACKGROUND OF INVENTION [0001] Professional cutting boards for food preparation lack optimum means for, at least, (a) control of food for accurate manual slicing in various directions for proper preparation and pleasing presentation;",
"(b) proper collection of food juices generated during slicing for disposal or reuse;",
"and (c) positive ventilation of the immediate slicing area to minimize a food preparer's exposure to airborne irritants.",
"It is the object of the invention to provide these means.",
"Further objects and advantages will become evident as described in more detail below.",
"BRIEF DESCRIPTION OF THE INVENTION [0002] The instant invention is a rigid, flat, elongate cutting board made of material suitable to back the manual cutting of food, that is, to provide a durable and easily-cleaned surface that is compatible with knife blades.",
"At least a portion of the cutting surface is provided with a printed or inlaid grid pattern as an aid to cutting reproducible thicknesses of foods items.",
"[0003] Vertical holes are drilled through the board at the intersection of the grid lines to permit drainage of food juices through the board into a tray optionally mounted below the board.",
"A vertical rigid food guide and a vertical rigid knife guard are also provided, each having dowels depending therefrom which can be inserted into the top openings of the vertical holes for support.",
"[0004] The cutting board is also provided with means for holding the base of a blower, in a plurality of orientations that allow the blower to blow air directly across the food as it is being cut and away from the user.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0005] FIG. 1 is a perspective view of the preferred embodiment of the instant invention as viewed from above the right side of the invention.",
"[0006] FIG. 2 is both a rear end view and a front end view of the preferred embodiment.",
"[0007] FIG. 3 is a perspective view of the preferred embodiment as viewed from below the right side of the invention.",
"[0008] FIG. 4 is a right side view of the preferred embodiment.",
"[0009] FIG. 5 depicts a typical use of the preferred embodiment.",
"DETAILED DESCRIPTION OF THE INVENTION [0010] Referring now to the drawings, in which like elements are represented by like indicia in each drawing, FIG. 1 is a perspective view of the preferred embodiment of the instant invention as viewed from above the right side 110 of the invention.",
"A rigid, flat, elongate cutting board 1 , made of material suitable to back the manual cutting of food, has an upper surface 2 upon which to cut food, at least a portion of which is provided with a printed or inlaid grid pattern 3 as an aid to cutting reproducible thicknesses of food items.",
"[0011] In this embodiment, the cutting board 1 is rectangular, but in other embodiments, other shapes such as, but not limited to, oval may be used.",
"Vertical holes, e.g., 4 , 5 , 6 , 7 , 8 , 9 and 10 are drilled through the board at the intersection of lines in the grid pattern 3 .",
"The grid pattern shown in this embodiment is square, but in other embodiments, other patterns such as, but not limited to, triangular may be used.",
"A vertical rigid food guide 11 and a vertical rigid knife guard 12 are also provided, each having dowels 13 , 14 , 15 , 16 and 17 depending therefrom which are gripped by the top openings of the vertical holes 4 , 5 , 6 , 7 , and 8 , respectively, for support.",
"The number and positioning of the dowels may be changed within the scope of this invention so long as they provide secure support for the food guide 11 and the knife guard 12 when food and a knife are pressed against them.",
"[0012] Holes 9 and 10 and all the rest of the holes at the grid points remain open to permit drainage of food juices through the board into a tray optionally mounted below the board (see FIG. 3 ).",
"It is important for hygiene that all of the drain holes be sufficiently large and smooth-bored for complete cleaning.",
"[0013] A blower 18 attached to blower support means (not visible in this view) at the front end 19 of the board 1 is aimed to blow air directly at high velocity lengthwise across the upper surface 2 .",
"Unlike most kitchen vents, the blower 18 uses air emitting from the positive side of the blower to move air contaminated with food odors and irritants positively away from a user standing at either right side 110 or left side 111 of the board.",
"The typical draft vent of most kitchens and some ranges is effective at moving large volumes of air from a food preparation environment, but applies negligible velocity to the air adjacent to food being cut and the person cutting the food.",
"[0014] In this embodiment, the blower 18 is preferably articulable vertically and horizontally so that it may be optimally aimed by the user.",
"[0015] The lower surface of the board is provided with a blower support means (see FIGS. 2 and 3 ) for holding the base of the blower both at the front end 19 and the rear end 112 .",
"Placement of the blower support means at other locations along the periphery of the board are within the scope of this invention.",
"[0016] The food guide 11 in this embodiment is elongate both in height and in the lengthwise direction of the cutting board 1 .",
"This is to ensure that it will resist the sidewards pressure on food by the user even if the item to be cut is large.",
"The knife guard is elongate in height but is preferably not elongate in length because it is meant to provide a stop against horizontal motion of the knife blade without significantly constraining the width of the food being cut.",
"[0017] In this embodiment, both the forward food guide end 113 and the knife guard 12 are shown rounded so as not to grate on the blade of a knife, but in other embodiments either or both may be planar or multifaceted in the vertical direction.",
"[0018] FIG. 2 is both a rear end view and a front end view of the preferred embodiment minus the blower 18 (see FIG. 1 ).",
"Taking FIG. 2 as a rear end view, it shows the rear end 112 of the cutting board 1 resting on a board support 20 .",
"The board end support 20 may be one piece transverse to the length of the cutting board 1 , as shown, or it may be more than one piece so long as the cutting board 1 is stably supported on a flat surface 21 (shown in dashed lines as environmental structure).",
"One or more resilient pads 22 may also be provided to protect the surface 21 and keep the cutting board 1 from rocking.",
"A blower support means 23 is provided here, taking the form in this embodiment of a pair of slots 23 extending inwardly through the board end support 20 from the rear end 112 parallel to the length of the cutting board 1 .",
"The front end view in this embodiment is identical to the rear end view with the front end indicium 19 substituted for the rear end indicium 112 .",
"[0019] FIG. 3 is a perspective view of the preferred embodiment as viewed from below the right side 110 of the invention.",
"It shows the fan 18 having blower attachment means 30 attached to the blower support means 23 .",
"In this preferred embodiment, the blower attachment means takes the form of a pair of elongate tangs inserted into the pair of slots 23 .",
"The slots 23 may extend through the board end support 20 and into extensions 31 attached to the lower surface 32 of the cutting board 1 for rigidity of support.",
"Note that in this embodiment, the extensions 31 are made narrow enough that they fall between adjacent rows of drain holes exemplified by drain holes 33 and 34 .",
"[0020] Drain holes 8 and 10 in this figure correspond with drain holes 8 and 10 in FIG. 1 , illustrating that the drain holes pass all the way through the cutting board 1 .",
"[0021] Other embodiments of this invention may utilize one or more alternatively-shaped slots in the board end support 20 , so dimensioned as to provide adequate support for the blower 18 without extensions 31 .",
"It is also possible within the scope of this invention to have the slots 23 made in the front end 19 of the cutting board 1 , preferably positioned so that the corresponding blower attachment means does not obstruct any of the drain holes.",
"[0022] A juice collection tray 35 is provided in this preferred embodiment.",
"It comprises a preferably square collection portion 36 surrounded by a support lip 37 .",
"The support lip 37 cooperates with transverse support grooves 38 (only one visible in this view) so that the tray 35 may be slid in and out in the direction of the arrows A underneath the cutting board 1 .",
"For this purpose, the depth of the collection portion 36 must be less than the vertical distance between the lower extremity of the resilient pads 22 and the lower surface 32 of the cutting board 1 .",
"Other means for supporting the tray 35 under the cutting board 1 that are currently known in the art are within the scope of this invention.",
"[0023] This figure also shows a center board support 39 , the need for which depends on the length and rigidity of the cutting board 1 .",
"Like the board end supports 20 , this support may consist alternatively within the scope of this invention as a plurality of supports.",
"FIG. 4 is a right side view of the preferred embodiment minus the blower attachment.",
"It shows all of the elements identified in the other figures that are visible in this view.",
"The left side view of this embodiment is a mirror image of this right side view with the left side indicium 111 substituted for the right side indicium 110 .",
"[0024] FIG. 5 depicts a typical use of the preferred embodiment.",
"The food guide 11 has been pressed downwardly into the cutting board 1 so that the dowels fit into their corresponding holes (see FIG. 1 ).",
"Food to be sliced 50 (in this case an onion, shown in dashed lines to indicate environmental structure) has been placed against the right side 51 of the food guide 11 , and the knife guard 12 has been pressed downwardly on the opposite side of the food so that its dowel (again refer to FIG. 1 ) fits into a corresponding hole.",
"The position of the knife guard 12 relative to the food guide 11 determines the angle of the cut.",
"When the edge 52 of the knife 53 (again shown in dashed lines to indicate environmental structure) is placed against the food guide 11 at point 54 and against the knife guard 12 at point 55 , the knife 53 will cut the food 50 along a straight line between them.",
"[0025] In embodiments, the cutting board 1 may also have a cutout portion through it (not shown) which would allow waste to be pushed off the surface.",
"Embodiments may also include a food pushing device (not shown) for pushing food forwardly between the food guide 11 and the knife guard 12 ."
] |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to U.S. patent application Ser. No. ______ entitled GAS TURBINE FLOATING COLLAR and having Attorney Docket No. 2993-614US, filed simultaneously herewith, the specification of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates generally to gas turbine engine combustors and, more particularly, to a floating collar arrangement therefor.
BACKGROUND OF THE ART
[0003] Gas turbine combustors are typically provided with floating collars or seals to permit relative radial or lateral motion between the combustor and the fuel nozzle while minimizing leakage therebetween. The collar is subject to wear and heat, and is therefore cast/machined form a heat resistant material. As fuel nozzles, combustors and related components must be periodically removed for cleaning, inspection, repair and, occasionally replacement, the floating collar arrangement is provided in a manner which facilitates such removal, to thereby facilitate maintenance. Floating collar arrangements have become quite elaborate in the recent art, as designers continuously improve gas turbine efficiency. Such improvement, however, often comes at the expense of economical operation for the operator, as elaborate parts are typically more expensive to repair and replace. Accordingly, there is a need to provide a solution which addresses these and other limitations of the prior art, and in particular, there is a need to provided economical solutions to enable the emerging general aviation very small turbofan gas turbine market.
SUMMARY OF THE INVENTION
[0004] In one aspect, the present invention provides a gas turbine combustor floating collar assembly for receiving a fuel nozzle swirler body, the combustor having a nozzle opening defined in a dome thereof, the swirler body having an abutment shoulder extending therearound, the assembly comprising a mounting arrangement including a mounting flange spaced apart from the dome and circumscribing the opening, the flange fixedly bonded to the dome, and a cap spaced apart in an axial direction relative to the combustor from the mounting flange, the cap fixedly bonded to the mounting flange; and a floating collar slidably trapped between the mounting flange and the cap such that relative axial movement is substantially restrained but relative radial movement is permitted, the collar having a central aperture alignable with the dome opening and adapted for axial sliding engagement with the nozzle body, wherein the floating collar cannot be released from the mounting arrangement and the mounting arrangement cannot be released from the combustor without damaging at least one of the combustor, the mounting arrangement and the floating collar.
[0005] In another aspect, the present invention provides a method of providing a floating collar assembly on a gas turbine engine, the method comprising the steps of providing an assembly having a combustor with a nozzle opening defined in a dome thereof, a mounting arrangement including a sheet metal mounting flange, a sheet metal cap, and a sheet metal floating collar, the mounting flange, cap and floating collar each having a central aperture alignable with the dome opening, the floating collar aperture adapted for axial sliding engagement with a fuel nozzle air swirler body; fixedly bonding the mounting flange to the combustor dome in a spaced apart manner such that the flange central opening is generally aligned with dome opening; inserting the floating collar into the mounting flange; and fixedly bonding the cap to the mounting flange to thereby slidingly trap the floating collar between cap and the mounting flange.
[0006] Further details of these and other aspects of the present invention will be apparent from the detailed description and Figures included below.
DESCRIPTION OF THE DRAWINGS
[0007] Reference is now made to the accompanying Figures depicting aspects of the present invention, in which:
[0008] FIG. 1 is a schematic longitudinal sectional view of a turbofan gas turbine engine;
[0009] FIG. 2 is a partial sectional view of a combustor in accordance with an embodiment of the present invention;
[0010] FIG. 3 is an isometric view of a portion of FIG. 2 ; and
[0011] FIG. 4 is an exploded isometric view of FIG. 3 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] FIG. 1 illustrates a gas turbine engine 10 of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a multistage compressor 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases.
[0013] FIG. 2 shows an enlarged axial sectional view of a combustor 16 having a liner 20 and a dome 22 having an exterior side 24 and a central opening 26 for receiving a air swirler fuel nozzle (depicted in stippled lines in FIG. 2 ) of the type generally described in U.S. Pat. No. 6,289,676 or 6,082,113, for example, and which are incorporated herein by reference. A mounting arrangement 28 is provided as will now be described.
[0014] An annular mounting flange 30 is fixedly bonded, preferably by a weld 32 , to the exterior side 24 of dome 22 , and includes an axially-disposed annular portion 30 a , a radially disposed annular flange portion 30 b , both defining a central aperture 34 therein. Central aperture 44 can be aligned with dome opening 26 when mounting flange 30 is mounted on the combustor. Mounting flange 30 may also include a plurality of legs 36 as will be described further below.
[0015] An annular cap 40 is provided and fixedly bonded, preferably by a weld 42 , to mounting flange 30 , preferably at legs 36 . Cap is provided in a spaced-apart manner relative to mounting flange 30 , as will be described further below. Cap 40 has a central aperture 44 which is aligned with dome opening 26 when mounted on combustor 16 and adapted to receive the fuel nozzle therein.
[0016] A floating collar 50 is provided having a axially-disposed nozzle collar portion 50 a , and a radially disposed annular flange portion 50 b , both surrounding a central aperture 54 , and a smooth transition 50 c joins portions 50 a and 50 b . Central aperture 54 and collar portion 50 a are provided for axially slidingly engaging a circumferential shoulder of the fuel nozzle swirler body (stippled lines in FIG. 2 ). Collar portion 50 a preferably extends to, or inside, dome 22 though opening 26 . Flange portion 50 b is trapped between opposed surfaces of mounting flange 30 and cap 40 , with mounting flange 30 and cap 40 being sufficiently spaced apart to permit radial (relative to the engine axis of FIG. 1 ) sliding motion to occur between floating collar 50 and mounting flange 30 /cap 40 . An anti-rotation tang 56 depends from flange portion 50 b and is likewise trapped between adjacent mounting flange legs 36 , to thereby limit the amount by which floating collar 50 may rotate relative to mounting flange 30 /cap 40 .
[0017] In use, the fuel nozzle air swirler (not shown) is positioned within central aperture 54 and delivers a fuel air mixture to combustor 16 . As forces acting upon the fuel nozzle and the combustor tend to cause relative movement therebetween, floating collar 50 is able to displace radially with the nozzle while maintaining sealing with respect to combustor through maintaining sliding engagement with mounting flange 30 and cap 40 . Welds 32 and 42 ensure that mounting flange 30 and cap 40 maintain their spaced-apart relation and thereby keep floating collar 50 trapped therebetween.
[0018] Referring to FIG. 4 , mounting arrangement 28 is assembled through a process involving at least the following steps: welding mounting flange 30 to combustor dome 22 so that the flange central opening 36 is generally aligned with dome opening 26 ; inserting floating collar 50 into the mounting flange 30 , so that the collar portion 50 a extends through central opening 36 and is generally aligned with dome opening 26 , and preferably also so that anti-rotation tang 56 is trapped between two closely adjacent legs 36 ; and welding cap 40 to mounting flange 30 , preferably at legs 36 , to slidingly trap the floating collar between cap and the mounting flange. The order of operations may be any suitable, and need not be chronologically as described.
[0019] Mounting arrangement 28 and floating collar 50 are preferably provided from sheet metal using a suitable fabrication process. An simplified example process is to provide a sheet of metal, cut a blank, and perform at least one bending operation to provide the floating collar. Referring again to FIG. 2 , it is evident that a sheet metal collar 50 has a continuous transition 50 c is provided as a result of a sheet metal forming operation, such a bending, and helps strengthen the collar 50 . Unlike prior art collars made by investment casting and/or machining processes (see U.S. Pat. Nos. 4,454,711, 4,322,945 and 6,497,105, for example), the present invention's use of sheet metal advantageously permits a very light weight and inexpensively-provided part, due to its simple geometry, and yet provides good performance and reliability.
[0020] Unlike the prior art, the mounting assembly of the present invention is geometrically simple, lightweight, easy to manufacture and east to assemble. Contrary to the prior art which teaches providing a high-cost device which facilitates replacement, the design and method of the present invention instead has relatively low initial cost, which assists in providing a lower-overall cost to the gas turbine engine, thereby facilitating the provision of an affordable general aviation turbofan engine, for example. As well, because the initial cost is lower, the cost of replacement may also be lowered.
[0021] The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. For example, the present invention may be applied to any gas turbine engine, and is particularly suitable for airborne gas turbine applications. The means by which flange 30 is mounted to cap 40 may be different than that described. For example legs 36 may be replaced or supplemented with a continuous or discontinuous flange or lip, and/or may extend from flange 30 , cap 40 or both. The mode of anti-rotation may be any desirable. Though welding is preferred, brazing or other bonding methods may be used. Other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the equivalents accorded to the appended claims. | A simplified floating collar mounting arrangement is provided comprising a collar mounted between spaced-apart mounting flanges. The arrangement offers reduced part count and simplicity, and therefore improves reliability. | Identify the most important claim in the given context and summarize it | [
"CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application relates to U.S. patent application Ser.",
"No. ______ entitled GAS TURBINE FLOATING COLLAR and having Attorney Docket No. 2993-614US, filed simultaneously herewith, the specification of which is incorporated herein by reference.",
"TECHNICAL FIELD [0002] The invention relates generally to gas turbine engine combustors and, more particularly, to a floating collar arrangement therefor.",
"BACKGROUND OF THE ART [0003] Gas turbine combustors are typically provided with floating collars or seals to permit relative radial or lateral motion between the combustor and the fuel nozzle while minimizing leakage therebetween.",
"The collar is subject to wear and heat, and is therefore cast/machined form a heat resistant material.",
"As fuel nozzles, combustors and related components must be periodically removed for cleaning, inspection, repair and, occasionally replacement, the floating collar arrangement is provided in a manner which facilitates such removal, to thereby facilitate maintenance.",
"Floating collar arrangements have become quite elaborate in the recent art, as designers continuously improve gas turbine efficiency.",
"Such improvement, however, often comes at the expense of economical operation for the operator, as elaborate parts are typically more expensive to repair and replace.",
"Accordingly, there is a need to provide a solution which addresses these and other limitations of the prior art, and in particular, there is a need to provided economical solutions to enable the emerging general aviation very small turbofan gas turbine market.",
"SUMMARY OF THE INVENTION [0004] In one aspect, the present invention provides a gas turbine combustor floating collar assembly for receiving a fuel nozzle swirler body, the combustor having a nozzle opening defined in a dome thereof, the swirler body having an abutment shoulder extending therearound, the assembly comprising a mounting arrangement including a mounting flange spaced apart from the dome and circumscribing the opening, the flange fixedly bonded to the dome, and a cap spaced apart in an axial direction relative to the combustor from the mounting flange, the cap fixedly bonded to the mounting flange;",
"and a floating collar slidably trapped between the mounting flange and the cap such that relative axial movement is substantially restrained but relative radial movement is permitted, the collar having a central aperture alignable with the dome opening and adapted for axial sliding engagement with the nozzle body, wherein the floating collar cannot be released from the mounting arrangement and the mounting arrangement cannot be released from the combustor without damaging at least one of the combustor, the mounting arrangement and the floating collar.",
"[0005] In another aspect, the present invention provides a method of providing a floating collar assembly on a gas turbine engine, the method comprising the steps of providing an assembly having a combustor with a nozzle opening defined in a dome thereof, a mounting arrangement including a sheet metal mounting flange, a sheet metal cap, and a sheet metal floating collar, the mounting flange, cap and floating collar each having a central aperture alignable with the dome opening, the floating collar aperture adapted for axial sliding engagement with a fuel nozzle air swirler body;",
"fixedly bonding the mounting flange to the combustor dome in a spaced apart manner such that the flange central opening is generally aligned with dome opening;",
"inserting the floating collar into the mounting flange;",
"and fixedly bonding the cap to the mounting flange to thereby slidingly trap the floating collar between cap and the mounting flange.",
"[0006] Further details of these and other aspects of the present invention will be apparent from the detailed description and Figures included below.",
"DESCRIPTION OF THE DRAWINGS [0007] Reference is now made to the accompanying Figures depicting aspects of the present invention, in which: [0008] FIG. 1 is a schematic longitudinal sectional view of a turbofan gas turbine engine;",
"[0009] FIG. 2 is a partial sectional view of a combustor in accordance with an embodiment of the present invention;",
"[0010] FIG. 3 is an isometric view of a portion of FIG. 2 ;",
"and [0011] FIG. 4 is an exploded isometric view of FIG. 3 .",
"DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0012] FIG. 1 illustrates a gas turbine engine 10 of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a multistage compressor 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases.",
"[0013] FIG. 2 shows an enlarged axial sectional view of a combustor 16 having a liner 20 and a dome 22 having an exterior side 24 and a central opening 26 for receiving a air swirler fuel nozzle (depicted in stippled lines in FIG. 2 ) of the type generally described in U.S. Pat. No. 6,289,676 or 6,082,113, for example, and which are incorporated herein by reference.",
"A mounting arrangement 28 is provided as will now be described.",
"[0014] An annular mounting flange 30 is fixedly bonded, preferably by a weld 32 , to the exterior side 24 of dome 22 , and includes an axially-disposed annular portion 30 a , a radially disposed annular flange portion 30 b , both defining a central aperture 34 therein.",
"Central aperture 44 can be aligned with dome opening 26 when mounting flange 30 is mounted on the combustor.",
"Mounting flange 30 may also include a plurality of legs 36 as will be described further below.",
"[0015] An annular cap 40 is provided and fixedly bonded, preferably by a weld 42 , to mounting flange 30 , preferably at legs 36 .",
"Cap is provided in a spaced-apart manner relative to mounting flange 30 , as will be described further below.",
"Cap 40 has a central aperture 44 which is aligned with dome opening 26 when mounted on combustor 16 and adapted to receive the fuel nozzle therein.",
"[0016] A floating collar 50 is provided having a axially-disposed nozzle collar portion 50 a , and a radially disposed annular flange portion 50 b , both surrounding a central aperture 54 , and a smooth transition 50 c joins portions 50 a and 50 b .",
"Central aperture 54 and collar portion 50 a are provided for axially slidingly engaging a circumferential shoulder of the fuel nozzle swirler body (stippled lines in FIG. 2 ).",
"Collar portion 50 a preferably extends to, or inside, dome 22 though opening 26 .",
"Flange portion 50 b is trapped between opposed surfaces of mounting flange 30 and cap 40 , with mounting flange 30 and cap 40 being sufficiently spaced apart to permit radial (relative to the engine axis of FIG. 1 ) sliding motion to occur between floating collar 50 and mounting flange 30 /cap 40 .",
"An anti-rotation tang 56 depends from flange portion 50 b and is likewise trapped between adjacent mounting flange legs 36 , to thereby limit the amount by which floating collar 50 may rotate relative to mounting flange 30 /cap 40 .",
"[0017] In use, the fuel nozzle air swirler (not shown) is positioned within central aperture 54 and delivers a fuel air mixture to combustor 16 .",
"As forces acting upon the fuel nozzle and the combustor tend to cause relative movement therebetween, floating collar 50 is able to displace radially with the nozzle while maintaining sealing with respect to combustor through maintaining sliding engagement with mounting flange 30 and cap 40 .",
"Welds 32 and 42 ensure that mounting flange 30 and cap 40 maintain their spaced-apart relation and thereby keep floating collar 50 trapped therebetween.",
"[0018] Referring to FIG. 4 , mounting arrangement 28 is assembled through a process involving at least the following steps: welding mounting flange 30 to combustor dome 22 so that the flange central opening 36 is generally aligned with dome opening 26 ;",
"inserting floating collar 50 into the mounting flange 30 , so that the collar portion 50 a extends through central opening 36 and is generally aligned with dome opening 26 , and preferably also so that anti-rotation tang 56 is trapped between two closely adjacent legs 36 ;",
"and welding cap 40 to mounting flange 30 , preferably at legs 36 , to slidingly trap the floating collar between cap and the mounting flange.",
"The order of operations may be any suitable, and need not be chronologically as described.",
"[0019] Mounting arrangement 28 and floating collar 50 are preferably provided from sheet metal using a suitable fabrication process.",
"An simplified example process is to provide a sheet of metal, cut a blank, and perform at least one bending operation to provide the floating collar.",
"Referring again to FIG. 2 , it is evident that a sheet metal collar 50 has a continuous transition 50 c is provided as a result of a sheet metal forming operation, such a bending, and helps strengthen the collar 50 .",
"Unlike prior art collars made by investment casting and/or machining processes (see U.S. Pat. Nos. 4,454,711, 4,322,945 and 6,497,105, for example), the present invention's use of sheet metal advantageously permits a very light weight and inexpensively-provided part, due to its simple geometry, and yet provides good performance and reliability.",
"[0020] Unlike the prior art, the mounting assembly of the present invention is geometrically simple, lightweight, easy to manufacture and east to assemble.",
"Contrary to the prior art which teaches providing a high-cost device which facilitates replacement, the design and method of the present invention instead has relatively low initial cost, which assists in providing a lower-overall cost to the gas turbine engine, thereby facilitating the provision of an affordable general aviation turbofan engine, for example.",
"As well, because the initial cost is lower, the cost of replacement may also be lowered.",
"[0021] The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed.",
"For example, the present invention may be applied to any gas turbine engine, and is particularly suitable for airborne gas turbine applications.",
"The means by which flange 30 is mounted to cap 40 may be different than that described.",
"For example legs 36 may be replaced or supplemented with a continuous or discontinuous flange or lip, and/or may extend from flange 30 , cap 40 or both.",
"The mode of anti-rotation may be any desirable.",
"Though welding is preferred, brazing or other bonding methods may be used.",
"Other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the equivalents accorded to the appended claims."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to recorder devices and more particularly to a hinged recording table at the front of the recorder providing access to the interior thereof.
2. Prior Art
This invention is directed to recording apparatus of the type used for recording electric analogue signals on a moving belt or strip-like sheet of recording media such as paper. The recorder includes a housing having a meter or other measuring signal responsive device and a meter controlled measurement indicator such as a recording pin. The housing has a foldout recording table in a front area which has a recording or writing edge over which the recording media is moved during operation of the apparatus. Further the housing includes a drive system located adjacent the writing edge controlling movement of the recording media and a tear-off edge positioned adjacent the drive.
In typical prior recorders of the above described type using paper rolls to supply the recording media, it is necessary to position the recording table in such a manner that the writing edge of the recording table is located as close as possible to the writing apparatus or indicator. On the other hand, it is necessary to give easy access to the paper supply roll located interior of the assembly and to the meter or other unit which controls movement of the recording pin or pins. Not only is it necessary to allow access to the area in which the storage paper roll is located, easy access must also be provided to allow threading of the paper around the writing edge and through the drive means. A complicating factor is the fact that in order to keep paper losses low during the threading operation and upon tearing off of the recording media, the drive roller for the recording media and the tear-off edge must be both arranged closely adjacent the writing edge.
These factors necessitated a particular construction and arrangement of the foldout recording table. For example recording machines of the type above described are known wherein the recording table is opened or folded out by means of a drop movement. A drop movement of this type presents a complex movement consisting of both of a linear movement of the table, or portions of it, and a simultaneous superimposed swing or pivoting movement. In such constructions slide members or coulisses are required for the drop movement. The connecting members are normally positioned on the inside of the housing and the arrangement of the coulisses which allow the drop movement causes the construction of such recorders to become complicated and costly. Additionally depending upon whether the recorder is a single or a multi-channel recorder, various different assembly and construction changes must be applied to both the housing and the recording table.
It would therefore be a definite advance in the art to provide a recorder having a recording table which is capable of undergoing a drop and simultaneous pivoting motion which operates in the simplest possible manner for the purpose of inserting a new paper supply roll and threading the paper strip while maintaining the amount of waste paper or other recording medium which is not used for recording as small as possible. It would further be an advance in the art to eliminate the heretofore used coulisses attached to the housing. Additionally, it would be an advance if a simple, uncomplex construction could be provided which is usable both in association with single and multi-channel recorders requiring only a corresponding change in width of the recording table.
SUMMARY OF THE INVENTION
My invention provides an improved recorder of the type above discussed wherein the recording table consists of two rectangular plate members placed one above the other with one of the plates pivotably attached to the housing. The rectangular plate members are held in relation to one another by guide members with the guide members having end recesses receiving side portions of the rectangular members with at least one of the rectangular members slidable in the guides in relation to the other of the rectangular members such that one of the plate members of the recording table is movable longitudinally relative to the housing to shorten the longitudinal length of the recording table allowing clearance of the non-pivoted end of the recording table with respect to the remainder of the housing whereby the recording table may be rotated outwardly.
In specific embodiments of this invention the outermost plate of the table is bent adjacent a drive wheel with the drive wheel acting on the recording media at the bend. Further the outermost recording table plate carries pressure rollers in opposition to the driving roller. In yet another disclosed embodiment, the supply paper roll may be carried on the back side of the recording or writing table.
In the illustrated preferred embodiments disclosed, the writing table with its two plates can be constructed in any given width so as to correspond with the width of the paper used depending upon whether a single channel or a multi-channel recorder is being equipped with the recording table. No additional parts are needed other than plates of different width.
Other objects, features and advantages of the invention will be readily apparent from the following description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic sectional view of a recorder according to this invention illustrating, by broken lines, the opening of the recording table.
FIGS. 2a and b are side plan views of the recording table of this invention with FIG. 2a illustrating the recording table in full longitudinally extended position and FIG. 2b illustrating the table in shortened position.
FIG. 3 is a front plan view of the recorder of FIG. 1 with the recording table closed.
FIG. 4 is a fragmentary partially sectional view of the recording table taken along the lines IV--IV of FIG. 1.
FIG. 5 is a view similar to FIG. 4 taken along the lines V--V of FIG. 2a.
FIG. 6 is a fragmentary view taken along the lines VI--VI of FIG. 2a.
FIG. 7 is a fragmentary enlarged view of the writing end of a modification of the recording table of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a recording device according to this invention including a housing 1 having disposed therein a meter or signal responsive device 2 which is equipped with an indicator 3 such as an oscillating pin which is moved in response to a signal input to the meter 2. Both the meter and the indicator 3 are available devices and constitute no part of this invention. Positioned within the housing 1 below the meter 2 is a paper supply roll 4 supplying a strip or band of paper 5 which is directed by means of free rollers 6 and 7 over the writing edge 9 of a recording table 10 where it is acted upon by the indicator 3. A drive cylinder 8 contacts the paper 5 on a front side of the recording table 10 to cause movement of the paper 5.
The writing edge 9 comprises the topmost edge of the recording table 10 which in turn is constructed of various parts as will be hereinafter more fully described. The drive for the paper 5, including the drive cylinder 8 which may be motor driven, is positioned immediately adjacent the writing edge 9 and in a position to engage the front side of the writing table. The drive cylinder 8 may be positioned behind a clear housing face portion such as the cover portion 11 composed of Plexiglas. The cover portion 11 is bent inwardly below the drive roller to a position adjacent the front face of the recording table 10 where it terminates forming a tear-off edge 11'. The tear-off edge 11' allows the recorder paper to be separated closely adjacent the writing edge 9 thereby reducing the consumption of the paper or other recording material which is not intentionally recorded upon.
The recording table 10 is pivotably mounted to the housing about an axis of rotation 12 which, in the embodiment illustrated, is disposed at the bottom of the recording table.
As shown in FIG. 1, the recording table may assume an operating position illustrated by the solid lines designated 10 where the recording table closes the front of the recorder housing 1. Alternatively the recording table may be moved to a service position 10' opening the front of the housing 1 allowing access to the interior thereof, as illustrated in broken lines. It will be apparent that in order to move the recording table 10 from the operating position 10 to the service position 10' it will be necessary for the table to undergo a linear movement downwardly to allow the writing edge 9 to clear the tear-off edge 11' and to thereafter undergo a pivotable or swinging movement to the open position 10'. Upon closure of the unit by swinging from the service position 10' to the closed position, will thereafter be necessary for the table to undergo a reverse longitudinal movement to bring the recording edge 9 to a position sufficiently close to the indicator 3 so that the indicator may operate upon paper passing around the recording edge 9. Once in the closed position, means must be provided to maintain the proper longitudinal positioning of the writing table elements.
The construction of the recording table is further explained in FIGS. 2a and b and FIGS. 4 through 6. The recording table 10 consists of the actual paper run-off table which includes a substantially rectangular plate 13 having an end forming the writing edge 9. The plate 13 is laterally fixed in two side guides 14 and 15 which may be formed of synthetic material such as plastic or elastic or flexible material. In FIGS. 1, 2a and 2b only the side guide 14 is illustrated. During longitudinal displacement of the recording table 10 in the direction indicated by the double headed arrow in FIGS. 2a and 2b, the side guides 14 and 15 provide guidance and support for the table 13 and for the side edges of the recording media 5. As shown in FIG. 2a the side guide 14 has a shape which is essentially a rectangular base formed with a trapezoid top attached to the base on the shorter base of the trapezoid. From each end of the side guide, notches or recesses 16, 17, 18 and 19 extend inwardly towards the center line of the side guide, illustrated by the dot-dash line of FIGS. 2a and 2b. The recesses 16 through 19 are positioned on two planes as spaced pairs with the recesses 16 and 17 aligned and connected through a connecting groove 14b in the inside face of the side guide 14. The recesses 18 and 19 are aligned and are connected through a groove 14a in the inside face of the side guide.
The side guide 15 is formed as a mirror image of the side guide 14 relative to the plane aligned with the dot-dash line such that the side guides 14 and 15 are identical and a description of the side guides 15 is therefore not necessary.
The rectangular plate 13 of the recording table is snugly fitted in the upper recesses 16 and 17 and the groove 14b as illustrated in FIG. 4. The side edges of the plate 13 being fitted with notches for that purpose.
On the other hand, a second plate 20 forming the back plate of the recording table 10 is provided with a longer notch and is received in the recesses 18 and 19 and the groove 14a with longitudinal clearance such that it is displaceable in the side guides in a longitudinal direction. The bottom end of plate 20, as illustrated in 2b, is equipped with a pivotable connector 21 forming a bearing connection at the pivot point 12 for attachment of the bottom plate 20 to the housing whereby the recording table 10 will be pivotable about the axis of rotation 12. Because of the interconnection of the plates 13 and 20 through the side guides 14 and 15, the plates will move in unison when pivoted around the pivot point 12. However the plates 13 and 20 are longitudinally movable relative to one another and, as such, the entire table 10 is capable of a linear displacement within itself allowing its length to be shortened from the dimension illustrated in 2a to the dimension illustrated in 2b.
In an alternative embodiment, of course the plate 13 can be displaceable with respect to the side guide and the plate 20 can be fixedly attached.
In order to maintain the table in the full extended position, an opening 22a is provided through plate 20 and receives a catch member 22 which may be spring backed as at 22b to be urged into position forming an abutment with the bottom end of plate 13, the catch 22 being in fixed longitudinal position on the plate 20.
Thus, when the recording table is in the closed position illustrated in FIG. 10, the writing edge 9 will be held adjacent the indicator 3. Upon depressing the catch 22, plate 13, forming the paper run off table, can be pushed downwardly over the catch 22 with respect to the plate 20 thereby allowing shortening of the writing table.
In a further development of the writing table, counter pressure rollers 23 and 24 are attached to the back side of the writing plate 13. These rollers, which may be constructed of a synthetic material or a similar flexible material to the material of drive roll 8 are positioned to be opposed to the drive roller 8. The counter rollers 23 and 24 act to cause the recording paper 5 to be synchronously moved around the recording edge 9 when the table 10 is in the operating position.
FIG. 3 illustrates the exterior of the front of the recorder housing 1. The table 10 is illustrated closed with the exterior portions of the guide rails 14 and 15 shown disposed on either side of the plate 13. The catch 22 is positioned intermediate the sides in an opening 22a through plate 20 with the catch 22 located below the plate 13. Generally the catch 22 will be covered by the paper 5 during operation as the paper is dispensed past the drive roll 8. A control panel 25 is arranged on one side of the housing 1 and the control panel 5 supports the drive roll 8 which is covered by the Plexiglas cover 11 provided with the tear-off edge 11'. By use of a Plexiglas or other clear covering 11 actual recording on the paper 5 can be followed by the observer. FIG. 3, of course, illustrates the recorder in an operating position. If it is desired to open the housing 1 for servicing or other reasons the catch 22 is depressed and the paper run-off table plate 13 is pushed down over the catch to an end position in which the writing edge 9 clears the covering 11 and in particular the tear-off edge 11'. In this position the recording table 10 can be pivoted out approximately 90°.
In a further modification of the invention the table 10 with the plate 13 forming the paper run-off table may be provided with a bent end construction as illustrated in FIG. 7 forming an angulation adjacent the writing edge 9. Thus the drive cylinder 8 is arranged at the angle formed by the bend.
In a further embodiment, illustrated partially in FIG. 1, the paper supply roll 4 may be supported by attachments to the writing table as at 20b. In other embodiments the paper roll 4 may be attached interiorly of the housing with the paper roll axis attached to side walls of the housing. In the modification where the paper roll is carried by the writing table, it is attached on the side of plate 20 which is internal of the housing or which faces into the housing. In this manner the supply roll is capable of being pivoted out of the housing with the recording table 10. When the recording media is then to be replaced the supply roll 4 can then be set onto the corresponding support mandrel or arbor in the holders 20b when the table is open to the position illustrated at 10'. The paper leading edge is then drawn over the recording edge 9 and the recording table is folded shut. In this embodiment it is not necessary to thereafter thread the paper as it is when the paper roll is supported in the housing.
The recorder of this invention is thus distinguished by its simplicity of opening and closing operations which eliminate the requirement of any complex link connections or movements of the recording table. Thus the recording table and therefore the recorder, has a greatly reduced susceptibility to mechanical defects. In addition, because of the simple design herein described, the construction of the housing 1, the control panel 5, the arrangement of the paper supply roll 4, deflection sheaves 6 and 7 and drive cylinder are all independent of the width of the recording carrier 5. The symmetrically constructed and therefore identical guide rails 14 and 15 are standard parts which can properly index with chosen width plates 13 and 20 to provide run-off tables of any desired width. Therefore, in the case of a modular construction of the type disclosed, the construction of single or multi-channel recorders merely requires that the width L of the housing as well as the plates 13 and 20 be correspondingly varied.
Although the teachings of my invention have herein been discussed with reference to specific theories and embodiments, it is to be understood that these are by way of illustration only and that others may wish to utilize my invention in different designs or applications. | A recorder such as a pen line recorder is disclosed having a housing with a hinged front which forms a foldout recording table giving access to the interior, the recording table consists of two rectangular plate members one of which is hinged to the housing adjacent a bottom thereof and the other one of which projects upwardly into the housing securing the front in place. The two rectangular members are received in side guide members and are slidable in the guide members with respect to one another whereby one of the members may be moved first downwardly with respect to the other member to provide clearance at the top of the housing and then both members may be pivoted outwardly. | Briefly outline the background technology and the problem the invention aims to solve. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to recorder devices and more particularly to a hinged recording table at the front of the recorder providing access to the interior thereof.",
"Prior Art This invention is directed to recording apparatus of the type used for recording electric analogue signals on a moving belt or strip-like sheet of recording media such as paper.",
"The recorder includes a housing having a meter or other measuring signal responsive device and a meter controlled measurement indicator such as a recording pin.",
"The housing has a foldout recording table in a front area which has a recording or writing edge over which the recording media is moved during operation of the apparatus.",
"Further the housing includes a drive system located adjacent the writing edge controlling movement of the recording media and a tear-off edge positioned adjacent the drive.",
"In typical prior recorders of the above described type using paper rolls to supply the recording media, it is necessary to position the recording table in such a manner that the writing edge of the recording table is located as close as possible to the writing apparatus or indicator.",
"On the other hand, it is necessary to give easy access to the paper supply roll located interior of the assembly and to the meter or other unit which controls movement of the recording pin or pins.",
"Not only is it necessary to allow access to the area in which the storage paper roll is located, easy access must also be provided to allow threading of the paper around the writing edge and through the drive means.",
"A complicating factor is the fact that in order to keep paper losses low during the threading operation and upon tearing off of the recording media, the drive roller for the recording media and the tear-off edge must be both arranged closely adjacent the writing edge.",
"These factors necessitated a particular construction and arrangement of the foldout recording table.",
"For example recording machines of the type above described are known wherein the recording table is opened or folded out by means of a drop movement.",
"A drop movement of this type presents a complex movement consisting of both of a linear movement of the table, or portions of it, and a simultaneous superimposed swing or pivoting movement.",
"In such constructions slide members or coulisses are required for the drop movement.",
"The connecting members are normally positioned on the inside of the housing and the arrangement of the coulisses which allow the drop movement causes the construction of such recorders to become complicated and costly.",
"Additionally depending upon whether the recorder is a single or a multi-channel recorder, various different assembly and construction changes must be applied to both the housing and the recording table.",
"It would therefore be a definite advance in the art to provide a recorder having a recording table which is capable of undergoing a drop and simultaneous pivoting motion which operates in the simplest possible manner for the purpose of inserting a new paper supply roll and threading the paper strip while maintaining the amount of waste paper or other recording medium which is not used for recording as small as possible.",
"It would further be an advance in the art to eliminate the heretofore used coulisses attached to the housing.",
"Additionally, it would be an advance if a simple, uncomplex construction could be provided which is usable both in association with single and multi-channel recorders requiring only a corresponding change in width of the recording table.",
"SUMMARY OF THE INVENTION My invention provides an improved recorder of the type above discussed wherein the recording table consists of two rectangular plate members placed one above the other with one of the plates pivotably attached to the housing.",
"The rectangular plate members are held in relation to one another by guide members with the guide members having end recesses receiving side portions of the rectangular members with at least one of the rectangular members slidable in the guides in relation to the other of the rectangular members such that one of the plate members of the recording table is movable longitudinally relative to the housing to shorten the longitudinal length of the recording table allowing clearance of the non-pivoted end of the recording table with respect to the remainder of the housing whereby the recording table may be rotated outwardly.",
"In specific embodiments of this invention the outermost plate of the table is bent adjacent a drive wheel with the drive wheel acting on the recording media at the bend.",
"Further the outermost recording table plate carries pressure rollers in opposition to the driving roller.",
"In yet another disclosed embodiment, the supply paper roll may be carried on the back side of the recording or writing table.",
"In the illustrated preferred embodiments disclosed, the writing table with its two plates can be constructed in any given width so as to correspond with the width of the paper used depending upon whether a single channel or a multi-channel recorder is being equipped with the recording table.",
"No additional parts are needed other than plates of different width.",
"Other objects, features and advantages of the invention will be readily apparent from the following description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure, and in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatic sectional view of a recorder according to this invention illustrating, by broken lines, the opening of the recording table.",
"FIGS. 2a and b are side plan views of the recording table of this invention with FIG. 2a illustrating the recording table in full longitudinally extended position and FIG. 2b illustrating the table in shortened position.",
"FIG. 3 is a front plan view of the recorder of FIG. 1 with the recording table closed.",
"FIG. 4 is a fragmentary partially sectional view of the recording table taken along the lines IV--IV of FIG. 1. FIG. 5 is a view similar to FIG. 4 taken along the lines V--V of FIG. 2a.",
"FIG. 6 is a fragmentary view taken along the lines VI--VI of FIG. 2a.",
"FIG. 7 is a fragmentary enlarged view of the writing end of a modification of the recording table of this invention.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 illustrates a recording device according to this invention including a housing 1 having disposed therein a meter or signal responsive device 2 which is equipped with an indicator 3 such as an oscillating pin which is moved in response to a signal input to the meter 2.",
"Both the meter and the indicator 3 are available devices and constitute no part of this invention.",
"Positioned within the housing 1 below the meter 2 is a paper supply roll 4 supplying a strip or band of paper 5 which is directed by means of free rollers 6 and 7 over the writing edge 9 of a recording table 10 where it is acted upon by the indicator 3.",
"A drive cylinder 8 contacts the paper 5 on a front side of the recording table 10 to cause movement of the paper 5.",
"The writing edge 9 comprises the topmost edge of the recording table 10 which in turn is constructed of various parts as will be hereinafter more fully described.",
"The drive for the paper 5, including the drive cylinder 8 which may be motor driven, is positioned immediately adjacent the writing edge 9 and in a position to engage the front side of the writing table.",
"The drive cylinder 8 may be positioned behind a clear housing face portion such as the cover portion 11 composed of Plexiglas.",
"The cover portion 11 is bent inwardly below the drive roller to a position adjacent the front face of the recording table 10 where it terminates forming a tear-off edge 11'.",
"The tear-off edge 11'",
"allows the recorder paper to be separated closely adjacent the writing edge 9 thereby reducing the consumption of the paper or other recording material which is not intentionally recorded upon.",
"The recording table 10 is pivotably mounted to the housing about an axis of rotation 12 which, in the embodiment illustrated, is disposed at the bottom of the recording table.",
"As shown in FIG. 1, the recording table may assume an operating position illustrated by the solid lines designated 10 where the recording table closes the front of the recorder housing 1.",
"Alternatively the recording table may be moved to a service position 10'",
"opening the front of the housing 1 allowing access to the interior thereof, as illustrated in broken lines.",
"It will be apparent that in order to move the recording table 10 from the operating position 10 to the service position 10'",
"it will be necessary for the table to undergo a linear movement downwardly to allow the writing edge 9 to clear the tear-off edge 11'",
"and to thereafter undergo a pivotable or swinging movement to the open position 10'.",
"Upon closure of the unit by swinging from the service position 10'",
"to the closed position, will thereafter be necessary for the table to undergo a reverse longitudinal movement to bring the recording edge 9 to a position sufficiently close to the indicator 3 so that the indicator may operate upon paper passing around the recording edge 9.",
"Once in the closed position, means must be provided to maintain the proper longitudinal positioning of the writing table elements.",
"The construction of the recording table is further explained in FIGS. 2a and b and FIGS. 4 through 6.",
"The recording table 10 consists of the actual paper run-off table which includes a substantially rectangular plate 13 having an end forming the writing edge 9.",
"The plate 13 is laterally fixed in two side guides 14 and 15 which may be formed of synthetic material such as plastic or elastic or flexible material.",
"In FIGS. 1, 2a and 2b only the side guide 14 is illustrated.",
"During longitudinal displacement of the recording table 10 in the direction indicated by the double headed arrow in FIGS. 2a and 2b, the side guides 14 and 15 provide guidance and support for the table 13 and for the side edges of the recording media 5.",
"As shown in FIG. 2a the side guide 14 has a shape which is essentially a rectangular base formed with a trapezoid top attached to the base on the shorter base of the trapezoid.",
"From each end of the side guide, notches or recesses 16, 17, 18 and 19 extend inwardly towards the center line of the side guide, illustrated by the dot-dash line of FIGS. 2a and 2b.",
"The recesses 16 through 19 are positioned on two planes as spaced pairs with the recesses 16 and 17 aligned and connected through a connecting groove 14b in the inside face of the side guide 14.",
"The recesses 18 and 19 are aligned and are connected through a groove 14a in the inside face of the side guide.",
"The side guide 15 is formed as a mirror image of the side guide 14 relative to the plane aligned with the dot-dash line such that the side guides 14 and 15 are identical and a description of the side guides 15 is therefore not necessary.",
"The rectangular plate 13 of the recording table is snugly fitted in the upper recesses 16 and 17 and the groove 14b as illustrated in FIG. 4. The side edges of the plate 13 being fitted with notches for that purpose.",
"On the other hand, a second plate 20 forming the back plate of the recording table 10 is provided with a longer notch and is received in the recesses 18 and 19 and the groove 14a with longitudinal clearance such that it is displaceable in the side guides in a longitudinal direction.",
"The bottom end of plate 20, as illustrated in 2b, is equipped with a pivotable connector 21 forming a bearing connection at the pivot point 12 for attachment of the bottom plate 20 to the housing whereby the recording table 10 will be pivotable about the axis of rotation 12.",
"Because of the interconnection of the plates 13 and 20 through the side guides 14 and 15, the plates will move in unison when pivoted around the pivot point 12.",
"However the plates 13 and 20 are longitudinally movable relative to one another and, as such, the entire table 10 is capable of a linear displacement within itself allowing its length to be shortened from the dimension illustrated in 2a to the dimension illustrated in 2b.",
"In an alternative embodiment, of course the plate 13 can be displaceable with respect to the side guide and the plate 20 can be fixedly attached.",
"In order to maintain the table in the full extended position, an opening 22a is provided through plate 20 and receives a catch member 22 which may be spring backed as at 22b to be urged into position forming an abutment with the bottom end of plate 13, the catch 22 being in fixed longitudinal position on the plate 20.",
"Thus, when the recording table is in the closed position illustrated in FIG. 10, the writing edge 9 will be held adjacent the indicator 3.",
"Upon depressing the catch 22, plate 13, forming the paper run off table, can be pushed downwardly over the catch 22 with respect to the plate 20 thereby allowing shortening of the writing table.",
"In a further development of the writing table, counter pressure rollers 23 and 24 are attached to the back side of the writing plate 13.",
"These rollers, which may be constructed of a synthetic material or a similar flexible material to the material of drive roll 8 are positioned to be opposed to the drive roller 8.",
"The counter rollers 23 and 24 act to cause the recording paper 5 to be synchronously moved around the recording edge 9 when the table 10 is in the operating position.",
"FIG. 3 illustrates the exterior of the front of the recorder housing 1.",
"The table 10 is illustrated closed with the exterior portions of the guide rails 14 and 15 shown disposed on either side of the plate 13.",
"The catch 22 is positioned intermediate the sides in an opening 22a through plate 20 with the catch 22 located below the plate 13.",
"Generally the catch 22 will be covered by the paper 5 during operation as the paper is dispensed past the drive roll 8.",
"A control panel 25 is arranged on one side of the housing 1 and the control panel 5 supports the drive roll 8 which is covered by the Plexiglas cover 11 provided with the tear-off edge 11'.",
"By use of a Plexiglas or other clear covering 11 actual recording on the paper 5 can be followed by the observer.",
"FIG. 3, of course, illustrates the recorder in an operating position.",
"If it is desired to open the housing 1 for servicing or other reasons the catch 22 is depressed and the paper run-off table plate 13 is pushed down over the catch to an end position in which the writing edge 9 clears the covering 11 and in particular the tear-off edge 11'.",
"In this position the recording table 10 can be pivoted out approximately 90°.",
"In a further modification of the invention the table 10 with the plate 13 forming the paper run-off table may be provided with a bent end construction as illustrated in FIG. 7 forming an angulation adjacent the writing edge 9.",
"Thus the drive cylinder 8 is arranged at the angle formed by the bend.",
"In a further embodiment, illustrated partially in FIG. 1, the paper supply roll 4 may be supported by attachments to the writing table as at 20b.",
"In other embodiments the paper roll 4 may be attached interiorly of the housing with the paper roll axis attached to side walls of the housing.",
"In the modification where the paper roll is carried by the writing table, it is attached on the side of plate 20 which is internal of the housing or which faces into the housing.",
"In this manner the supply roll is capable of being pivoted out of the housing with the recording table 10.",
"When the recording media is then to be replaced the supply roll 4 can then be set onto the corresponding support mandrel or arbor in the holders 20b when the table is open to the position illustrated at 10'.",
"The paper leading edge is then drawn over the recording edge 9 and the recording table is folded shut.",
"In this embodiment it is not necessary to thereafter thread the paper as it is when the paper roll is supported in the housing.",
"The recorder of this invention is thus distinguished by its simplicity of opening and closing operations which eliminate the requirement of any complex link connections or movements of the recording table.",
"Thus the recording table and therefore the recorder, has a greatly reduced susceptibility to mechanical defects.",
"In addition, because of the simple design herein described, the construction of the housing 1, the control panel 5, the arrangement of the paper supply roll 4, deflection sheaves 6 and 7 and drive cylinder are all independent of the width of the recording carrier 5.",
"The symmetrically constructed and therefore identical guide rails 14 and 15 are standard parts which can properly index with chosen width plates 13 and 20 to provide run-off tables of any desired width.",
"Therefore, in the case of a modular construction of the type disclosed, the construction of single or multi-channel recorders merely requires that the width L of the housing as well as the plates 13 and 20 be correspondingly varied.",
"Although the teachings of my invention have herein been discussed with reference to specific theories and embodiments, it is to be understood that these are by way of illustration only and that others may wish to utilize my invention in different designs or applications."
] |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 07/408,876, filed on Sep. 18, 1989, now U.S. Pat. No. 5,235,098, which is a Continuation in Part of U.S. application Ser. No. 065,426, filed Jun. 23, 1987, now abandoned herewith.
BACKGROUND OF THE INVENTION
The compound dodecahydro-3a,6,6,9a-tetramethyl-naphtho[2,1-b]furan (hereinafter Naphthofuran II) is a synthetic congener of Ambergris, a rare perfumery composition of natural origin having a sweet, woody, amber bouquet. Naphthofuran II has been used in perfume compositions and in cleaning formulations, and as a fragrance for toiletries and household products where a persistent amber effect is desired. Naphthofuran II is also a component of tincture of Ambergris and synthetic Naphthofuran II has been used in artificial Ambergris formulations.
Naphthofuran II may be produced synthetically from 3-ethenyldecahydro-2-hydroxy-2,5,5,8a-pentamethyl-1-naphthalenepropanol, commonly known as sclareol. One method for this conversion is a two stage oxidation followed by a hydride reduction and cyclization. See, for example, U.S. Pat. No. 3,050,532; U.S. Pat. No. 3,029,255; and Aust. J. Chem., 1971, 24, 591. Another method involves oxidation of sclareol to sclareol oxide followed by a multi-step synthesis to produce Napthofuran II as a mixture of stereoisomers, as described in Helv. Chim. Acta, 1942, 25 621; J. Chem. Soc., 1960, 4613; Helv. Chim. Acta, 1950, 33 1251; U.S. Pat. No. 3,029,255, 1962; Helv. Chim. Acta, 1950, 33 1308; J. Am. Chem. Soc., 1963, 85 3979); and Helv. Chim. Acta, 1951, 34 1664.
These methods, however, lack simplicity and are base, upon multiple synthetic reactions. Moreover, they produce undesirable side reactions and do not generate high yields of Naphthofuran II. Accordingly, it is an object of the invention to develop a simple method for the production of Naphthofuran II for sclareol. Another object is the production of a high yield of Naphthofuran II without the complications caused by side reactions.
SUMMARY OF THE INVENTION
These and other objects are achieved by the invention which is directed to a method for the production of Naphthofuran (II) from sclareol. In this method, an alkoxy-radical fragmentation reaction is used to convert sclareol derivatives to a 9-haloethyl decalin derivative of the formula I: ##STR1## wherein X is iodo, bromo or chloro and R is C 2 to C 5 alkanoyl. Basic hydrolysis of this 9-haloethyl decalin derivative produces a naphthofuran of the formula II ##STR2##
Several alternatives for the alkoxy-radical fragmentation reaction can be used according to the method of the invention. In the first, a sclareol alkanoate derivative of the formula III: ##STR3## IIIa: R is --CH═CH 2 , R is C 2 to C 5 alkanoyl IIIb: R is ##STR4## R is C 2 to C 5 alkanoyl IIIc: R is CH 2 CH 3 , R is C 2 to C 5 alkanoyl
wherein R is vinyl, epoxyethyl or ethyl, and R is as defined above is treated with iodine and an oxidizing agent to produce the decalin derivative of formula I wherein X is iodo.
In the second method, sclareol oxide of the formula IV: ##STR5## is treated with hydrogen peroxide in the presence of an acid catalyst to produce a peroxide intermediate V which is then treated with a metallic halide reducing agent to produce the decalin derivative of formula I wherein R' is acetyl.
The invention described herein includes the novel 9-haloethyl decalin derivatives of formula I, an epoxysclareol acetate (IIIa) and a sclareol oxide-13-hydroperoxide intermediate V.
DETAILED DESCRIPTION OF THE INVENTION
A process of the present invention produces a high yield of Napthofuran II from sclareol derivatives through steps which employ an alkoxy-radical fragmentation reaction and a hydrolysis. It avoids production of side products that could alter the fragrance qualities of Napthofuran II.
According to one process of the invention, the sclareol alkanoate derivative of formula III can be converted to the decalin derivative of formula I wherein X is iodide by treatment with iodine and an oxidant in an inert solvent. The oxidant can be, e.g., mercuric oxide, lead tetraacetate, iodosobenzene diacetate, periodinane, iodosobenzene or iodoxybenzene. Preferred oxidants include iodosobenzene, lead tetraacetate and iodosobenzene diacetate, the later two being especially preferred. The amount of oxidant used may be from about 50 to about 250 mole percent, about 50 to about 200 mole percent being preferred and about 100 to about 200 mole percent being especially preferred, the mole percentage being measured relative to the molar amount of the sclareol alkanoate derivative present. The reaction may be performed in an inert solvent, such as an aromatic hydrocarbon, an aliphatic hydrocarbon or a halocarbon. Preferred solvents are benzene, toluene, chlorobenzene, xylene, hexane, cyclohexane, dichloroethylene, tetrachloroethane, and carbon tetrachloride. The especially preferred solvents include benzene, carbon tetrachloride and chlorobenzene, with benzene being particularly preferred. The reaction is usually performed in the presence of an acid scavenger such as an amine or an alkali or alkaline earth metal carbonate. Calcium carbonate, pyridine, sodium carbonate and triethylamine are preferred acid scavengers. The reaction may be conducted at a temperature of about 60° C. to about 130° C. with about 70° C. to about 120° C. being preferred and about 75° C. to about 85° C. being most preferred.
The sclareol alkanoate derivatives where R is C 3 to C 5 alkanoyl can be prepared using the methods of Buchi and Bieman, as described in Example 1, the teachings of which are incorporated herein by reference.
According to another alternative for the alkoxy-radical reaction employed in the process of the present invention, treatment of sclareol oxide with a source for hydrogen peroxide such as hydrogen peroxide itself, or a hydrogen peroxide generating system in an inert solvent in the presence of an alkanoic acid such as acetic acid gives a hydroperoxide intermediate. An example of a hydrogen peroxide generating system which may be useful comprises a mixture of barium peroxide and a protic acid such as acetic acid or carbonic acid. Other protonic or Bronsted acids can also be used. Preferred acids include lower alkyl carboxylic acids, chloro, dichloro and trifluoroacetic acid, formic acid, phosphoric acid and buffers derived from phosphoric acid. Acetic acid is especially preferred. The amount of acid used may be from about 10 to about 5000 mole percent with about 100 to about 4000 mole percent being preferred and about 3500 mole percent being particularly preferred, the mole percentage being measured relative to the amount of sclareol oxide present. Solvents such as dimethoxyethane, dioxane, ethyl ether, t-butanol, ethyl acetate, dichloromethane, tetrahydrofuran, dichoroethane, water t-butyl methyl ether, toluene and hexane may also be used. Preferred solvents are t-butyl methyl ether, t-butanol and tetrahydrofuran, the latter being especially preferred. A useful temperature range is between about 0° C. and about 50° C. with about 10° C. to about 40° C. being preferred and about 20° C. to about 30° C. being the most preferred. The peroxide treatment can take from about 0.5 to about 10 hours, about 0.5 to about 6 hours being preferred and about 3 to 4 hours being especially preferred.
The hydroperoxide intermediate can be fragmented to provide the decalin derivative of formula I wherein X is Cl, Br or I and R' is acetyl upon treatment with an appropriate metal halide reducing agent, such as a ferrous halide and a catalytic amount of a cupric halide, the cupric halide being Cl, Br or I. Other metal halide reducing agents may also be used in this reaction, including halide salts of copper (I), chromium (II), titanium (III), vanadium (II); and alkanols such as methanol, ethanol, isopropanol and t-butanol, as well as water, tetrahydrofuran, dioxane, ether and mixtures thereof may be included. The alcohols, tetrahydrofuran and water are preferred, with methanol being especially preferred. The reaction may be performed in the temperature range of about 0° C. to about 50° C. Preferably about 10° C. to about 35° C., most Preferably about 30° C. The time for the reaction is fifteen minutes to about 2 hours with about a half hour to about 2 hours being preferred and about a half to 1 hour being especially preferred.
The haloethyl decalin derivatives of formula I where R' is acetyl produced in the foregoing fashion are converted to naphthofuran II in high yield according to the process of the present invention by hydrolysis with a metal hydroxide in an appropriate solvent. Alkali or alkaline earth metal hydroxides are preferred. Potassium hydroxide is the most preferred. A variety of protic or aprotic solvents mixed with water may be used, such as lower alkyl alcohols, ethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dimethylsulfoxide, ethylene glycol, dimethylformamide, N-methylpyrrolidone or acetonitrile. The preferred solvent is a mixture of water and alcohols or diols, such as, methanol, ethanol, propanol, isopropanol, n-butanol, t-butanol, ethylene glycol. The most preferred solvent is a mixture of water and isopropanol. The reaction may be carried out in the temperature range of about 25° C. to about 150° C. The preferred temperature range is about 50° C. to about 100° C. The most preferred temperature range is about 70° C. to about 85° C.
The process of the present invention may be applied to other labdane derivatives such as manool (VI), larixol (VII), torulosol (VIII) and cupressic acid (IX) to provide compounds of general formula XI, wherein R a and R b are as described in VI-IX with X equal to halogen. ##STR6## VI R a is CH 3 , R b is H VII R a is CH 3 , R b is OH
VIII R a is CH 2 OH, R b is H
IX R a is CO 2 H, R b is H
Compound X may be converted into useful terpenoid derivatives of formula I by reducing the methylene group and treating with alkanoic acid as previously described.
The alkoxy-radical fragmentation can be applied pursuant to reaction procedures such as in Waegell et al., J. Chem Res. S., 1981, 236. The following examples illustrate some further embodiments of the invention.
In certain reactions described herein, conventional protection and deprotection reactions may be used to further enhance yields of preferred compounds. For example, when R b is hydroxyl, a protective group, e.g., methoxy, may be used, which is then removed using standard deprotection conditions.
Experimental Section
General. Benzene was dried over 4A molecular sieves prior to use. Sclareol, purchased from R. J. Reynolds Tobacco Co, was recrystallized from hexane prior to use. All other reagents and solvents were of reagent grade and were used as received.
IR spectra were obtained with a Perkin-Elmer 710B spectrophotometer. Routine 1 H-NMR spectral data reported at 250 MHz were recorded on a Bruker WM250 NMR instrument and the 13 C-NMR spectra were obtained on the same instrument at 62.5 MHz. Mass spectra were obtained with a Hewlett-Packard 5985 mass spectrophotometer. Column chromatography way performed with Merck 60 brand of silica gel. GLC analyses were obtained with a Hewlett-Packard Model 5840 or a Perkin-Elmer model 920 gas chromatograph, using either a 6 ft., 2-mm i.d. glass column packed with 3% nonpolar silicone on diatomaceous earth, 100-120 mesh or a 10 ft., 2 mm i.d. glass column packed with 2% polyethylene glycol on diatomaceous earth, 100-120 mesh. Where indicated, percentages refer to computer calculated peak areas without correction for response. Melting points were determined with a Thomas Model 40 micro hot-stage apparatus and are uncorrected. Optical rotations were obtained in chloroform solution at ambient temperature unless otherwise noted using a Perkin-Elmer 241 polarimeter.
EXAMPLE 1
Sclareol Epoxide Derivative
T-butyl hydroperoxide (3 mL, 0.027 mol) in CH 2 Cl 2 (30 mL) was added to a mixture of sclareol monoacetate which may be prepared as described by G. Buchi and K. Bieman in Croat. Chem. Acta 1957, 29 163-171 (7.00 g, 0.02 mol) vanadium (IV) bis(2,4-pentanedionate) oxide (0.100 g, 0.38 mmol) and methylene chloride (60 mL) over a 1 h period. The mixture was heated at reflux for 2 h and then t-butyl hydroperoxide (1 mL, 0.009 mol) in methylene chloride (15 mL) was added over a 0.5 h period. The mixture was heated at reflux for an additional 2 h and then stirred at 25° C. The phases were separated and the aqueous phase was extracted with methylene chloride (2×25 mL). The combined organic layers were washed with 10% sodium sulfite solution (2×30 mL) (negative starch iodide test), saturated sodium bicarbonate solution and dried (Na 2 SO 4 ). Evaporation of solvents provided 7.038 g of a nearly colorless solid. Crystallization from hexane/ethyl acetate gave 6.399 g of [1R-(1α-(R*),2β,4aβ,8aα)]-2-acetyloxy-α-oxiranyldecahydro-α,2,5,5,8a-pentamethyl-1-naphthalenepropanol (IIIb), mp 129.5° C.-131° C.; [α] D-35.75° C. (c, 3.43). 1 H-NMR (250 MHz, CDCl 3 ) δ0.74 (3H, s), 0.79 (3H, s), 0.82 (3H, s), 1.25 (3H, s), 1.41 (3H, 3), 1.88 (3H, s). 0.9-1.8 (16H, m), 2.51-2.93 (4H, m); 13 C-NMR δ15.68 (q), 18.34 (t), 19.07 (t), 20.01 (t), 20.64 (q), 21.40 (q), 22.79 (q), 25.84 (q), 33.07 (s), 33.28 (q), 38.82 (t), 39.55 (s), 39.66 (t), 41.90 (t), 41.95 (t), 44.03 (t), 55.70 (d), 57.72 (d), 69.41 (s), 88.08 (s), 169.85 (s); IR (CHCl 3 ) v max 3530, 2940, 1720, 1460, 1385, 1360, 1260 cm -1 ; MS, m/e 306, 291, 273, 109, 95, 81, 43. Anal. Calcd for C 22 H 38 O 4 : C, 72.09, H, 10.45 . Found: C, 72.17; H, 10.45.
EXAMPLE 2
Dihydro Sclareol Derivative
A mixture of sclareol monoacetate (3.50 g, 0.01 mol), platinum oxide (0.225 g), sodium nitrite (0.01 g) and ethanol (40 mL) was shaken under a hydrogen atmosphere (40 psi) for 2.5 h. The mixture was filtered through celite and the solids were washed with ethanol. The solvent was evaporated and the residue crystallized from hexane to give 2.69 g of [1R-[1α,(S*),2β,4aβ,8aα]]-2-acetyloxy-α-ethyldecahydro-α,2,5,5,8a-pentamethyl-1-naphthalenepropanol (IIIc), mp 92°-94° C., [α]D-27.35° (C.1.547). See, e.g., D. B. Bigley, N. A. J. Rogers, J. A. Barltrop in J. Chem. Soc., 1960, 4613-4627 and R. K. Grant, C. Huntrakal, and R. T. Weavers, Aust. J. Chem. 1972, 25 365-74.) 1 H-NMR (250 MHz, CDCl 3 ) δ0.78 (3H,s), 0.84 (3H,s), 0.87 (3H,s) 0.90 (3H,t, J= 7.5 Hz), 1.16 (3H, s), 1.47 (3H, s), 1.93 (3H, s), 0.8-1.9 (18H, m), 2.60-2.68 (1H, m). IR (CDCl 3 ) v max 35.80, 3450, 2950, 1720, 1455, 1485, 1460, 1260 cm -1 . MS, m/e 352, 292, 274, 259, 245, 204, 137, 109, 95, 43.
EXAMPLE 3
Sclareol Acetate Derivative
A mixture of sclareol monoacetate (1.050 g, 0.003 mol), iodosobenzene diacetate (0.966 g, 0.003 mol), calcium carbonate (1.2 g, 0.012 mol ) and benzene (60 mL) was heated at reflux and a solution of iodine (0.762 g, 0.003 mol) in benzene 25 mL) was added dropwise over a 45 min period. The mixture was heated at reflux for 1.5 h, cooled, decanted from solids, washed with 5% sodium thiosulfate solution (2×30 mL) and dried (NaSO 4 ). The solvent was evaporated and the residue Kugelrohr distilled (bath 60° C., 0.5 mm) to remove most of the iodobenzene. Chromatography (eluant:hexane:ethyl acetate; 20:1) of the residue gave 0.429 g of [1R-(1α,2β,4aβ,8aα)]-decahydro-1-(2-iodoethyl)-2,5,5,8a-tetramethyl-2-naphthalenol acetate, the decalin derivative of formula I wherein X is I and R' is C(O)CH 3 . Crystallization from hexane provides a pure sample; mp 94°-99° C. with decomposition; [α]D-4.28 (c, 1.33). 1 H-NMR (250 MHz, CDCl 3 ) δ0.77 (3H, s), 0.81 (3H, s), 0.85 (3H, s), 1.46 (3H, s), 1.93 (3H,s), 0.85-2.1 (13H, m), 2.62-2.73 (1H, m), 3.09-3.35 (2H, m); 13 C-NMR δ7.59 (t), 15.78 (q), 18.32 (t), 19.92 (t), 20.48 (q), 21.43 (q), 22.91 (q), 31.84 (t), 33.16 (s), 33.31 (q), 38.95 (t), 39.26 (t), 39.73 (t), 41.83 (t), 55.66 (d), 61.17 (d), 87.26 (s), 169.73 (s); IR (CHCl 3 ) v max 2940, 1720, 1450, 1385, 1360, 1250 cm -1 ; MS, m/e 346, 331, 279, 219, 137, 109, 95, 43. Anal Calcd for C 18 H 31 IO 2 : C, 53.20; H, 7.69; I, 31.23. Found: C, 53.76; H, 7.99; I, 30.91.
The reaction also provides 0.639 g of [1R-[1R-(1 α,2β,4aβ,8aα)]]-1-(5-iodo-3,4-epoxy-3-methylpentyl)decahydro-2,5,5,8a-tetramethyl-2-naphthalenol acetate as a mixture of isomers. 1 H-NMR (250 MHz, CDCl 3 ) 0.78 (3H, s), 0.81 (3H, s), 0.86 (3H, s), 1.28 and 1.34 (3H, 2s), 1.46 and 1.47 (3H, 2s), 1.930 and 1.932 (3H, 2s), 0.8-2.0 (15H, m), 2.6-2.75 (1H, m), 2.9-3.4 (3H, m); IR (CDCl 3 ) v max 2930, 1720, 1455, 1385, 1360, 1255 cm -1 . MS, m/e 416, 401, 384, 289, 245, 204, 137, 109, 95, 43.
EXAMPLE 4
Sclareol Acetate Derivative
To a mixture of lead tetraacetate [5.32 g, 0.012 mol, washed with hexane (2×50 mL)], calcium carbonate (2.40 g, 0.024 mol) sclareol monoacetate (2.10 g, 0.006 mol) and benzene (150 mL) heated at reflux was added a solution of iodine (1.524 g, 0.006 mol) in benzene (90 mL) over a 1.5 h period. The mixture was heated at reflux for 1 h, cooled and filtered. The filtrate was washed with 5% sodium thiosulfate solution (2×50 mL), saturated sodium bicarbonate solution, dried (Na 2 SO 4 ) and evaporated. Chromatography (eluant:hexane:ethyl acetate; 20:1) gave 1.209 g of the iodoacetate (I; X=I, R'=C(O)CH 3 ) and 0.906 g of iodoepoxide. The compounds were characterized as described in Example 3.
EXAMPLE 5
Decalin Derivative
A mixture of epoxide (IIIb) (0.732 G, 0.002 mol, from Example 1) iodosobenzenediacetate (1.288 g, 0.004 mol), calcium carbonate (0.8 g, 0.008 mol) and benzene (40 mL) was heated at reflux and a solution of iodine (0.508 g, 0.002 mol) in benzene (25 mL) was added dropwise over a 45 min period. The mixture was heated at reflux for 1.5 h and cooled to provide 0.433 g of the decalin derivative of formula I wherein X is I and R' is C(O)CH 3 . Work-up and chromatography were as described in Example 3.
EXAMPLE 7
Decalin Derivative
A mixture of lead tetraacetate (3.547 g, 0.008 mol), calcium carbonate (1.60 g, 0.016 mol), the dihydrosclareol derivative of Example 2 (1.418 g, 0.004 mol) and benzene (200 mL) was heated at reflux and a solution of iodine (1.016 g, 0.004 mol) in benzene (50 mL) was added over a 1.5 h period. The mixture was heated at reflux for 1 h, cooled and filtered. Work-up and chromatography as described in Example 4 gave 0.794 g of the decalin derivative of formula I wherein X is I and R is C(O)CH 3 and 0.388 g of 13-nor-vinyl-13-ketosclareol acetate. which was identical to an authentic sample as reported by D. B. Bigley, N. A. J. Rogers, J. A. Barltrop in J. Chem. Soc., 1960 4613-4627.
EXAMPLE 8
Decalin Derivative
Acetic acid (2 mL) was added to a mixture of sclareol oxide (IV) (0.262 g, 0.001 mol, which may be prepared as described by D. B. Bigley, N. A. J. Rogers and J. A. Barltrop in J. Chem. Soc., 1960, 4613-4627), tetrahydrofuran (8 mL), and 30% hydrogen peroxide (6 mL). The mixture was stirred at 25° C. for 4 h, poured onto water (10 mL) and extracted with hexane/ethyl acetate (9:1, 4×10 mL). The extracts were washed with water (2×5 mL), saturated sodium bicarbonate solution (2×10 mL) and dried (Na 2 SO 4 ). Evaporation of solvents provided 0.327 g of the hydroperioxide intermediate as a colorless solid. 1 H-NMR (60 MHz, CDCl 3 ) δ0.080 (6H, s), 0.87 (3H, s) 1.38 (3H, s), 1.43 (3H, s), )0.8-2.2 (16H, m) 7.52 (1H, s).
A solution of the hydroperoxide intermediate (0.001 mol) in methanol (10 mL) was added dropwise over a 30 min period to a solution of ferrous chloride (0.398 g, 0.002 mol) and cupric chloride (0.034 g, 0.0002 mol) in methanol (6 mL) at 25° C. The mixture was stirred at 25° C. for 15 min. The mixture was poured onto water (20 mL) and extracted with hexane ethyl acetate (9:1, 4×15 ml). The extracts were washed with water (2×10 mL), saturated sodium bicarbonate solution (2×10 mL) and dried (Na 2 SO 4 ). The solvents were evaporated and the residue chromatographed to provide 0.229 g of [1R-[1α,2β4aβ,8aα)]decahydro-1-(2-chloroethyl)-2,5,5,8a-tetramethyl-2-naphthalenol acetate, the decalin derivative of formula I wherein X is Cl and R' is C(O)CH 3 . Recrystallization from hexane provided an analytical sample. mp 99°-101.5° C. [α ]D-15.76 (c, 1.76). 1 H NMR (250 MHz, CDCl 3 ) δ0.73 (3H, s), 0.78 (3H, s), 0.81 (3H, s), 1.43 (3H, s), 1.87 (3H, s), 0.7-2.05 (13H, m), 2.6-2.7 (1H, m), 3.36-3.59 (2H, m); 13 C-NMR δ15.56 (q), 18.28 (t), 19.87 (t), 20.39 (q), 21.37 (q), 22.65 (q), 29.88 (t), 33.07 (s), 33.22 (q), 38.87 (t), 39.09 (s), 39.68 (t), 41.78 (t), 45.76 (t), 55.59 (d), 56.93 (d), 87.00 (s), 169.30 (s); IR (CHCl 3 ) v max 2930, 1725, 1460, 1440, 1390, 1370, 12.55 cm -1 ; MS, m/e 272, 256, 254, 241, 239, 137, 124, 109. Anal. Calcd for C 18 H 31 C10 2 : C, 68.65; H, 9.92; C1, 11.26. Found: C, 68.82; H, 10.08; C1, 11.12.
EXAMPLE 10
Decalin Derivative
[1R-(1α,2β,4aβ,8aα)]-Decahydro-1-(2-bromoethyl)-2,5,5,8a-tetramethyl-2-naphthalenol acetate
The decalin derivative of formula I wherein X is Br may be prepared by reaction of the hydroperoxide intermediate of Example 9 with ferrous bromide and cupric bromide in a manner similar to that described in Example 9.
EXAMPLE 11
Dodecahydro-3a,6,6,9a-tetramethylnaphtho[2,1-b]furan
A mixture of the decalin derivative of formula I wherein X is I and R' is C(O)CH 3 (0.610 g, 0.0015 mol from any of Examples 3 through 8), potassium hydroxide (0.953 g, 0.009 mol), isopropanol:water (6:1, 50 mL) was heated at reflux for 18 h. The mixture was cooled and concentrated under reduced pressure. The residue was added to water and extracted with hexane (4×20 mL). The extracts were washed with water (15 mL), brine (15 mL) and dried (Na 2 SO 4 ). The solvents were evaporated and the residue chromatographed (eluant; hexane:ethyl acetate; 20:1). Kugelrohr distillation (bath 120° C., 1 mm) gave 0.286 g of compound II, mp 74.5°-76° C.; [α]D-29.90° (c, 3.01 benzene); literature reference: mp 75°-76° C., [α]D-28.0° (benzene) see M. Stoll and M. Hinder in Helv. Chim. Acta, 1953, 36, 1995- 2008; NMR(250 MHz, CDCl 3 ) δ0.83 (6H, s), 0.88 (3H, s), 1.08 (3H, s), 0.8-2.0 (14H, m), 3.75-3.96 (2H, m); 13 C-NMR δ15.06 (q), 18.47 (t), 20.72 (t), 22.69 (2q), 33.10 (s), 36.27 (s), 39.36 (t), 40.06 (t), 42.54 (t), 57.36 (d), 60.22 (d), 64.94 (t), 79.84 (s); IR (melt) v max 2930, 1480, 1460, 1390, 1375 cm -1 ; MS, m/e 236, 221, 204, 137, 97.
EXAMPLE 12
Dodecahydro-3a,6,6,9a-tetramethylnaphtho[2,1-b]furan
A mixture of the decalin derivative of formula I wherein X is Cl and R' is C(O)CH 3 (0.124 g, 0.36 mmol from Example 9) potassium hydroxide (0.118 g) isopropanol (10 mL) and water (1.5 mL) was reacted as described in Example 11 to provide after work-up and kugelrohr distillation 0.077 g of Napthofuran II.
While certain preferred embodiments have been described herein in detail, numerous alternative embodiments are possible and contemplated as falling within the scope of the invention described herein. Consequently, the claims are not to be so limited. | The method is directed to the preparation of dodecahydro-3a,6,6,9a-tetramethyl-naphtho[2,1-b]furan from sclareol using an alkoxy-radical fragmentation reaction. A novel 9-haloethyl decalin derivative is an intermediate in this method. | Briefly describe the main invention outlined in the provided context. | [
"CROSS REFERENCE TO RELATED APPLICATIONS This application is a division of application Ser.",
"No. 07/408,876, filed on Sep. 18, 1989, now U.S. Pat. No. 5,235,098, which is a Continuation in Part of U.S. application Ser.",
"No. 065,426, filed Jun. 23, 1987, now abandoned herewith.",
"BACKGROUND OF THE INVENTION The compound dodecahydro-3a,6,6,9a-tetramethyl-naphtho[2,1-b]furan (hereinafter Naphthofuran II) is a synthetic congener of Ambergris, a rare perfumery composition of natural origin having a sweet, woody, amber bouquet.",
"Naphthofuran II has been used in perfume compositions and in cleaning formulations, and as a fragrance for toiletries and household products where a persistent amber effect is desired.",
"Naphthofuran II is also a component of tincture of Ambergris and synthetic Naphthofuran II has been used in artificial Ambergris formulations.",
"Naphthofuran II may be produced synthetically from 3-ethenyldecahydro-2-hydroxy-2,5,5,8a-pentamethyl-1-naphthalenepropanol, commonly known as sclareol.",
"One method for this conversion is a two stage oxidation followed by a hydride reduction and cyclization.",
"See, for example, U.S. Pat. No. 3,050,532;",
"U.S. Pat. No. 3,029,255;",
"and Aust.",
"J. Chem.",
", 1971, 24, 591.",
"Another method involves oxidation of sclareol to sclareol oxide followed by a multi-step synthesis to produce Napthofuran II as a mixture of stereoisomers, as described in Helv.",
"Chim.",
"Acta, 1942, 25 621;",
"J. Chem.",
"Soc.",
", 1960, 4613;",
"Helv.",
"Chim.",
"Acta, 1950, 33 1251;",
"U.S. Pat. No. 3,029,255, 1962;",
"Helv.",
"Chim.",
"Acta, 1950, 33 1308;",
"J. Am.",
"Chem.",
"Soc.",
", 1963, 85 3979);",
"and Helv.",
"Chim.",
"Acta, 1951, 34 1664.",
"These methods, however, lack simplicity and are base, upon multiple synthetic reactions.",
"Moreover, they produce undesirable side reactions and do not generate high yields of Naphthofuran II.",
"Accordingly, it is an object of the invention to develop a simple method for the production of Naphthofuran II for sclareol.",
"Another object is the production of a high yield of Naphthofuran II without the complications caused by side reactions.",
"SUMMARY OF THE INVENTION These and other objects are achieved by the invention which is directed to a method for the production of Naphthofuran (II) from sclareol.",
"In this method, an alkoxy-radical fragmentation reaction is used to convert sclareol derivatives to a 9-haloethyl decalin derivative of the formula I: ##STR1## wherein X is iodo, bromo or chloro and R is C 2 to C 5 alkanoyl.",
"Basic hydrolysis of this 9-haloethyl decalin derivative produces a naphthofuran of the formula II ##STR2## Several alternatives for the alkoxy-radical fragmentation reaction can be used according to the method of the invention.",
"In the first, a sclareol alkanoate derivative of the formula III: ##STR3## IIIa: R is --CH═CH 2 , R is C 2 to C 5 alkanoyl IIIb: R is ##STR4## R is C 2 to C 5 alkanoyl IIIc: R is CH 2 CH 3 , R is C 2 to C 5 alkanoyl wherein R is vinyl, epoxyethyl or ethyl, and R is as defined above is treated with iodine and an oxidizing agent to produce the decalin derivative of formula I wherein X is iodo.",
"In the second method, sclareol oxide of the formula IV: ##STR5## is treated with hydrogen peroxide in the presence of an acid catalyst to produce a peroxide intermediate V which is then treated with a metallic halide reducing agent to produce the decalin derivative of formula I wherein R'",
"is acetyl.",
"The invention described herein includes the novel 9-haloethyl decalin derivatives of formula I, an epoxysclareol acetate (IIIa) and a sclareol oxide-13-hydroperoxide intermediate V. DETAILED DESCRIPTION OF THE INVENTION A process of the present invention produces a high yield of Napthofuran II from sclareol derivatives through steps which employ an alkoxy-radical fragmentation reaction and a hydrolysis.",
"It avoids production of side products that could alter the fragrance qualities of Napthofuran II.",
"According to one process of the invention, the sclareol alkanoate derivative of formula III can be converted to the decalin derivative of formula I wherein X is iodide by treatment with iodine and an oxidant in an inert solvent.",
"The oxidant can be, e.g., mercuric oxide, lead tetraacetate, iodosobenzene diacetate, periodinane, iodosobenzene or iodoxybenzene.",
"Preferred oxidants include iodosobenzene, lead tetraacetate and iodosobenzene diacetate, the later two being especially preferred.",
"The amount of oxidant used may be from about 50 to about 250 mole percent, about 50 to about 200 mole percent being preferred and about 100 to about 200 mole percent being especially preferred, the mole percentage being measured relative to the molar amount of the sclareol alkanoate derivative present.",
"The reaction may be performed in an inert solvent, such as an aromatic hydrocarbon, an aliphatic hydrocarbon or a halocarbon.",
"Preferred solvents are benzene, toluene, chlorobenzene, xylene, hexane, cyclohexane, dichloroethylene, tetrachloroethane, and carbon tetrachloride.",
"The especially preferred solvents include benzene, carbon tetrachloride and chlorobenzene, with benzene being particularly preferred.",
"The reaction is usually performed in the presence of an acid scavenger such as an amine or an alkali or alkaline earth metal carbonate.",
"Calcium carbonate, pyridine, sodium carbonate and triethylamine are preferred acid scavengers.",
"The reaction may be conducted at a temperature of about 60° C. to about 130° C. with about 70° C. to about 120° C. being preferred and about 75° C. to about 85° C. being most preferred.",
"The sclareol alkanoate derivatives where R is C 3 to C 5 alkanoyl can be prepared using the methods of Buchi and Bieman, as described in Example 1, the teachings of which are incorporated herein by reference.",
"According to another alternative for the alkoxy-radical reaction employed in the process of the present invention, treatment of sclareol oxide with a source for hydrogen peroxide such as hydrogen peroxide itself, or a hydrogen peroxide generating system in an inert solvent in the presence of an alkanoic acid such as acetic acid gives a hydroperoxide intermediate.",
"An example of a hydrogen peroxide generating system which may be useful comprises a mixture of barium peroxide and a protic acid such as acetic acid or carbonic acid.",
"Other protonic or Bronsted acids can also be used.",
"Preferred acids include lower alkyl carboxylic acids, chloro, dichloro and trifluoroacetic acid, formic acid, phosphoric acid and buffers derived from phosphoric acid.",
"Acetic acid is especially preferred.",
"The amount of acid used may be from about 10 to about 5000 mole percent with about 100 to about 4000 mole percent being preferred and about 3500 mole percent being particularly preferred, the mole percentage being measured relative to the amount of sclareol oxide present.",
"Solvents such as dimethoxyethane, dioxane, ethyl ether, t-butanol, ethyl acetate, dichloromethane, tetrahydrofuran, dichoroethane, water t-butyl methyl ether, toluene and hexane may also be used.",
"Preferred solvents are t-butyl methyl ether, t-butanol and tetrahydrofuran, the latter being especially preferred.",
"A useful temperature range is between about 0° C. and about 50° C. with about 10° C. to about 40° C. being preferred and about 20° C. to about 30° C. being the most preferred.",
"The peroxide treatment can take from about 0.5 to about 10 hours, about 0.5 to about 6 hours being preferred and about 3 to 4 hours being especially preferred.",
"The hydroperoxide intermediate can be fragmented to provide the decalin derivative of formula I wherein X is Cl, Br or I and R'",
"is acetyl upon treatment with an appropriate metal halide reducing agent, such as a ferrous halide and a catalytic amount of a cupric halide, the cupric halide being Cl, Br or I. Other metal halide reducing agents may also be used in this reaction, including halide salts of copper (I), chromium (II), titanium (III), vanadium (II);",
"and alkanols such as methanol, ethanol, isopropanol and t-butanol, as well as water, tetrahydrofuran, dioxane, ether and mixtures thereof may be included.",
"The alcohols, tetrahydrofuran and water are preferred, with methanol being especially preferred.",
"The reaction may be performed in the temperature range of about 0° C. to about 50° C. Preferably about 10° C. to about 35° C., most Preferably about 30° C. The time for the reaction is fifteen minutes to about 2 hours with about a half hour to about 2 hours being preferred and about a half to 1 hour being especially preferred.",
"The haloethyl decalin derivatives of formula I where R'",
"is acetyl produced in the foregoing fashion are converted to naphthofuran II in high yield according to the process of the present invention by hydrolysis with a metal hydroxide in an appropriate solvent.",
"Alkali or alkaline earth metal hydroxides are preferred.",
"Potassium hydroxide is the most preferred.",
"A variety of protic or aprotic solvents mixed with water may be used, such as lower alkyl alcohols, ethyl ether, tetrahydrofuran, dioxane, dimethoxyethane, dimethylsulfoxide, ethylene glycol, dimethylformamide, N-methylpyrrolidone or acetonitrile.",
"The preferred solvent is a mixture of water and alcohols or diols, such as, methanol, ethanol, propanol, isopropanol, n-butanol, t-butanol, ethylene glycol.",
"The most preferred solvent is a mixture of water and isopropanol.",
"The reaction may be carried out in the temperature range of about 25° C. to about 150° C. The preferred temperature range is about 50° C. to about 100° C. The most preferred temperature range is about 70° C. to about 85° C. The process of the present invention may be applied to other labdane derivatives such as manool (VI), larixol (VII), torulosol (VIII) and cupressic acid (IX) to provide compounds of general formula XI, wherein R a and R b are as described in VI-IX with X equal to halogen.",
"##STR6## VI R a is CH 3 , R b is H VII R a is CH 3 , R b is OH VIII R a is CH 2 OH, R b is H IX R a is CO 2 H, R b is H Compound X may be converted into useful terpenoid derivatives of formula I by reducing the methylene group and treating with alkanoic acid as previously described.",
"The alkoxy-radical fragmentation can be applied pursuant to reaction procedures such as in Waegell et al.",
", J. Chem Res.",
"S., 1981, 236.",
"The following examples illustrate some further embodiments of the invention.",
"In certain reactions described herein, conventional protection and deprotection reactions may be used to further enhance yields of preferred compounds.",
"For example, when R b is hydroxyl, a protective group, e.g., methoxy, may be used, which is then removed using standard deprotection conditions.",
"Experimental Section General.",
"Benzene was dried over 4A molecular sieves prior to use.",
"Sclareol, purchased from R. J. Reynolds Tobacco Co, was recrystallized from hexane prior to use.",
"All other reagents and solvents were of reagent grade and were used as received.",
"IR spectra were obtained with a Perkin-Elmer 710B spectrophotometer.",
"Routine 1 H-NMR spectral data reported at 250 MHz were recorded on a Bruker WM250 NMR instrument and the 13 C-NMR spectra were obtained on the same instrument at 62.5 MHz.",
"Mass spectra were obtained with a Hewlett-Packard 5985 mass spectrophotometer.",
"Column chromatography way performed with Merck 60 brand of silica gel.",
"GLC analyses were obtained with a Hewlett-Packard Model 5840 or a Perkin-Elmer model 920 gas chromatograph, using either a 6 ft.",
", 2-mm i.d. glass column packed with 3% nonpolar silicone on diatomaceous earth, 100-120 mesh or a 10 ft.",
", 2 mm i.d. glass column packed with 2% polyethylene glycol on diatomaceous earth, 100-120 mesh.",
"Where indicated, percentages refer to computer calculated peak areas without correction for response.",
"Melting points were determined with a Thomas Model 40 micro hot-stage apparatus and are uncorrected.",
"Optical rotations were obtained in chloroform solution at ambient temperature unless otherwise noted using a Perkin-Elmer 241 polarimeter.",
"EXAMPLE 1 Sclareol Epoxide Derivative T-butyl hydroperoxide (3 mL, 0.027 mol) in CH 2 Cl 2 (30 mL) was added to a mixture of sclareol monoacetate which may be prepared as described by G. Buchi and K. Bieman in Croat.",
"Chem.",
"Acta 1957, 29 163-171 (7.00 g, 0.02 mol) vanadium (IV) bis(2,4-pentanedionate) oxide (0.100 g, 0.38 mmol) and methylene chloride (60 mL) over a 1 h period.",
"The mixture was heated at reflux for 2 h and then t-butyl hydroperoxide (1 mL, 0.009 mol) in methylene chloride (15 mL) was added over a 0.5 h period.",
"The mixture was heated at reflux for an additional 2 h and then stirred at 25° C. The phases were separated and the aqueous phase was extracted with methylene chloride (2×25 mL).",
"The combined organic layers were washed with 10% sodium sulfite solution (2×30 mL) (negative starch iodide test), saturated sodium bicarbonate solution and dried (Na 2 SO 4 ).",
"Evaporation of solvents provided 7.038 g of a nearly colorless solid.",
"Crystallization from hexane/ethyl acetate gave 6.399 g of [1R-(1α-(R*),2β,4aβ,8aα)]-2-acetyloxy-α-oxiranyldecahydro-α,2,5,5,8a-pentamethyl-1-naphthalenepropanol (IIIb), mp 129.5° C.-131° C.;",
"[α] D-35.75° C. (c, 3.43).",
"1 H-NMR (250 MHz, CDCl 3 ) δ0.74 (3H, s), 0.79 (3H, s), 0.82 (3H, s), 1.25 (3H, s), 1.41 (3H, 3), 1.88 (3H, s).",
"0.9-1.8 (16H, m), 2.51-2.93 (4H, m);",
"13 C-NMR δ15.68 (q), 18.34 (t), 19.07 (t), 20.01 (t), 20.64 (q), 21.40 (q), 22.79 (q), 25.84 (q), 33.07 (s), 33.28 (q), 38.82 (t), 39.55 (s), 39.66 (t), 41.90 (t), 41.95 (t), 44.03 (t), 55.70 (d), 57.72 (d), 69.41 (s), 88.08 (s), 169.85 (s);",
"IR (CHCl 3 ) v max 3530, 2940, 1720, 1460, 1385, 1360, 1260 cm -1 ;",
"MS, m/e 306, 291, 273, 109, 95, 81, 43.",
"Anal.",
"Calcd for C 22 H 38 O 4 : C, 72.09, H, 10.45 .",
"Found: C, 72.17;",
"H, 10.45.",
"EXAMPLE 2 Dihydro Sclareol Derivative A mixture of sclareol monoacetate (3.50 g, 0.01 mol), platinum oxide (0.225 g), sodium nitrite (0.01 g) and ethanol (40 mL) was shaken under a hydrogen atmosphere (40 psi) for 2.5 h. The mixture was filtered through celite and the solids were washed with ethanol.",
"The solvent was evaporated and the residue crystallized from hexane to give 2.69 g of [1R-[1α,(S*),2β,4aβ,8aα]]-2-acetyloxy-α-ethyldecahydro-α,2,5,5,8a-pentamethyl-1-naphthalenepropanol (IIIc), mp 92°-94° C., [α]D-27.35° (C[.",
"].1.547).",
"See, e.g., D. B. Bigley, N. A. J. Rogers, J. A. Barltrop in J. Chem.",
"Soc.",
", 1960, 4613-4627 and R. K. Grant, C. Huntrakal, and R. T. Weavers, Aust.",
"J. Chem.",
"1972, 25 365-74.) 1 H-NMR (250 MHz, CDCl 3 ) δ0.78 (3H,s), 0.84 (3H,s), 0.87 (3H,s) 0.90 (3H,t, J= 7.5 Hz), 1.16 (3H, s), 1.47 (3H, s), 1.93 (3H, s), 0.8-1.9 (18H, m), 2.60-2.68 (1H, m).",
"IR (CDCl 3 ) v max 35.80, 3450, 2950, 1720, 1455, 1485, 1460, 1260 cm -1 .",
"MS, m/e 352, 292, 274, 259, 245, 204, 137, 109, 95, 43.",
"EXAMPLE 3 Sclareol Acetate Derivative A mixture of sclareol monoacetate (1.050 g, 0.003 mol), iodosobenzene diacetate (0.966 g, 0.003 mol), calcium carbonate (1.2 g, 0.012 mol ) and benzene (60 mL) was heated at reflux and a solution of iodine (0.762 g, 0.003 mol) in benzene 25 mL) was added dropwise over a 45 min period.",
"The mixture was heated at reflux for 1.5 h, cooled, decanted from solids, washed with 5% sodium thiosulfate solution (2×30 mL) and dried (NaSO 4 ).",
"The solvent was evaporated and the residue Kugelrohr distilled (bath 60° C., 0.5 mm) to remove most of the iodobenzene.",
"Chromatography (eluant:hexane:ethyl acetate;",
"20:1) of the residue gave 0.429 g of [1R-(1α,2β,4aβ,8aα)]-decahydro-1-(2-iodoethyl)-2,5,5,8a-tetramethyl-2-naphthalenol acetate, the decalin derivative of formula I wherein X is I and R'",
"is C(O)CH 3 .",
"Crystallization from hexane provides a pure sample;",
"mp 94°-99° C. with decomposition;",
"[α]D-4.28 (c, 1.33).",
"1 H-NMR (250 MHz, CDCl 3 ) δ0.77 (3H, s), 0.81 (3H, s), 0.85 (3H, s), 1.46 (3H, s), 1.93 (3H,s), 0.85-2.1 (13H, m), 2.62-2.73 (1H, m), 3.09-3.35 (2H, m);",
"13 C-NMR δ7.59 (t), 15.78 (q), 18.32 (t), 19.92 (t), 20.48 (q), 21.43 (q), 22.91 (q), 31.84 (t), 33.16 (s), 33.31 (q), 38.95 (t), 39.26 (t), 39.73 (t), 41.83 (t), 55.66 (d), 61.17 (d), 87.26 (s), 169.73 (s);",
"IR (CHCl 3 ) v max 2940, 1720, 1450, 1385, 1360, 1250 cm -1 ;",
"MS, m/e 346, 331, 279, 219, 137, 109, 95, 43.",
"Anal Calcd for C 18 H 31 IO 2 : C, 53.20;",
"H, 7.69;",
"I, 31.23.",
"Found: C, 53.76;",
"H, 7.99;",
"I, 30.91.",
"The reaction also provides 0.639 g of [1R-[1R-(1 α,2β,4aβ,8aα)]]-1-(5-iodo-3,4-epoxy-3-methylpentyl)decahydro-2,5,5,8a-tetramethyl-2-naphthalenol acetate as a mixture of isomers.",
"1 H-NMR (250 MHz, CDCl 3 ) 0.78 (3H, s), 0.81 (3H, s), 0.86 (3H, s), 1.28 and 1.34 (3H, 2s), 1.46 and 1.47 (3H, 2s), 1.930 and 1.932 (3H, 2s), 0.8-2.0 (15H, m), 2.6-2.75 (1H, m), 2.9-3.4 (3H, m);",
"IR (CDCl 3 ) v max 2930, 1720, 1455, 1385, 1360, 1255 cm -1 .",
"MS, m/e 416, 401, 384, 289, 245, 204, 137, 109, 95, 43.",
"EXAMPLE 4 Sclareol Acetate Derivative To a mixture of lead tetraacetate [5.32 g, 0.012 mol, washed with hexane (2×50 mL)], calcium carbonate (2.40 g, 0.024 mol) sclareol monoacetate (2.10 g, 0.006 mol) and benzene (150 mL) heated at reflux was added a solution of iodine (1.524 g, 0.006 mol) in benzene (90 mL) over a 1.5 h period.",
"The mixture was heated at reflux for 1 h, cooled and filtered.",
"The filtrate was washed with 5% sodium thiosulfate solution (2×50 mL), saturated sodium bicarbonate solution, dried (Na 2 SO 4 ) and evaporated.",
"Chromatography (eluant:hexane:ethyl acetate;",
"20:1) gave 1.209 g of the iodoacetate (I;",
"X=I, R'=C(O)CH 3 ) and 0.906 g of iodoepoxide.",
"The compounds were characterized as described in Example 3.",
"EXAMPLE 5 Decalin Derivative A mixture of epoxide (IIIb) (0.732 G, 0.002 mol, from Example 1) iodosobenzenediacetate (1.288 g, 0.004 mol), calcium carbonate (0.8 g, 0.008 mol) and benzene (40 mL) was heated at reflux and a solution of iodine (0.508 g, 0.002 mol) in benzene (25 mL) was added dropwise over a 45 min period.",
"The mixture was heated at reflux for 1.5 h and cooled to provide 0.433 g of the decalin derivative of formula I wherein X is I and R'",
"is C(O)CH 3 .",
"Work-up and chromatography were as described in Example 3.",
"EXAMPLE 7 Decalin Derivative A mixture of lead tetraacetate (3.547 g, 0.008 mol), calcium carbonate (1.60 g, 0.016 mol), the dihydrosclareol derivative of Example 2 (1.418 g, 0.004 mol) and benzene (200 mL) was heated at reflux and a solution of iodine (1.016 g, 0.004 mol) in benzene (50 mL) was added over a 1.5 h period.",
"The mixture was heated at reflux for 1 h, cooled and filtered.",
"Work-up and chromatography as described in Example 4 gave 0.794 g of the decalin derivative of formula I wherein X is I and R is C(O)CH 3 and 0.388 g of 13-nor-vinyl-13-ketosclareol acetate.",
"which was identical to an authentic sample as reported by D. B. Bigley, N. A. J. Rogers, J. A. Barltrop in J. Chem.",
"Soc.",
", 1960 4613-4627.",
"EXAMPLE 8 Decalin Derivative Acetic acid (2 mL) was added to a mixture of sclareol oxide (IV) (0.262 g, 0.001 mol, which may be prepared as described by D. B. Bigley, N. A. J. Rogers and J. A. Barltrop in J. Chem.",
"Soc.",
", 1960, 4613-4627), tetrahydrofuran (8 mL), and 30% hydrogen peroxide (6 mL).",
"The mixture was stirred at 25° C. for 4 h, poured onto water (10 mL) and extracted with hexane/ethyl acetate (9:1, 4×10 mL).",
"The extracts were washed with water (2×5 mL), saturated sodium bicarbonate solution (2×10 mL) and dried (Na 2 SO 4 ).",
"Evaporation of solvents provided 0.327 g of the hydroperioxide intermediate as a colorless solid.",
"1 H-NMR (60 MHz, CDCl 3 ) δ0.080 (6H, s), 0.87 (3H, s) 1.38 (3H, s), 1.43 (3H, s), )0.8-2.2 (16H, m) 7.52 (1H, s).",
"A solution of the hydroperoxide intermediate (0.001 mol) in methanol (10 mL) was added dropwise over a 30 min period to a solution of ferrous chloride (0.398 g, 0.002 mol) and cupric chloride (0.034 g, 0.0002 mol) in methanol (6 mL) at 25° C. The mixture was stirred at 25° C. for 15 min.",
"The mixture was poured onto water (20 mL) and extracted with hexane ethyl acetate (9:1, 4×15 ml).",
"The extracts were washed with water (2×10 mL), saturated sodium bicarbonate solution (2×10 mL) and dried (Na 2 SO 4 ).",
"The solvents were evaporated and the residue chromatographed to provide 0.229 g of [1R-[1α,2β4aβ,8aα)]decahydro-1-(2-chloroethyl)-2,5,5,8a-tetramethyl-2-naphthalenol acetate, the decalin derivative of formula I wherein X is Cl and R'",
"is C(O)CH 3 .",
"Recrystallization from hexane provided an analytical sample.",
"mp 99°-101.5° C. [α ]D-15.76 (c, 1.76).",
"1 H NMR (250 MHz, CDCl 3 ) δ0.73 (3H, s), 0.78 (3H, s), 0.81 (3H, s), 1.43 (3H, s), 1.87 (3H, s), 0.7-2.05 (13H, m), 2.6-2.7 (1H, m), 3.36-3.59 (2H, m);",
"13 C-NMR δ15.56 (q), 18.28 (t), 19.87 (t), 20.39 (q), 21.37 (q), 22.65 (q), 29.88 (t), 33.07 (s), 33.22 (q), 38.87 (t), 39.09 (s), 39.68 (t), 41.78 (t), 45.76 (t), 55.59 (d), 56.93 (d), 87.00 (s), 169.30 (s);",
"IR (CHCl 3 ) v max 2930, 1725, 1460, 1440, 1390, 1370, 12.55 cm -1 ;",
"MS, m/e 272, 256, 254, 241, 239, 137, 124, 109.",
"Anal.",
"Calcd for C 18 H 31 C10 2 : C, 68.65;",
"H, 9.92;",
"C1, 11.26.",
"Found: C, 68.82;",
"H, 10.08;",
"C1, 11.12.",
"EXAMPLE 10 Decalin Derivative [1R-(1α,2β,4aβ,8aα)]-Decahydro-1-(2-bromoethyl)-2,5,5,8a-tetramethyl-2-naphthalenol acetate The decalin derivative of formula I wherein X is Br may be prepared by reaction of the hydroperoxide intermediate of Example 9 with ferrous bromide and cupric bromide in a manner similar to that described in Example 9.",
"EXAMPLE 11 Dodecahydro-3a,6,6,9a-tetramethylnaphtho[2,1-b]furan A mixture of the decalin derivative of formula I wherein X is I and R'",
"is C(O)CH 3 (0.610 g, 0.0015 mol from any of Examples 3 through 8), potassium hydroxide (0.953 g, 0.009 mol), isopropanol:water (6:1, 50 mL) was heated at reflux for 18 h. The mixture was cooled and concentrated under reduced pressure.",
"The residue was added to water and extracted with hexane (4×20 mL).",
"The extracts were washed with water (15 mL), brine (15 mL) and dried (Na 2 SO 4 ).",
"The solvents were evaporated and the residue chromatographed (eluant;",
"hexane:ethyl acetate;",
"20:1).",
"Kugelrohr distillation (bath 120° C., 1 mm) gave 0.286 g of compound II, mp 74.5°-76° C.;",
"[α]D-29.90° (c, 3.01 benzene);",
"literature reference: mp 75°-76° C., [α]D-28.0° (benzene) see M. Stoll and M. Hinder in Helv.",
"Chim.",
"Acta, 1953, 36, 1995- 2008;",
"NMR(250 MHz, CDCl 3 ) δ0.83 (6H, s), 0.88 (3H, s), 1.08 (3H, s), 0.8-2.0 (14H, m), 3.75-3.96 (2H, m);",
"13 C-NMR δ15.06 (q), 18.47 (t), 20.72 (t), 22.69 (2q), 33.10 (s), 36.27 (s), 39.36 (t), 40.06 (t), 42.54 (t), 57.36 (d), 60.22 (d), 64.94 (t), 79.84 (s);",
"IR (melt) v max 2930, 1480, 1460, 1390, 1375 cm -1 ;",
"MS, m/e 236, 221, 204, 137, 97.",
"EXAMPLE 12 Dodecahydro-3a,6,6,9a-tetramethylnaphtho[2,1-b]furan A mixture of the decalin derivative of formula I wherein X is Cl and R'",
"is C(O)CH 3 (0.124 g, 0.36 mmol from Example 9) potassium hydroxide (0.118 g) isopropanol (10 mL) and water (1.5 mL) was reacted as described in Example 11 to provide after work-up and kugelrohr distillation 0.077 g of Napthofuran II.",
"While certain preferred embodiments have been described herein in detail, numerous alternative embodiments are possible and contemplated as falling within the scope of the invention described herein.",
"Consequently, the claims are not to be so limited."
] |
FIELD OF THE INVENTION
This invention relates to the field of telephony, and in particular to a ringing signal discriminator.
BACKGROUND TO THE INVENTION
Ringing signal discriminators (referred to below as ring discriminators) detect the presence of ringing signals from other signals that may be present on a telephone line, such as noise, dual tone multifrequency (DTMF) signals, crosstalk from other telephone lines, control signals of various types, harmonics generated from various signals and noise such as control signals, etc.
In certain jurisdictions a ringing detector is required to react to any signal of at least a certain amplitude within the frequency band of 23 and 54 Hz as a true ringing signal, and outside of the band of 18 and 64 Hz as a false signal. 18-24 and 45-64 Hz zones are insensitive zones (see FIG. 1). Frequencies 20 and 60 Hz are chosen roughly in the middle of the insensitive zones as two digital thresholds between which the existence of a ringing signal is considered to be true. The reason for that is that the factor 3 (60/20) is easy to detect digitally.
A ringing signal is thus considered to have a frequency of between 20 Hz and 60 Hz. Only +/- 8.3% separates 64 Hz, a false ringing frequency threshold, and 54 Hz, which is within the band and which is a true ringing frequency threshold. It has been found that circuits that use analog signals are slow in detecting the ringing signal, requiring several ringing cycles to be able to detect the ringing signal, and are sensitive to tolerance variations in the components which make up the ringing signal.
Slow ringing signal detection can result in lost calls due to a receiving party taking a handset off hook prior to completion of ringing signal detection. Ringing signals cannot be recognized in this case though they exist, and connection of the call cannot be made. Sensitivity to tolerance variations can result in in-band ringing signals not being detected or out-of-band signals being mistaken for in-band ringing signals.
SUMMARY OF THE INVENTION
The present invention is a ring discriminator which can detect the presence of a ringing signal at the end of only one and a half of a first ringing cycle, and thus can provide a ringing control signal extremely quickly to a called party or to equipment which is enabled in the presence of a ringing signal. Further, the sensitivity of the present invention to component tolerance variations is substantially reduced due to a ringing signal detection mechanism which is for the most part digital.
In accordance with the present invention, a ring discriminator is comprised of apparatus for receiving an input ringing signal, a counter, apparatus for applying clock pulses to the counter, apparatus for enabling the counter to count clock pulses from a cycle of ringing current, and apparatus for determining a clock pulse count on the counter to distinguish a frequency characteristic of the ringing signal. It is preferred that the cycle of ringing current is a first cycle in a ring burst.
In accordance with a further embodiment, in the aforenoted ring discriminator the counter enabling apparatus is comprised of apparatus for detecting the beginning and the end of a single pulse period for generating an enable pulse beginning and ending at the beginning and end of the single pulse period, and for applying the enable pulse to the counter.
BRIEF INTRODUCTION TO THE DRAWINGS
A better understanding of the invention will be obtained by reading the description of the invention below, with reference to the following drawings, in which:
FIG. 1 is a frequency chart of in-band and out-of-band ringing signals,
FIG. 2 is a schematic diagram of a preferred embodiment of the present invention, and
FIG. 3 is a waveform diagram illustrating the forms of signals at various locations in the circuit illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the invention will be described with reference to both of FIGS. 2 and 3 together. A ringing signal to be discriminated, shown as the RING IN signal in FIG. 1, is applied to the input of an operational amplifier 1, which acts to both buffer the ringing signal and to limit it (e.g. by clipping) into somewhat square-wave form.
The output signal of clipping operational amplifier 1 is applied to the inputs of a differentiator 3, which differentiates the leading edge of the output signal from operational amplifier 1. That differentiated signal is shown as the DIFF OUT signal in FIG. 3.
The output signal of operational amplifier 1 is also applied to the input of an integrator 5, which has a fast charge time and a slow discharge time. The integrated output signal may be detected across capacitor C1, and is shown in FIG. 3 as signal CAP C1.
Both the integrator and differentiator are of conventional and well known construction.
The output signal of the integrator 5 is applied to one input of a comparator 7, which converts the output of the integrator into square wave. Since the integrator integrates the ringing signals over all cycles of each ring burst, the square wave output signal from integrator 5 is a pulse which lasts the interval of the ring burst (i.e. corresponds to the ring burst envelope), but starts later than the beginning of the first ringing cycle by a phase shift of 90 degrees. This will occur at whatever the frequency of the ringing signal.
Both the output signal of the comparator 7 and the output signal of the differentiator 3 are applied to respective inputs of NAND gate 9. The output of the NAND gate 9 is applied to the clock input CLK of a first self-latching flip flop 11. The Q output of flip flop 11 is applied to the clock input CLK of a second self-latching flip flop 13, and the /Q output of flip flop 13 is connected to another input of NAND gate 9. An enable pulse is provided at the /Q output of flip flop 11, as will be described below.
Prior to the receipt of an input ringing signal, the /Q output of flip flop 13 is at high logic level, as may be seen from waveform U4 in FIG. 3, and is applied to an input of NAND gate 9. With the receipt of ringing signals, the output of the comparator 7 (signal U1 OUTPUT in FIG. 3) goes to high logic level, with the envelope of the ringing burst, and is received at an input to NAND gate 9. Pulses resulting from differentiation of the leading edges of the ringing cycles as indicated by the DIFF OUT signal are applied to an input of NAND gate 9. The result are pulses at the output of NAND gate 9 of the waveform U5 OUTPUT shown in FIG. 3. Those pulses are received at the CLK input of flip flop 11.
With the receipt of the first pulse at the CLK input of flip flop 11, its /Q output goes to high logic level, shown as waveform U3 /Q OUTPUT, and its Q output goes to low logic level. With the receipt of the second pulse at the CLK input of flip flop 11, its /Q output goes to low logic level and its Q output goes to high logic level, as may be seen in FIG. 2. Thus for the interval of one ringing cycle the output /Q is at high logic level, and outside that ringing cycle that output is at low logic level.
The inverse of that pulse, at the Q output of flip flop 11, is applied as a clock pulse to the CLK input of flip flop 13. As a result, the /Q output of flip flop 13 changes from high to low logic level at the termination of the clock pulse applied to its CLK input. That low logic level signal, applied to an input of NAND gate 9, causes inhibition of the differentiated leading edges of the ringing signal from passing through NAND gate 9. As a result only two of such pulses pass through NAND gate 9, representing the beginning of successive ringing cycles, i.e. the beginning and the end of a single ringing cycle (shifted 180 degrees) and being the first ringing cycle of a ring burst. This may be seen from the waveform diagrams of FIG. 3.
Thus only a single pulse signal /Q OUTPUT is provided at the /Q output of flip flop 11 resulting from the first ringing cycle of a ring burst. That single pulse signal is used as an enable signal to an enable input of a binary counter 15.
A clock signal is also applied to the counter 15, preferably through an AND gate 17 with the enable pulse, as shown.
Thus during the interval of an enable pulse, clock signals can pass through AND gate 17 to the counter 15, which is enabled to count clock pulses during that interval. The count reached by the counter represents the period of the enable pulse, which corresponds directly to the frequency of the input ringing signal.
To discriminate the frequency of a received ringing signal as being within or outside a standard ringing frequency band, the Q6 and Q7 terminals of the counter are connected to the respective inputs of a NOR gate 19 and to the respective inputs of a NAND gate 21. The outputs of gates 19 and 21 are applied to the inputs of an AND gate 23. The output of AND gate 23 is an output signal which indicates by a TRUE signal if the input ringing signal frequency is within a band indicated by the clock count reached by counter 15 during the interval when it is enabled.
To reset the circuit, the U1 OUTPUT signal, which lasts for the interval of the ring burst envelope, from the output of comparator 7, is applied to the clear inputs CLR of both flip flops 11 and 13, and to the reset input RESET of the counter 15. Thus when the U1 OUTPUT signal goes to low logic level, at the end of a ring burst, both flip flops are reset to their initial state and the counter is cleared, ready for receipt of a subsequent ring burst.
As an example in the diagram illustrated if the count reaches 01000000 (decimal 64) the frequency of the input ringing signal is 60 Hz and if the count reaches 11000000 (decimal 192) the frequency of the input ringing signal is 20 Hz. These frequencies represent the highest and lowest threshold frequencies of the ringing signal band. The clock frequency, the clock pulses of which are counted by the counter 15, in this case can be calculated as 64 (count)×60 (Hz)=3840 Hz, or 192 (count)×20 Hz=3840 Hz.
It will of course be recognized that the number of bits counted in the counter 15 may be used, a different counter may be used, and various forms of logical circuits may be used to realize the present invention, other than the exact circuitry shown, to realize the present invention. In addition the present invention can be used to discriminate signals other than ringing signals, and the term ringing signals should be construed to mean any input signals of similar characteristic which are capable of being discriminated by the present invention. In addition the circuitry connected to the output of the counter 15 may be used to indicate the frequency or period of the ringing input signal, rather than merely that the ringing input signal is within a particular band of frequencies.
A person understanding this invention may now conceive of alternative structures and embodiments or variations of the above. All of those which fall within the scope of the claims appended hereto are considered to be part of the present invention. | A ring discriminator comprised of apparatus for receiving an input ringing signal, a counter, apparatus for applying clock pulses to the counter, apparatus for enabling the counter to count clock pulses from a cycle of ringing current, and apparatus for determining a clock pulse count on the counter to distinguish a frequency characteristic of the ringing signal. | Summarize the key points of the given document. | [
"FIELD OF THE INVENTION This invention relates to the field of telephony, and in particular to a ringing signal discriminator.",
"BACKGROUND TO THE INVENTION Ringing signal discriminators (referred to below as ring discriminators) detect the presence of ringing signals from other signals that may be present on a telephone line, such as noise, dual tone multifrequency (DTMF) signals, crosstalk from other telephone lines, control signals of various types, harmonics generated from various signals and noise such as control signals, etc.",
"In certain jurisdictions a ringing detector is required to react to any signal of at least a certain amplitude within the frequency band of 23 and 54 Hz as a true ringing signal, and outside of the band of 18 and 64 Hz as a false signal.",
"18-24 and 45-64 Hz zones are insensitive zones (see FIG. 1).",
"Frequencies 20 and 60 Hz are chosen roughly in the middle of the insensitive zones as two digital thresholds between which the existence of a ringing signal is considered to be true.",
"The reason for that is that the factor 3 (60/20) is easy to detect digitally.",
"A ringing signal is thus considered to have a frequency of between 20 Hz and 60 Hz.",
"Only +/- 8.3% separates 64 Hz, a false ringing frequency threshold, and 54 Hz, which is within the band and which is a true ringing frequency threshold.",
"It has been found that circuits that use analog signals are slow in detecting the ringing signal, requiring several ringing cycles to be able to detect the ringing signal, and are sensitive to tolerance variations in the components which make up the ringing signal.",
"Slow ringing signal detection can result in lost calls due to a receiving party taking a handset off hook prior to completion of ringing signal detection.",
"Ringing signals cannot be recognized in this case though they exist, and connection of the call cannot be made.",
"Sensitivity to tolerance variations can result in in-band ringing signals not being detected or out-of-band signals being mistaken for in-band ringing signals.",
"SUMMARY OF THE INVENTION The present invention is a ring discriminator which can detect the presence of a ringing signal at the end of only one and a half of a first ringing cycle, and thus can provide a ringing control signal extremely quickly to a called party or to equipment which is enabled in the presence of a ringing signal.",
"Further, the sensitivity of the present invention to component tolerance variations is substantially reduced due to a ringing signal detection mechanism which is for the most part digital.",
"In accordance with the present invention, a ring discriminator is comprised of apparatus for receiving an input ringing signal, a counter, apparatus for applying clock pulses to the counter, apparatus for enabling the counter to count clock pulses from a cycle of ringing current, and apparatus for determining a clock pulse count on the counter to distinguish a frequency characteristic of the ringing signal.",
"It is preferred that the cycle of ringing current is a first cycle in a ring burst.",
"In accordance with a further embodiment, in the aforenoted ring discriminator the counter enabling apparatus is comprised of apparatus for detecting the beginning and the end of a single pulse period for generating an enable pulse beginning and ending at the beginning and end of the single pulse period, and for applying the enable pulse to the counter.",
"BRIEF INTRODUCTION TO THE DRAWINGS A better understanding of the invention will be obtained by reading the description of the invention below, with reference to the following drawings, in which: FIG. 1 is a frequency chart of in-band and out-of-band ringing signals, FIG. 2 is a schematic diagram of a preferred embodiment of the present invention, and FIG. 3 is a waveform diagram illustrating the forms of signals at various locations in the circuit illustrated in FIG. 1. DETAILED DESCRIPTION OF THE INVENTION A preferred embodiment of the invention will be described with reference to both of FIGS. 2 and 3 together.",
"A ringing signal to be discriminated, shown as the RING IN signal in FIG. 1, is applied to the input of an operational amplifier 1, which acts to both buffer the ringing signal and to limit it (e.g. by clipping) into somewhat square-wave form.",
"The output signal of clipping operational amplifier 1 is applied to the inputs of a differentiator 3, which differentiates the leading edge of the output signal from operational amplifier 1.",
"That differentiated signal is shown as the DIFF OUT signal in FIG. 3. The output signal of operational amplifier 1 is also applied to the input of an integrator 5, which has a fast charge time and a slow discharge time.",
"The integrated output signal may be detected across capacitor C1, and is shown in FIG. 3 as signal CAP C1.",
"Both the integrator and differentiator are of conventional and well known construction.",
"The output signal of the integrator 5 is applied to one input of a comparator 7, which converts the output of the integrator into square wave.",
"Since the integrator integrates the ringing signals over all cycles of each ring burst, the square wave output signal from integrator 5 is a pulse which lasts the interval of the ring burst (i.e. corresponds to the ring burst envelope), but starts later than the beginning of the first ringing cycle by a phase shift of 90 degrees.",
"This will occur at whatever the frequency of the ringing signal.",
"Both the output signal of the comparator 7 and the output signal of the differentiator 3 are applied to respective inputs of NAND gate 9.",
"The output of the NAND gate 9 is applied to the clock input CLK of a first self-latching flip flop 11.",
"The Q output of flip flop 11 is applied to the clock input CLK of a second self-latching flip flop 13, and the /Q output of flip flop 13 is connected to another input of NAND gate 9.",
"An enable pulse is provided at the /Q output of flip flop 11, as will be described below.",
"Prior to the receipt of an input ringing signal, the /Q output of flip flop 13 is at high logic level, as may be seen from waveform U4 in FIG. 3, and is applied to an input of NAND gate 9.",
"With the receipt of ringing signals, the output of the comparator 7 (signal U1 OUTPUT in FIG. 3) goes to high logic level, with the envelope of the ringing burst, and is received at an input to NAND gate 9.",
"Pulses resulting from differentiation of the leading edges of the ringing cycles as indicated by the DIFF OUT signal are applied to an input of NAND gate 9.",
"The result are pulses at the output of NAND gate 9 of the waveform U5 OUTPUT shown in FIG. 3. Those pulses are received at the CLK input of flip flop 11.",
"With the receipt of the first pulse at the CLK input of flip flop 11, its /Q output goes to high logic level, shown as waveform U3 /Q OUTPUT, and its Q output goes to low logic level.",
"With the receipt of the second pulse at the CLK input of flip flop 11, its /Q output goes to low logic level and its Q output goes to high logic level, as may be seen in FIG. 2. Thus for the interval of one ringing cycle the output /Q is at high logic level, and outside that ringing cycle that output is at low logic level.",
"The inverse of that pulse, at the Q output of flip flop 11, is applied as a clock pulse to the CLK input of flip flop 13.",
"As a result, the /Q output of flip flop 13 changes from high to low logic level at the termination of the clock pulse applied to its CLK input.",
"That low logic level signal, applied to an input of NAND gate 9, causes inhibition of the differentiated leading edges of the ringing signal from passing through NAND gate 9.",
"As a result only two of such pulses pass through NAND gate 9, representing the beginning of successive ringing cycles, i.e. the beginning and the end of a single ringing cycle (shifted 180 degrees) and being the first ringing cycle of a ring burst.",
"This may be seen from the waveform diagrams of FIG. 3. Thus only a single pulse signal /Q OUTPUT is provided at the /Q output of flip flop 11 resulting from the first ringing cycle of a ring burst.",
"That single pulse signal is used as an enable signal to an enable input of a binary counter 15.",
"A clock signal is also applied to the counter 15, preferably through an AND gate 17 with the enable pulse, as shown.",
"Thus during the interval of an enable pulse, clock signals can pass through AND gate 17 to the counter 15, which is enabled to count clock pulses during that interval.",
"The count reached by the counter represents the period of the enable pulse, which corresponds directly to the frequency of the input ringing signal.",
"To discriminate the frequency of a received ringing signal as being within or outside a standard ringing frequency band, the Q6 and Q7 terminals of the counter are connected to the respective inputs of a NOR gate 19 and to the respective inputs of a NAND gate 21.",
"The outputs of gates 19 and 21 are applied to the inputs of an AND gate 23.",
"The output of AND gate 23 is an output signal which indicates by a TRUE signal if the input ringing signal frequency is within a band indicated by the clock count reached by counter 15 during the interval when it is enabled.",
"To reset the circuit, the U1 OUTPUT signal, which lasts for the interval of the ring burst envelope, from the output of comparator 7, is applied to the clear inputs CLR of both flip flops 11 and 13, and to the reset input RESET of the counter 15.",
"Thus when the U1 OUTPUT signal goes to low logic level, at the end of a ring burst, both flip flops are reset to their initial state and the counter is cleared, ready for receipt of a subsequent ring burst.",
"As an example in the diagram illustrated if the count reaches 01000000 (decimal 64) the frequency of the input ringing signal is 60 Hz and if the count reaches 11000000 (decimal 192) the frequency of the input ringing signal is 20 Hz.",
"These frequencies represent the highest and lowest threshold frequencies of the ringing signal band.",
"The clock frequency, the clock pulses of which are counted by the counter 15, in this case can be calculated as 64 (count)×60 (Hz)=3840 Hz, or 192 (count)×20 Hz=3840 Hz.",
"It will of course be recognized that the number of bits counted in the counter 15 may be used, a different counter may be used, and various forms of logical circuits may be used to realize the present invention, other than the exact circuitry shown, to realize the present invention.",
"In addition the present invention can be used to discriminate signals other than ringing signals, and the term ringing signals should be construed to mean any input signals of similar characteristic which are capable of being discriminated by the present invention.",
"In addition the circuitry connected to the output of the counter 15 may be used to indicate the frequency or period of the ringing input signal, rather than merely that the ringing input signal is within a particular band of frequencies.",
"A person understanding this invention may now conceive of alternative structures and embodiments or variations of the above.",
"All of those which fall within the scope of the claims appended hereto are considered to be part of the present invention."
] |
BACK GROUND OF THE INVENTION
1. Field of the Invention
This invention relates to brightness gradation reproduction between devices with different ranges of reproducible brightness.
2. Description of the Related Art
A printing systems that have a digital camera and a printer have become popular. An image data shot by the digital camera is input to the printer and the printer prints images expressed by the image data in his printing systems Image data is expressed using the device dependent color space that is dependent on each device. For example, a digital camera expresses image data using the RGB color space that is the digital camera device dependent color space, and the printer expresses image data using the CMYK color space that is the printer device dependent color space. Image data expressed by the RGB color space is converted to image data expressed by the CMYK color space that is the printer device dependent color space and output to the printer.
The brightness range that is reproducible for each color space differs for each device. By correlating the reproducible brightness by the digital camera and the reproducible brightness by the printer, the gradations of the image data shot using the digital camera are reflected in the image output by the printer.
However, the range of reproducible brightness by the printer is narrower than the range of reproducible brightness by the digital camera, and of the reproducible brightness by the digital camera, all the brightness that is lower than the black point are converted to black points. The black point is the minimum value of the reproducible brightness by the printer. Because of that, there is a problem that low brightness gradations in image data are not able to be reproduced in the images printed by the printer.
The problem described above is not a problem specialized in cases when outputting image data shot using a digital camera to a printer to print an image, but a problem that occurs in the same way between devices for which the range of reproducible brightness by the device receiving the image data is narrower than the range of reproducible brightness by the device sending the image data.
This invention was carried on in view of these problems, and the purpose is to reproduce gradations of the part for which the image data has low brightness between devices for which the range of reproducible brightness by the device that receives the image data is narrower than the range of reproducible brightness by the device that sends the image data.
SUMMARY OF THE INVENTION
In order to address at least part of the problem described above, a first aspect of this invention provides an image processing apparatus that outputs input image data that is input from an input device to an output device, wherein the input device has a input brightness area that is reproducible by the input device, wherein the output device has a output brightness area narrower than the input brightness area and is reproducible by the output device. The image processing apparatus in the first aspect of the invention comprises: a first color conversion processing module that converts the input image data to first intermediate image data, wherein the input image data is expressed using a input device dependent color space that depends on the input device, wherein the first intermediate image data at least expresses the brightness of the input image data and is expressed by an device independent color space that does not depend on each device, a brightness conversion module that converts the first intermediate image data to second intermediate image data so that gradation of first brightness is expressed in the output brightness area, wherein the first brightness is, of the first intermediate data, at least lower than the minimum value of the output brightness area, and a second color conversion processing module that converts the second intermediate data to output image data to output to the output device, wherein the output image data is expressed using an output device dependent color space that depends on the output device.
According to the image processing apparatus in the first aspect of this invention, it is possible to reproduce in the output image data the gradations of input brightness that is lower than the minimum value of the output brightness area in the input image data. Therefore, it is possible to ensure the gradation of the dark part of image data output by output device.
A second aspect of this invention provides a gradation reproduction method. The method is implemented by an image processing apparatus that outputs input image data that is input from an input device to an output device, wherein the input device has a input brightness area that is reproducible by the input device, wherein the output device has a output brightness area narrower than the input brightness area and is reproducible by the output device the gradation reproduction method comprising the steps of, The gradation reproduction method in the second aspect of the invention comprises the steps of: converting the input image data to first intermediate image data, wherein the input image data is expressed using a input device dependent color space that depends on the input device, wherein the first intermediate image data at least expresses the brightness of the input image data and is expressed by an device independent color space that does not depend on each device, converting the first intermediate image data to second intermediate image data so that gradation of first brightness is expressed in the output brightness area, wherein the first brightness is, of the first intermediate data at least lower than the minimum value of the output brightness area, and converting the second intermediate data to output image data to output to the output device, wherein the output image data is expressed using an output device dependent color space that depends on the output device.
The image processing apparatus in the second aspect of this invention may provides the same action and effect as the image processing apparatus in the first aspect of this invention. The image processing apparatus in the second aspect of this invention may also be realized in a variety of ways in the same manners as the image processing apparatus in the first aspect of this invention.
These and other objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 exemplary illustrates an example of an image output system in the first embodiment.
FIG. 2 exemplary illustrates a block chart describing the color conversion process in the first embodiment.
FIG. 3 exemplary illustrates an example of the contents of the input device profile in the first embodiment.
FIG. 4 exemplary illustrates an example of the contents of the output device profile of the first embodiment.
FIG. 5 exemplary illustrates a flow chart describing the printing process in the first embodiment.
FIG. 6 exemplary illustrates a brightness graph representing the brightness gradation in the first embodiment.
FIG. 7 exemplary illustrates a flow chart describing the brightness conversion process in the second embodiment.
FIG. 8 exemplary illustrates a brightness graph representing the brightness gradation in the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Following, embodiment aspects of the invention are described based on the following embodiments with references to the drawings.
A. First Embodiment
A1. System Configuration:
FIG. 1 exemplary illustrates an image output system 10 in the first embodiment. The image output system 10 has an image processing apparatus 20 , a printer 30 , and a digital camera 40 . The digital camera 40 and the image processing apparatus 20 , as well as the image processing apparatus 20 and the printer 30 are respectively connected locally via a USB cable. The image processing apparatus 20 converts the image data 50 so as to be reproduced in the image on which the gradations of the brightness of image data 50 obtained from the digital camera 40 is printed with printer 30 . The image processing apparatus 20 outputs the converted image data 50 a to the printer 30 .
The image processing apparatus 20 is a typical personal computer equipped with a CPU, RAM, and ROM. The functional blocks of the image processing apparatus are illustrated in the FIG. 1 . Each functional block is controlled by the CPU 100 . The memory 120 stores an image data obtaining module 130 , a color conversion module 140 , a profile storage area 150 and a printing module 160 . Each functional block is implemented using software. Each functional block may be constituted using hardware. The RAM 110 is readable/writable memory. The image data recording area 111 is constituted as part of the RAM 110 .
An input/output unit 170 sends and receives image data between the printer 30 and the digital camera 40 .
The image data obtaining module 130 records the image data 50 obtained from the digital camera 40 onto the image data recording area 111 .
An input device profile PF 1 and an output device profile PF 2 are stored in the profile storage area 150 . The input device profile PF 1 includes the color conversion information from the device dependent color space of the digital camera 40 that is the input device to the device independent color space. Also, the output device profile PF 2 includes the color conversion information from the device independent color space to the device dependent color space of the printer 30 that is the output device.
The color conversion module 140 uses the input device profile PF 1 and the output device profile PF 2 to convert the color space of the image data 50 from the device dependent color space that depends on the digital camera 40 as the input device to the device dependent color space that depends on the printer 30 as the output device. Converting the color space means converting each pixel value of the pixels that constitute the image data 50 expressed by the device dependent color space that depends on the digital camera 40 to each of the pixel values of the image data 50 a expressed by the device dependent color space that depends on the printer 30 . The conversion process implemented by the color conversion module 140 is described later.
The printing module 160 converts the image data 50 a converted by the color conversion module 140 to a format that is able to be interpreted by the printer 30 , and outputs the converted image data 50 a that is converted by printing module 160 to the printer 30 via the input/output unit 170 .
FIG. 2 exemplary illustrates a block chart that describes the color conversion process implemented by the color conversion module 140 in the first embodiment. The color conversion module 140 has an input signal color conversion module 141 , a brightness conversion module 142 , and an output signal color conversion module 143 . The input signal color conversion module 141 correlates to the “first color conversion module” of this invention. The brightness conversion module 142 correlates to the “brightness conversion module” of this invention. The output signal color conversion module 143 correlates to the “second color conversion module” of the first embodiment. In the first embodiment, the device dependent color space of the digital camera 40 that is the input device is the RGB color space, and the pixel values of each pixel of the image data expressed by the RGB color space are expressed as (R, G, B). The device independent color space is the Lab color space and the image values of each pixel of the image data expressed by the Lab color spaces are expressed as (L, a, b). “L” represents brightness, and “a” and “b” represent chromaticity. The device dependent color space of the printer 30 that is the output device is the CMYK color space, and the pixel values of each pixel of the image data expressed by the CMYK color space are expressed as (C, M, Y, K).
The input signal color conversion module 141 implements color conversion processing from the device dependent color space of the input device, specifically, the digital camera 40 , to the device independent color space. In specific terms, the input signal color conversion module 141 obtains from the input device profile PF 1 the information for color conversion from the device dependent color space of the input device to the device independent color space. The input signal color conversion module 141 uses the obtained color conversion information to convert image data expressed using the RGB color space color space to image data expressed using the Lab color space. The color conversion information includes a color conversion table from the RGB color space to the Lab color space. The input signal color conversion module 141 uses the color conversion table to convert each pixel value of the image data 50 from (R, G, B) expressed using the RGB color space to (L, a, b) expressed using the Lab color space. It is also possible to include in the color conversion information an RGB-Lab color conversion matrix, for example.
The contents of the input device profile PF 1 are described with reference to the FIG. 3 . FIG. 3 exemplary illustrates of the contents of the input device profile PF 1 in the first embodiment. The input device profile PF 1 includes a header part PF 11 , device independent color space conversion information PF 12 , and input device color space information PF 13 . The header part PF 11 includes the device type indicating the type of input device, the model name, and the creation date and time of the input device profile PF 1 . The device independent color space conversion information PF 12 includes an RGB-Lab color conversion table as the color conversion information necessary for converting the image data 50 expressed using the device dependent color space (RGB color space) of the digital camera 40 that is the input device to the image data 50 expressed using the device independent color space (Lab color space).
The color space information PF 13 includes information relating to the color space that the digital camera, which is the input device, is able to reproduce. The input device profile PF 1 is stored in the memory 120 together with installation of the input device driver. The input device profile PF 1 is able to be supplied correlated to the image data 50 , for example.
The brightness conversion module 142 , in the Lab color space that is the device independent color space, converts the input brightness L of the image data 50 and calculates the output brightness L′ so that the gradation of the reproducible brightness by the input device is reproduced within the range of reproducible brightness by the output device.
Though an illustration is omitted in FIG. 3 , the color conversion module 140 includes a color area mapping module to correlate of the input color area expressing the reproducible range of chromaticity by the input device and the output color area that expresses the range of reproducible chromaticity by the output device. The color area mapping module converts the chromaticity (a, b) of the image data 50 to the chromaticity (a′, b′), wherein the chromaticity (a, b) is expressed by the reproducible color area by the digital camera that is the input device, and the chromaticity (a′, b′) is expressed by the reproducible color area by the printer that is the output device.
The pixel values of the image data 50 are converted (L, a, b) to (L′, a′, b′) by the brightness conversion module 142 and the color area mapping module.
The output signal color conversion module 143 implements color conversion processing from the device independent space to the device dependent color space of the digital camera 40 that is the output device. In specific terms, the output signal color conversion module 143 obtains the color conversion information from the output device profile PF 2 . The output device profile PF 2 includes information to convert from the device independent color space of the output device to the device dependent color space. The output signal color conversion module 143 uses the obtained color conversion information to convert image data expressed using the Lab color space color space to image data expressed using the CMYK color space. The color conversion information includes a color conversion table from the Lab color space to the CMYK color space. The output signal color conversion module 143 uses the color conversion table to convert each pixel value of the image data 50 from (L′, a′, b′) expressed by the Lab color space to (C, M, Y, K) expressed by the CMYK color space. It is also possible to include in the color conversion information a Lab-CMYK color conversion matrix, for example.
The contents of the output device profile PF 2 are described using FIG. 4 . FIG. 4 exemplary illustrates an example of the contents of the output device profile PF 2 in the first embodiment. The output device profile PF 2 has the same constitution as the input device profile PF 1 , and consists of a header part PF 21 , device independent color space conversion information PF 22 , and input device color space information PF 23 . The header part PF 21 includes the device type that indicates the input device type, the model name, and the creation date and time of the output device profile PF 2 . The device independent color space information PF 22 includes the Lab-CMYK color conversion table as color conversion information necessary to confer the image data 50 expressed by the device independent color space (Lab color space) to image data 50 a expressed by the device dependent color space (CMYK color space) of the printer 30 that is the output device. The color space information PF 23 includes information relating to the reproducible color space by the printer which is the output device.
A2. Printing Process:
FIG. 5 exemplary illustrates a flow chart for describing the printing process in the first embodiment. The image processing apparatus 20 starts this printing process with printing instructions from the user as the trigger. When the image processing apparatus 20 receives the printing instructions from the user, the image processing apparatus 20 reads the image data recorded in the image data recording area 111 (step S 10 ), implements input signal color conversion processing, and converts each pixel value (R, G, B) of the image data 50 expressed by the RGB color space to (L, a, b) expressed by the Lab color space (step S 11 ).
The image processing apparatus 20 implements color area and brightness conversion on each pixel value (L, a, b) of the image data 50 expressed by the Lab color space, and converts each pixel value to (L′, a′, b′) (step S 12 ). In the first embodiment, only the selected input brightness L input that is the brightness of the achromatic pixels of the pixels of the image data 50 are converted to the output brightness L output using the equation 3 shown below.
[
Equation
3
]
L
output
=
(
L
max
-
L
black
)
(
L
output
L
max
)
γ
+
L
black
γ
=
L
max
L
max
-
L
black
,
(
Equation
3
)
L max : Maximum value of brightness for the Lab color space
L black : Minimum value of the reproducible brightness by the printer
L input : selected input brightness
L output : Output brightness
Gradation change by the input brightness conversion process is described in reference to FIG. 6 . FIG. 6 exemplary illustrates a brightness graph 300 that expresses brightness gradation changes in the first embodiment. The horizontal axis of the brightness graph 300 represents the RGB value of the input image data 50 , and the vertical axis represents the output brightness L of the image data. For the input RGB values, each value (R, G, B) changes in sequence from (0, 0, 0) to (1, 1, 1) (2, 2, 2) . . . (255, 255, 255). The output brightness L output has a range from 0 to 100. L black that represents the minimum value of the reproducible brightness by the printer 30 which is the output device shows black points that are the darkest spots of the brightness.
The input brightness graph L input shows the reproducible brightness by the digital camera 40 for the input RGB values. As shown in FIG. 6 , as the input RGB value increases, the output brightness L gradually becomes higher, in other words, as the input RGB value increases, the brightness is higher. The output brightness graph Ls shows the reproducible output brightness Lout by the printer 30 when using the conventional method. The output brightness graph L output is a graph representing the output brightness L output calculated applying equation 3 in the first embodiment to the input RGB values.
The range of reproducible brightness by the printer 30 is a range from L black to 100, and is narrower than the range of reproducible brightness by the digital camera 40 (0 to 100). Because of that, with the conventional brightness conversion processing, as shown in the output brightness graph Ls, when the RGB values of each pixel value of the input image data is included in the range R 1 from (0, 0, 0) to the P 1 (r, g, b), all of the input brightness L input are converted to L black , and the gradations of the input brightness L input are not reproduced with the output brightness L out .
In the first embodiment, by the brightness conversion module 142 implementing the brightness conversion process applying equation 3, the output brightness graph L output -graph is obtained as a graph representing brightness that is able to be reproduced by the printer 30 . By applying the equation 3, as shown by the arrow, the brightness conversion module 142 converts the input brightness L input on the input brightness graph L input -graph to the output brightness L output on the output brightness graph L output -graph. Specifically, the brightness conversion module 142 reproduces as L black to L 1 the low brightness gradations from 0 to L black of the input brightness L input for the input RGB values included in the range R 1 .
According to the image processing apparatus of the first embodiment described above, by applying equation 3, even when the range of reproducible brightness by the printer that is the output device is narrower than the range of reproducible brightness by the digital camera that is the input device, it is possible to reproduce the gradations of the brightness of the image data shot using the digital camera in the image printed using the printer. Conventionally, of the image data brightness, brightness lower than the black points of the printer were all converted to printer black points, and with images output by the printer, low brightness gradations were not expressed, but with this invention, it is possible to express gradation of low brightness of image data shot using the digital camera for images output by the printer.
Also, equation 3 is applied not only to low brightness input brightness but to all the input brightness, so for reproducible brightness by the printer, it is possible to ensure gradation properties for the low brightness part and also to reproduce gradations smoothly for all the brightness.
B. Second Embodiment
With the first embodiment described above, by applying equation 3 to the achromatic input brightness, the gradation properties of the reproducible brightness by the printer are ensured. In the second embodiment, considering chroma saturation, the gradations of the brightness in a digital camera are reproduced in the range for which brightness is able to be reproduced by the printer. The system configuration in the second embodiment is the same as the system configuration in the first embodiment.
B1. Brightness Conversion Process:
FIG. 7 exemplary illustrates a flow chart for describing the brightness conversion process in the second embodiment. This brightness conversion process is implemented by the brightness conversion module 142 , and correlates to the process of step S 12 in FIG. 5 .
The brightness conversion module 142 calculates the input chroma saturation C input of each pixel value of the image data expressed using the Lab color space (step 30 ). The brightness conversion module 142 calculates the input chroma saturation C input by applying the equation 4 below.
[Equation 4]
C input =√{square root over ( a input 2 +b input 2 )} (Equation 4)
(Where a input and b input are the “a” and “b” values of the input pixels for the Lab color space)
The brightness conversion module 142 determines whether the input chroma saturation C input is lower than the chroma saturation threshold value C th (step S 31 ). The chroma saturation threshold value C th represents ⅔ of the lowest chroma saturation value for the outside edge of the chromaticity of the Lab color space. When the input chroma saturation C input is lower than the chroma saturation threshold value C th (step S 31 : Yes), the brightness conversion module 142 converts input brightness Linput to the output brightness L output by in consideration of the chroma saturation brightness (step S 32 ). In specific terms, the brightness conversion module 142 calculates the output brightness L final by applying the equation 5 below. Specifically, with a range for which the input chroma saturation C input is from 0 to the chroma saturation threshold value C th , the output brightness L final is calculated by varying the mixture ratio of the input brightness L input and the output brightness L output . Note that L output is the value calculated by applying equation 3 in the first embodiment, and correlates to the “tentative output brightness” for this invention.
[
Equation
5
]
L
final
=
(
L
input
*
(
C
input
C
max
)
)
+
(
L
output
*
(
C
max
-
C
input
C
max
)
)
(
Equation
5
)
C th : Chroma saturation threshold value for the Lab color space
L final : Output brightness after conversion
When the input chroma saturation C input is the chroma saturation threshold value C th or greater (step S 31 : No), the brightness conversion module 142 uses the input brightness L input as is as the output brightness L final applying equation 6 (step S 33 ). Specifically, with the range for which the input chroma saturation C input is from the chroma saturation threshold value C th to the chroma saturation maximum value, the input brightness L input is used as the output brightness L final .
[Equation 6]
L final =L input (Equation 6)
Gradation reproduction considering chroma saturation is described with reference to FIG. 8 . FIG. 8 exemplary illustrates a brightness graph 400 representing brightness gradation changes in the second embodiment. The horizontal axis of the brightness graph 400 represents the input chroma saturation C input of the image data 50 , and the vertical axis represents the brightness L of the image data. The input chroma saturation Cinput uses a value in the range from 0 to 60. The brightness L uses a value in the range from 0 to 100. L black representing the minimum value of the reproducible brightness by the printer 30 that is the output device shows the darkest point of the brightness, in other words, black points. In the second embodiment, described is an example of a color for which the brightness is L 4 when the input chroma saturation C input is 0.
The input brightness graph L input -graph shows the reproducible input brightness L input by the digital camera 40 for the input chroma saturation C input . As shown in FIG. 8 , with the digital camera 40 , as the input chroma saturation C input increases from 0 to 60, the brightness L also gradually increases from L 4 to L 2 and as the input chroma saturation Cinput gradually decreases from 60 to 0, the brightness L increases from L 2 to 100.
The output brightness graph L output -graph shows the reproducible output brightness L output by the printer 30 on the chroma saturation C input . The output brightness L output is calculated applying equation 3 in the first embodiment. The output brightness graph L final -graph shows the reproducible output brightness L final by the printer 30 on the input chroma saturation C input . The output brightness L final is calculated applying equation 5 in the second embodiment.
When brightness conversion processing is implemented applying only equation 3 in the first embodiment, as shown in the output brightness graph L output -graph, as the chroma saturation increases, the output brightness L output has a higher value than the input brightness Linput, with the result that and the brightness is not reproduced appropriately.
In the second embodiment, by the brightness conversion module 142 implementing brightness conversion processing applying equation 5, the output brightness graph L final -graph is obtained showing the output brightness Lfinal. As shown in the brightness graph 400 , as the input chroma saturation C input increases from 0 to the chroma saturation threshold value Cth, the output brightness L final increases from L black to L 5 so that the gradations of the input brightness L input are reproduced. As the input chroma saturation Cinput increases from the chroma saturation threshold value Cth to 60, the output brightness L final uses the same value as the input brightness L input , and increases from L 5 to L 2 . Even the part for which the input chroma saturation Cinput becomes lower from 60 to the chroma saturation threshold Cth, the output brightness L final uses the same value as the input brightness L input and increases from L 2 to L 3 . As the input chroma saturation C input decreases from the chroma saturation threshold value Cth to 0, the output brightness L final increases from L 3 to 100.
In the second embodiment, when the input chroma saturation C input is less than the chroma saturation threshold value Cth, the mixture ratio of the input brightness L input and the output brightness L output is varied to calculate the output brightness L final and the condition branching midway in the calculation is simplified, but when the input chroma saturation C input changes decreasingly from a maximum value of 60 to 0, the same as when the input chroma saturation C input is the chroma saturation threshold value Cth or greater, it is also possible to use the input brightness L input as the output brightness Lfinal. This is because in the range for which the brightness is high, it is possible for the printer 30 to reproduce the input brightness L input without converting the input brightness L input .
According to the image processing apparatus in the second embodiment described above, in the low chroma saturation area, in other words, the low chroma saturation area near the achromatic axis, the ratio of the output brightness L output is made higher than the input brightness L input to mix the input brightness L input and the output brightness L output , as the input chroma saturation C input comes closer to the chroma saturation threshold value Cth, by making the ratio of the input brightness L input higher than the output brightness L output and mixing the input brightness L input and the output brightness L output , it is possible to reproduce the gradations of the image data brightness with good precision. Also, in the high chroma saturation area, it is possible to use the input brightness as is as the output brightness, and it is possible to improve the precision of gradation reproduction.
C. Variation Embodiments
(1) In the first embodiment described above, the Lab color space was used as the device independent color space, but it is also possible to use the LUV color space or the YCrCb color space. It is acceptable as long as it is a device independent color space that uses brightness as one of the components.
(2) In the second embodiment described above, the chroma saturation threshold value Cth was set as ⅔ the chroma saturation value of the lowest chroma saturation value for the outside edge of the chroma saturation of the Lab color space, but it is also possible to use ½ the chroma saturation value of the lowest chroma saturation value, for example. The chroma saturation maximum value and the color area characteristics differ for each device, so it is preferable to set the chroma saturation maximum value and the chroma saturation threshold value Cth according to the device.
Above, various embodiments of the invention were described, but the invention is not limited to these embodiments, and it is clearly possible to have various constitutions in a range that does not stray from its key points.
The Japanese patent applications as the basis of the priority claim of this application are incorporated in the disclosure here of by reference:
(1) Japanese Patent Application No. 2005-90765(filing data: Mar. 28, 2005). | The purpose of this invention is to reproduce gradations of dark parts between devices with different ranges of reproducible brightness. The range of reproducible brightness by the printer is a range from L black to 100, and this is narrow in relation to the range of brightness that is able to be reproduced by the digital camera (0 to 100). An image processing apparatus converts the input brightness L input on the input brightness graph L input -graph to the output brightness L output on the output brightness graph L output -graph. Accordingly, the low brightness gradations 0 to L black of the input brightness L input in relation to the input RGB values included in the range R1 become L black to L1, the dark area gradations are reproduced. | Identify and summarize the most critical technical features from the given patent document. | [
"BACK GROUND OF THE INVENTION 1.",
"Field of the Invention This invention relates to brightness gradation reproduction between devices with different ranges of reproducible brightness.",
"Description of the Related Art A printing systems that have a digital camera and a printer have become popular.",
"An image data shot by the digital camera is input to the printer and the printer prints images expressed by the image data in his printing systems Image data is expressed using the device dependent color space that is dependent on each device.",
"For example, a digital camera expresses image data using the RGB color space that is the digital camera device dependent color space, and the printer expresses image data using the CMYK color space that is the printer device dependent color space.",
"Image data expressed by the RGB color space is converted to image data expressed by the CMYK color space that is the printer device dependent color space and output to the printer.",
"The brightness range that is reproducible for each color space differs for each device.",
"By correlating the reproducible brightness by the digital camera and the reproducible brightness by the printer, the gradations of the image data shot using the digital camera are reflected in the image output by the printer.",
"However, the range of reproducible brightness by the printer is narrower than the range of reproducible brightness by the digital camera, and of the reproducible brightness by the digital camera, all the brightness that is lower than the black point are converted to black points.",
"The black point is the minimum value of the reproducible brightness by the printer.",
"Because of that, there is a problem that low brightness gradations in image data are not able to be reproduced in the images printed by the printer.",
"The problem described above is not a problem specialized in cases when outputting image data shot using a digital camera to a printer to print an image, but a problem that occurs in the same way between devices for which the range of reproducible brightness by the device receiving the image data is narrower than the range of reproducible brightness by the device sending the image data.",
"This invention was carried on in view of these problems, and the purpose is to reproduce gradations of the part for which the image data has low brightness between devices for which the range of reproducible brightness by the device that receives the image data is narrower than the range of reproducible brightness by the device that sends the image data.",
"SUMMARY OF THE INVENTION In order to address at least part of the problem described above, a first aspect of this invention provides an image processing apparatus that outputs input image data that is input from an input device to an output device, wherein the input device has a input brightness area that is reproducible by the input device, wherein the output device has a output brightness area narrower than the input brightness area and is reproducible by the output device.",
"The image processing apparatus in the first aspect of the invention comprises: a first color conversion processing module that converts the input image data to first intermediate image data, wherein the input image data is expressed using a input device dependent color space that depends on the input device, wherein the first intermediate image data at least expresses the brightness of the input image data and is expressed by an device independent color space that does not depend on each device, a brightness conversion module that converts the first intermediate image data to second intermediate image data so that gradation of first brightness is expressed in the output brightness area, wherein the first brightness is, of the first intermediate data, at least lower than the minimum value of the output brightness area, and a second color conversion processing module that converts the second intermediate data to output image data to output to the output device, wherein the output image data is expressed using an output device dependent color space that depends on the output device.",
"According to the image processing apparatus in the first aspect of this invention, it is possible to reproduce in the output image data the gradations of input brightness that is lower than the minimum value of the output brightness area in the input image data.",
"Therefore, it is possible to ensure the gradation of the dark part of image data output by output device.",
"A second aspect of this invention provides a gradation reproduction method.",
"The method is implemented by an image processing apparatus that outputs input image data that is input from an input device to an output device, wherein the input device has a input brightness area that is reproducible by the input device, wherein the output device has a output brightness area narrower than the input brightness area and is reproducible by the output device the gradation reproduction method comprising the steps of, The gradation reproduction method in the second aspect of the invention comprises the steps of: converting the input image data to first intermediate image data, wherein the input image data is expressed using a input device dependent color space that depends on the input device, wherein the first intermediate image data at least expresses the brightness of the input image data and is expressed by an device independent color space that does not depend on each device, converting the first intermediate image data to second intermediate image data so that gradation of first brightness is expressed in the output brightness area, wherein the first brightness is, of the first intermediate data at least lower than the minimum value of the output brightness area, and converting the second intermediate data to output image data to output to the output device, wherein the output image data is expressed using an output device dependent color space that depends on the output device.",
"The image processing apparatus in the second aspect of this invention may provides the same action and effect as the image processing apparatus in the first aspect of this invention.",
"The image processing apparatus in the second aspect of this invention may also be realized in a variety of ways in the same manners as the image processing apparatus in the first aspect of this invention.",
"These and other objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with the accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 exemplary illustrates an example of an image output system in the first embodiment.",
"FIG. 2 exemplary illustrates a block chart describing the color conversion process in the first embodiment.",
"FIG. 3 exemplary illustrates an example of the contents of the input device profile in the first embodiment.",
"FIG. 4 exemplary illustrates an example of the contents of the output device profile of the first embodiment.",
"FIG. 5 exemplary illustrates a flow chart describing the printing process in the first embodiment.",
"FIG. 6 exemplary illustrates a brightness graph representing the brightness gradation in the first embodiment.",
"FIG. 7 exemplary illustrates a flow chart describing the brightness conversion process in the second embodiment.",
"FIG. 8 exemplary illustrates a brightness graph representing the brightness gradation in the second embodiment.",
"DESCRIPTION OF THE PREFERRED EMBODIMENT Following, embodiment aspects of the invention are described based on the following embodiments with references to the drawings.",
"A. First Embodiment A1.",
"System Configuration: FIG. 1 exemplary illustrates an image output system 10 in the first embodiment.",
"The image output system 10 has an image processing apparatus 20 , a printer 30 , and a digital camera 40 .",
"The digital camera 40 and the image processing apparatus 20 , as well as the image processing apparatus 20 and the printer 30 are respectively connected locally via a USB cable.",
"The image processing apparatus 20 converts the image data 50 so as to be reproduced in the image on which the gradations of the brightness of image data 50 obtained from the digital camera 40 is printed with printer 30 .",
"The image processing apparatus 20 outputs the converted image data 50 a to the printer 30 .",
"The image processing apparatus 20 is a typical personal computer equipped with a CPU, RAM, and ROM.",
"The functional blocks of the image processing apparatus are illustrated in the FIG. 1 .",
"Each functional block is controlled by the CPU 100 .",
"The memory 120 stores an image data obtaining module 130 , a color conversion module 140 , a profile storage area 150 and a printing module 160 .",
"Each functional block is implemented using software.",
"Each functional block may be constituted using hardware.",
"The RAM 110 is readable/writable memory.",
"The image data recording area 111 is constituted as part of the RAM 110 .",
"An input/output unit 170 sends and receives image data between the printer 30 and the digital camera 40 .",
"The image data obtaining module 130 records the image data 50 obtained from the digital camera 40 onto the image data recording area 111 .",
"An input device profile PF 1 and an output device profile PF 2 are stored in the profile storage area 150 .",
"The input device profile PF 1 includes the color conversion information from the device dependent color space of the digital camera 40 that is the input device to the device independent color space.",
"Also, the output device profile PF 2 includes the color conversion information from the device independent color space to the device dependent color space of the printer 30 that is the output device.",
"The color conversion module 140 uses the input device profile PF 1 and the output device profile PF 2 to convert the color space of the image data 50 from the device dependent color space that depends on the digital camera 40 as the input device to the device dependent color space that depends on the printer 30 as the output device.",
"Converting the color space means converting each pixel value of the pixels that constitute the image data 50 expressed by the device dependent color space that depends on the digital camera 40 to each of the pixel values of the image data 50 a expressed by the device dependent color space that depends on the printer 30 .",
"The conversion process implemented by the color conversion module 140 is described later.",
"The printing module 160 converts the image data 50 a converted by the color conversion module 140 to a format that is able to be interpreted by the printer 30 , and outputs the converted image data 50 a that is converted by printing module 160 to the printer 30 via the input/output unit 170 .",
"FIG. 2 exemplary illustrates a block chart that describes the color conversion process implemented by the color conversion module 140 in the first embodiment.",
"The color conversion module 140 has an input signal color conversion module 141 , a brightness conversion module 142 , and an output signal color conversion module 143 .",
"The input signal color conversion module 141 correlates to the “first color conversion module”",
"of this invention.",
"The brightness conversion module 142 correlates to the “brightness conversion module”",
"of this invention.",
"The output signal color conversion module 143 correlates to the “second color conversion module”",
"of the first embodiment.",
"In the first embodiment, the device dependent color space of the digital camera 40 that is the input device is the RGB color space, and the pixel values of each pixel of the image data expressed by the RGB color space are expressed as (R, G, B).",
"The device independent color space is the Lab color space and the image values of each pixel of the image data expressed by the Lab color spaces are expressed as (L, a, b).",
"“L”",
"represents brightness, and “a”",
"and “b”",
"represent chromaticity.",
"The device dependent color space of the printer 30 that is the output device is the CMYK color space, and the pixel values of each pixel of the image data expressed by the CMYK color space are expressed as (C, M, Y, K).",
"The input signal color conversion module 141 implements color conversion processing from the device dependent color space of the input device, specifically, the digital camera 40 , to the device independent color space.",
"In specific terms, the input signal color conversion module 141 obtains from the input device profile PF 1 the information for color conversion from the device dependent color space of the input device to the device independent color space.",
"The input signal color conversion module 141 uses the obtained color conversion information to convert image data expressed using the RGB color space color space to image data expressed using the Lab color space.",
"The color conversion information includes a color conversion table from the RGB color space to the Lab color space.",
"The input signal color conversion module 141 uses the color conversion table to convert each pixel value of the image data 50 from (R, G, B) expressed using the RGB color space to (L, a, b) expressed using the Lab color space.",
"It is also possible to include in the color conversion information an RGB-Lab color conversion matrix, for example.",
"The contents of the input device profile PF 1 are described with reference to the FIG. 3 .",
"FIG. 3 exemplary illustrates of the contents of the input device profile PF 1 in the first embodiment.",
"The input device profile PF 1 includes a header part PF 11 , device independent color space conversion information PF 12 , and input device color space information PF 13 .",
"The header part PF 11 includes the device type indicating the type of input device, the model name, and the creation date and time of the input device profile PF 1 .",
"The device independent color space conversion information PF 12 includes an RGB-Lab color conversion table as the color conversion information necessary for converting the image data 50 expressed using the device dependent color space (RGB color space) of the digital camera 40 that is the input device to the image data 50 expressed using the device independent color space (Lab color space).",
"The color space information PF 13 includes information relating to the color space that the digital camera, which is the input device, is able to reproduce.",
"The input device profile PF 1 is stored in the memory 120 together with installation of the input device driver.",
"The input device profile PF 1 is able to be supplied correlated to the image data 50 , for example.",
"The brightness conversion module 142 , in the Lab color space that is the device independent color space, converts the input brightness L of the image data 50 and calculates the output brightness L′ so that the gradation of the reproducible brightness by the input device is reproduced within the range of reproducible brightness by the output device.",
"Though an illustration is omitted in FIG. 3 , the color conversion module 140 includes a color area mapping module to correlate of the input color area expressing the reproducible range of chromaticity by the input device and the output color area that expresses the range of reproducible chromaticity by the output device.",
"The color area mapping module converts the chromaticity (a, b) of the image data 50 to the chromaticity (a′, b′), wherein the chromaticity (a, b) is expressed by the reproducible color area by the digital camera that is the input device, and the chromaticity (a′, b′) is expressed by the reproducible color area by the printer that is the output device.",
"The pixel values of the image data 50 are converted (L, a, b) to (L′, a′, b′) by the brightness conversion module 142 and the color area mapping module.",
"The output signal color conversion module 143 implements color conversion processing from the device independent space to the device dependent color space of the digital camera 40 that is the output device.",
"In specific terms, the output signal color conversion module 143 obtains the color conversion information from the output device profile PF 2 .",
"The output device profile PF 2 includes information to convert from the device independent color space of the output device to the device dependent color space.",
"The output signal color conversion module 143 uses the obtained color conversion information to convert image data expressed using the Lab color space color space to image data expressed using the CMYK color space.",
"The color conversion information includes a color conversion table from the Lab color space to the CMYK color space.",
"The output signal color conversion module 143 uses the color conversion table to convert each pixel value of the image data 50 from (L′, a′, b′) expressed by the Lab color space to (C, M, Y, K) expressed by the CMYK color space.",
"It is also possible to include in the color conversion information a Lab-CMYK color conversion matrix, for example.",
"The contents of the output device profile PF 2 are described using FIG. 4 .",
"FIG. 4 exemplary illustrates an example of the contents of the output device profile PF 2 in the first embodiment.",
"The output device profile PF 2 has the same constitution as the input device profile PF 1 , and consists of a header part PF 21 , device independent color space conversion information PF 22 , and input device color space information PF 23 .",
"The header part PF 21 includes the device type that indicates the input device type, the model name, and the creation date and time of the output device profile PF 2 .",
"The device independent color space information PF 22 includes the Lab-CMYK color conversion table as color conversion information necessary to confer the image data 50 expressed by the device independent color space (Lab color space) to image data 50 a expressed by the device dependent color space (CMYK color space) of the printer 30 that is the output device.",
"The color space information PF 23 includes information relating to the reproducible color space by the printer which is the output device.",
"A2.",
"Printing Process: FIG. 5 exemplary illustrates a flow chart for describing the printing process in the first embodiment.",
"The image processing apparatus 20 starts this printing process with printing instructions from the user as the trigger.",
"When the image processing apparatus 20 receives the printing instructions from the user, the image processing apparatus 20 reads the image data recorded in the image data recording area 111 (step S 10 ), implements input signal color conversion processing, and converts each pixel value (R, G, B) of the image data 50 expressed by the RGB color space to (L, a, b) expressed by the Lab color space (step S 11 ).",
"The image processing apparatus 20 implements color area and brightness conversion on each pixel value (L, a, b) of the image data 50 expressed by the Lab color space, and converts each pixel value to (L′, a′, b′) (step S 12 ).",
"In the first embodiment, only the selected input brightness L input that is the brightness of the achromatic pixels of the pixels of the image data 50 are converted to the output brightness L output using the equation 3 shown below.",
"[ Equation 3 ] L output = ( L max - L black ) ( L output L max ) γ + L black γ = L max L max - L black , ( Equation 3 ) L max : Maximum value of brightness for the Lab color space L black : Minimum value of the reproducible brightness by the printer L input : selected input brightness L output : Output brightness Gradation change by the input brightness conversion process is described in reference to FIG. 6 .",
"FIG. 6 exemplary illustrates a brightness graph 300 that expresses brightness gradation changes in the first embodiment.",
"The horizontal axis of the brightness graph 300 represents the RGB value of the input image data 50 , and the vertical axis represents the output brightness L of the image data.",
"For the input RGB values, each value (R, G, B) changes in sequence from (0, 0, 0) to (1, 1, 1) (2, 2, 2) .",
"(255, 255, 255).",
"The output brightness L output has a range from 0 to 100.",
"L black that represents the minimum value of the reproducible brightness by the printer 30 which is the output device shows black points that are the darkest spots of the brightness.",
"The input brightness graph L input shows the reproducible brightness by the digital camera 40 for the input RGB values.",
"As shown in FIG. 6 , as the input RGB value increases, the output brightness L gradually becomes higher, in other words, as the input RGB value increases, the brightness is higher.",
"The output brightness graph Ls shows the reproducible output brightness Lout by the printer 30 when using the conventional method.",
"The output brightness graph L output is a graph representing the output brightness L output calculated applying equation 3 in the first embodiment to the input RGB values.",
"The range of reproducible brightness by the printer 30 is a range from L black to 100, and is narrower than the range of reproducible brightness by the digital camera 40 (0 to 100).",
"Because of that, with the conventional brightness conversion processing, as shown in the output brightness graph Ls, when the RGB values of each pixel value of the input image data is included in the range R 1 from (0, 0, 0) to the P 1 (r, g, b), all of the input brightness L input are converted to L black , and the gradations of the input brightness L input are not reproduced with the output brightness L out .",
"In the first embodiment, by the brightness conversion module 142 implementing the brightness conversion process applying equation 3, the output brightness graph L output -graph is obtained as a graph representing brightness that is able to be reproduced by the printer 30 .",
"By applying the equation 3, as shown by the arrow, the brightness conversion module 142 converts the input brightness L input on the input brightness graph L input -graph to the output brightness L output on the output brightness graph L output -graph.",
"Specifically, the brightness conversion module 142 reproduces as L black to L 1 the low brightness gradations from 0 to L black of the input brightness L input for the input RGB values included in the range R 1 .",
"According to the image processing apparatus of the first embodiment described above, by applying equation 3, even when the range of reproducible brightness by the printer that is the output device is narrower than the range of reproducible brightness by the digital camera that is the input device, it is possible to reproduce the gradations of the brightness of the image data shot using the digital camera in the image printed using the printer.",
"Conventionally, of the image data brightness, brightness lower than the black points of the printer were all converted to printer black points, and with images output by the printer, low brightness gradations were not expressed, but with this invention, it is possible to express gradation of low brightness of image data shot using the digital camera for images output by the printer.",
"Also, equation 3 is applied not only to low brightness input brightness but to all the input brightness, so for reproducible brightness by the printer, it is possible to ensure gradation properties for the low brightness part and also to reproduce gradations smoothly for all the brightness.",
"B. Second Embodiment With the first embodiment described above, by applying equation 3 to the achromatic input brightness, the gradation properties of the reproducible brightness by the printer are ensured.",
"In the second embodiment, considering chroma saturation, the gradations of the brightness in a digital camera are reproduced in the range for which brightness is able to be reproduced by the printer.",
"The system configuration in the second embodiment is the same as the system configuration in the first embodiment.",
"B1.",
"Brightness Conversion Process: FIG. 7 exemplary illustrates a flow chart for describing the brightness conversion process in the second embodiment.",
"This brightness conversion process is implemented by the brightness conversion module 142 , and correlates to the process of step S 12 in FIG. 5 .",
"The brightness conversion module 142 calculates the input chroma saturation C input of each pixel value of the image data expressed using the Lab color space (step 30 ).",
"The brightness conversion module 142 calculates the input chroma saturation C input by applying the equation 4 below.",
"[Equation 4] C input =√{square root over ( a input 2 +b input 2 )} (Equation 4) (Where a input and b input are the “a”",
"and “b”",
"values of the input pixels for the Lab color space) The brightness conversion module 142 determines whether the input chroma saturation C input is lower than the chroma saturation threshold value C th (step S 31 ).",
"The chroma saturation threshold value C th represents ⅔ of the lowest chroma saturation value for the outside edge of the chromaticity of the Lab color space.",
"When the input chroma saturation C input is lower than the chroma saturation threshold value C th (step S 31 : Yes), the brightness conversion module 142 converts input brightness Linput to the output brightness L output by in consideration of the chroma saturation brightness (step S 32 ).",
"In specific terms, the brightness conversion module 142 calculates the output brightness L final by applying the equation 5 below.",
"Specifically, with a range for which the input chroma saturation C input is from 0 to the chroma saturation threshold value C th , the output brightness L final is calculated by varying the mixture ratio of the input brightness L input and the output brightness L output .",
"Note that L output is the value calculated by applying equation 3 in the first embodiment, and correlates to the “tentative output brightness”",
"for this invention.",
"[ Equation 5 ] L final = ( L input * ( C input C max ) ) + ( L output * ( C max - C input C max ) ) ( Equation 5 ) C th : Chroma saturation threshold value for the Lab color space L final : Output brightness after conversion When the input chroma saturation C input is the chroma saturation threshold value C th or greater (step S 31 : No), the brightness conversion module 142 uses the input brightness L input as is as the output brightness L final applying equation 6 (step S 33 ).",
"Specifically, with the range for which the input chroma saturation C input is from the chroma saturation threshold value C th to the chroma saturation maximum value, the input brightness L input is used as the output brightness L final .",
"[Equation 6] L final =L input (Equation 6) Gradation reproduction considering chroma saturation is described with reference to FIG. 8 .",
"FIG. 8 exemplary illustrates a brightness graph 400 representing brightness gradation changes in the second embodiment.",
"The horizontal axis of the brightness graph 400 represents the input chroma saturation C input of the image data 50 , and the vertical axis represents the brightness L of the image data.",
"The input chroma saturation Cinput uses a value in the range from 0 to 60.",
"The brightness L uses a value in the range from 0 to 100.",
"L black representing the minimum value of the reproducible brightness by the printer 30 that is the output device shows the darkest point of the brightness, in other words, black points.",
"In the second embodiment, described is an example of a color for which the brightness is L 4 when the input chroma saturation C input is 0.",
"The input brightness graph L input -graph shows the reproducible input brightness L input by the digital camera 40 for the input chroma saturation C input .",
"As shown in FIG. 8 , with the digital camera 40 , as the input chroma saturation C input increases from 0 to 60, the brightness L also gradually increases from L 4 to L 2 and as the input chroma saturation Cinput gradually decreases from 60 to 0, the brightness L increases from L 2 to 100.",
"The output brightness graph L output -graph shows the reproducible output brightness L output by the printer 30 on the chroma saturation C input .",
"The output brightness L output is calculated applying equation 3 in the first embodiment.",
"The output brightness graph L final -graph shows the reproducible output brightness L final by the printer 30 on the input chroma saturation C input .",
"The output brightness L final is calculated applying equation 5 in the second embodiment.",
"When brightness conversion processing is implemented applying only equation 3 in the first embodiment, as shown in the output brightness graph L output -graph, as the chroma saturation increases, the output brightness L output has a higher value than the input brightness Linput, with the result that and the brightness is not reproduced appropriately.",
"In the second embodiment, by the brightness conversion module 142 implementing brightness conversion processing applying equation 5, the output brightness graph L final -graph is obtained showing the output brightness Lfinal.",
"As shown in the brightness graph 400 , as the input chroma saturation C input increases from 0 to the chroma saturation threshold value Cth, the output brightness L final increases from L black to L 5 so that the gradations of the input brightness L input are reproduced.",
"As the input chroma saturation Cinput increases from the chroma saturation threshold value Cth to 60, the output brightness L final uses the same value as the input brightness L input , and increases from L 5 to L 2 .",
"Even the part for which the input chroma saturation Cinput becomes lower from 60 to the chroma saturation threshold Cth, the output brightness L final uses the same value as the input brightness L input and increases from L 2 to L 3 .",
"As the input chroma saturation C input decreases from the chroma saturation threshold value Cth to 0, the output brightness L final increases from L 3 to 100.",
"In the second embodiment, when the input chroma saturation C input is less than the chroma saturation threshold value Cth, the mixture ratio of the input brightness L input and the output brightness L output is varied to calculate the output brightness L final and the condition branching midway in the calculation is simplified, but when the input chroma saturation C input changes decreasingly from a maximum value of 60 to 0, the same as when the input chroma saturation C input is the chroma saturation threshold value Cth or greater, it is also possible to use the input brightness L input as the output brightness Lfinal.",
"This is because in the range for which the brightness is high, it is possible for the printer 30 to reproduce the input brightness L input without converting the input brightness L input .",
"According to the image processing apparatus in the second embodiment described above, in the low chroma saturation area, in other words, the low chroma saturation area near the achromatic axis, the ratio of the output brightness L output is made higher than the input brightness L input to mix the input brightness L input and the output brightness L output , as the input chroma saturation C input comes closer to the chroma saturation threshold value Cth, by making the ratio of the input brightness L input higher than the output brightness L output and mixing the input brightness L input and the output brightness L output , it is possible to reproduce the gradations of the image data brightness with good precision.",
"Also, in the high chroma saturation area, it is possible to use the input brightness as is as the output brightness, and it is possible to improve the precision of gradation reproduction.",
"C. Variation Embodiments (1) In the first embodiment described above, the Lab color space was used as the device independent color space, but it is also possible to use the LUV color space or the YCrCb color space.",
"It is acceptable as long as it is a device independent color space that uses brightness as one of the components.",
"(2) In the second embodiment described above, the chroma saturation threshold value Cth was set as ⅔ the chroma saturation value of the lowest chroma saturation value for the outside edge of the chroma saturation of the Lab color space, but it is also possible to use ½ the chroma saturation value of the lowest chroma saturation value, for example.",
"The chroma saturation maximum value and the color area characteristics differ for each device, so it is preferable to set the chroma saturation maximum value and the chroma saturation threshold value Cth according to the device.",
"Above, various embodiments of the invention were described, but the invention is not limited to these embodiments, and it is clearly possible to have various constitutions in a range that does not stray from its key points.",
"The Japanese patent applications as the basis of the priority claim of this application are incorporated in the disclosure here of by reference: (1) Japanese Patent Application No. 2005-90765(filing data: Mar. 28, 2005)."
] |
FIELD OF THE INVENTION
The present disclosure relates, in general, to memory devices, and more particularly, to a nonvolatile memory device and methods of siliciding both select and control gates of the device.
RELATED ART
It has been shown that non-volatile memory single-transistor bitcells having a dielectric with embedded nanoclusters for use as discrete charge storage elements, can be charged with electrons using hot carrier injection (HCI injection), HCI injection with reverse well/source bias, Fowler-Nordheim (FN) tunneling, or source side injection (SSI). HCI and SSI programming result in an efficient bitcell and fast programming, but the programming current for SSI programming is 10-100 times smaller than for HCI programming. While HCI programming can be achieved in a 1-transistor bitcell, SSI programming requires a bitcell with two gates in close proximity having a control gate and a select gate. Such a bitcell is known as a split gate bitcell. Bitcell programming times are 1-10 μsec, but read access times for nonvolatile memory embedded in a microcontroller are much faster, 10-20 nsec. Because of the very fast read access time, control of the RC delay on the control and select gates is becoming of higher importance. This is especially true for gates that may not be connected to metal lines for long distances. One way to reduce this RC delay is by silicidation of not only the select gate portion of the memory device but by silicidation of the control gate portions of the memory device as well.
Accordingly, a method of forming a memory device whereby control gates and select gates are silicided is needed. Additionally, methods for separating the control gate silicide from the select gate silicide are needed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limited by the accompanying figures, in which like references indicate similar elements, and in which:
FIG. 1 is a cross-sectional view of a nonvolatile memory device showing the portion to be used for the memory including a shallow trench isolation according to one embodiment of the present disclosure;
FIG. 2 is a cross-sectional view of a nonvolatile memory device having a select gate oxide with a first polysilicon layer and a nitride layer disposed above according to an embodiment of the present disclosure;
FIG. 3 is a cross-sectional view of a nonvolatile memory device after the first polysilicon layer has been patterned and etched according to an embodiment of the present disclosure;
FIG. 4 is a cross-sectional view of a nonvolatile memory device after formation of nanoclusters for charge storage and a second polysilicon layer for formation of the control gate to an embodiment of the present disclosure;
FIG. 5 is a cross-sectional view of a nonvolatile memory device after the control gate has been patterned and etched to an embodiment of the present disclosure;
FIG. 6 is a cross-sectional view of a nonvolatile memory device after the select gate has been patterned and etched to an embodiment of the present disclosure;
FIG. 7 is a cross-sectional view of a nonvolatile memory device after nitride spacers have been formed according to an embodiment of the present disclosure;
FIG. 8 is a cross-sectional view of a nonvolatile memory device after the control gate and the select gate have been silicided according to an embodiment of the present disclosure;
FIG. 9 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure after the structure in FIG. 5 has undergone a patterning and etching of one bitcell control gate;
FIG. 10 is a cross-sectional view of a nonvolatile memory device after the processes of FIG. 9 , and after the device has had nitride sidewall spacers and nitride spacers formed;
FIG. 11 is a cross-sectional view of a nonvolatile memory device after the processes of FIG. 10 and after the control gate and the select gate have been silicided;
FIG. 12 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure after the processes of FIG. 4 showing silicided control and select gates for a 2-bit storage cell;
FIG. 13 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure after the processes of FIG. 4 and after the polysilicon has been polished to form a control gate;
FIG. 14 is a cross-sectional view of the nonvolatile memory device of FIG. 13 after formation of the select gate and silicidation of both control gate and select gates;
FIG. 15 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure whereby the nanoclusters are deposited prior to forming the first polysilicon layer;
FIG. 16 is a cross-sectional view of the non-volatile memory device from FIG. 15 after the layers have been patterned and etched;
FIG. 17 is a cross-sectional view of the non-volatile memory device from FIG. 16 after formation of oxide sidewall spacers and deposition of a second polysilicon layer;
FIG. 18 is a cross-sectional view of the non-volatile memory device from FIG. 17 after the control gates and the select gates have been patterned and etched;
FIG. 19 is a cross-sectional view of the non-volatile memory device from FIG. 18 after formation of nitride sidewall spacers and nitride spacers for the select gates and control gates;
FIG. 20 is a cross-sectional view of the non-volatile memory device from FIG. 19 after silicidation of the select gates and control gates; and
FIG. 21 is a cross-sectional view of a non-volatile memory device according to another embodiment of the present disclosure showing a contact to multiple silicided control gates.
Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present disclosure.
DETAILED DESCRIPTION
FIGS. 1-8 show cross-sectional views of a semiconductor device during the various stages of manufacture of a memory device including nanoclusters and silicided select gates and control gates according to a first embodiment of the present invention.
FIG. 1 is a cross-sectional view of a nonvolatile memory (NVM) device 10 according to one embodiment of the present disclosure. Memory device 10 includes a substrate 12 that contains bitcell wells of a first conductivity type that may overlie a deep well of a second conductivity type, opposite the first conductivity type. In one embodiment, the first conductivity type includes p-type and the second conductivity type includes n-type dopant. These are not shown for clarity but are known to those of skill in the art. Memory device also includes an isolation structure 13 such as shallow trench isolation. Other isolation structures such as LOCOS are also contemplated.
FIG. 2 shows the memory device 10 after the gate oxide layer 17 has been formed. Typically this oxide is on the order of approximately 20-50 Å and has been thermally grown. Layer 17 can also be formed by other methods including chemical vapor deposition and can also be formed from another dielectric such as silicon oxynitride, hafnium oxide, aluminum oxide, or the like. A first layer of polysilicon 19 is then formed over oxide layer 17 . Polysilicon layer 19 will serve as the conductive layer for the select gate portion of the NVM device. In one embodiment, polysilicon layer 19 is approximately 1000 Å thick and includes an n-type dopant. Nitride layer 21 is deposited over polysilicon layer 19 . Nitride layer 21 may be used as an etch stop layer for subsequent processing steps as discussed later. In other embodiments, layer 21 may include silicon nitride, silicon oxynitride, silicon rich oxynitride, or the like. Nitride layer 21 is approximately 700-1000 Å or thicker and is formed by conventional processes including chemical vapor deposition (CVD).
FIG. 3 is a cross-sectional view of the NVM device after polysilicon layer 19 has been patterned and etched using conventional lithographic and etch methods. At this time, the well doping under the area that will become the control gate can be differentiated from the well doping under the select gate with a well implant layer 23 . This additional well implant can be n-type or p-type, depending on the relative values of the control and select gate threshold voltages.
FIG. 4 is a cross-sectional view of the memory device after formation of a layer of oxide 25 . The oxide layer 25 is formed to a thickness of approximately 50-70 Å and is thermally grown. Oxide layer 25 can also be another dielectric material such as silicon oxynitride or a high dielectric constant (high K) and may be formed by other methods including CVD, atomic layer deposition (ALD), or the like. Nanoclusters 29 can be formed by CVD, by aerosol deposition techniques, by spin on coating techniques, by self assembly techniques such as e.g. annealing a thin film to form the nanoclusters, or the like. Typical nanoclusters include Si, SiGe, Al, Au, a silicon and germanium alloy, or other types of conductive material or doped or undoped semiconductive material. The nanoclusters are formed at the preferred densities in the range of 5×10 11 cm −2 to 1.0×10 12 cm −2 and a diameter of 50-150 Å or larger and with a coverage of approximately 25%. A layer of dielectric 27 may then be deposited to serve as the dielectric separating the previously deposited nanoclusters 29 from the control gate. Dielectric layer 27 is typically SiO 2 and may be deposited to a thickness of 80-120 Å. Dielectric layer 27 can also be a layer of higher permittivity such as aluminum oxide. A second layer of polysilicon 31 is formed over dielectric 27 . Polysilicon 31 will serve as the conductive layer for the control gate portion of the NVM device. In one embodiment, polysilicon layer 31 is approximately 1500 Å thick and may include a p-type dopant. The thickness of polysilicon layer 31 will be dependent on the required length of the control gate so may be either less than or greater than 1500 Å thick.
Turning now to FIG. 5 , a cross sectional view of the memory device is shown after etch processes have been performed to form the control gate 33 in a sidewall spacer configuration. In one embodiment, an anisotropic dry etch is used. A further process may then be used to remove the nanoclusters and oxide from the top surface of nitride layer 21 while retaining the nanoclusters and oxide that separate the control gate portion of the device from the select gate portion of the device. This may be done by a dry etch or a combination of dry and wet etch processes and can also remove nitride layer 21 .
Lithographic and etch processes are then used to form the select gates 37 as shown in FIG. 6 . Select gate 37 is comprised of both polysilicon layer 19 as well as oxide layer 17 . Nitride layer 21 is now nitride layers 39 over the separate select gate regions 37 . In a preferred embodiment, nitride layers 39 are then removed. This may be performed using an isotropic wet etch in hot phosphoric acid without using a mask. At this time source and drain extensions may be formed by well know implantation techniques. The extensions may be doped n-type.
A layer of nitride or like material is then formed over the entire structure. The nitride may be formed by CVD or like processes and, according to one embodiment, be approximately 700 Å thick. A conventional anisotropic nitride etch process may then be used to form sidewall spacers 41 adjacent the control gates 33 , sidewall spacers 42 separating the select gates 37 , and sidewall spacers 43 that will further serve to separate oxide layer 25 from any further materials formed overlying select gates 37 . Sidewall spacers 41 , 42 , and 43 are shown in FIG. 7 .
FIG. 8 is a cross sectional view of the resulting structure in accordance with the first embodiment of the present invention. The structure of FIG. 7 has been processed to form select gate silicide 47 , control gate silicide 45 , and silicided source and drain areas 24 . In a preferred embodiment, a layer of metal such as titanium, tungsten, cobalt, nickel, an alloy or other like material is blanket deposited. An anneal reacts the metal with any exposed silicon to form a silicide. Any unreacted metal is subsequently removed. A final anneal can then be performed. The result is a memory device with silicided control gates and select gates whereby the silicided areas are electrically isolated from one another by dielectric materials. Sidewall spacers 41 , 42 , and 43 are silicide resistant areas and will, therefore, remain essentially unchanged.
It is noted that one of ordinary skill would see that by careful patterning of the select gate area, it would be possible to contact the control gate area in a way that no extra masking step for the control gate would be necessary to define the control gate contact area. The masking layer used to define select gate 37 , is shaped such that the subsequent sidewall spacer control gates, 33 , are contiguous and provide sufficient area to permit a lithographically defined contact to be patterned. This is more easily seen in FIG. 21 whereby a single contact 100 is seen to contact the control gates 33 prepared in the sidewall spacer method of the aforementioned embodiment.
FIGS. 9-11 show cross-sectional views of a semiconductor device during the various stages of manufacture of a memory device including nanoclusters and a silicided select gate and control gate according to a second embodiment of the present invention.
Turning now to FIG. 9 , a structure is shown after the structure of FIG. 5 has been patterned and etched according to a preferred embodiment resulting in a single bitcell device with control gate 33 . Conventional masking techniques are used subsequent to the formation of the spacer control gate to form the single bitcell. A conventional dry etch process, a wet etch or a combination of both may be used to attain the structure shown in FIG. 9 . Nitride layer 21 may then be removed using a masked or unmasked isotropic wet etch in hot phosphoric acid, or an anisotropic dry etch with conventional masking techniques.
A layer of nitride or like material is then formed over the entire structure. The nitride may be formed by CVD or like processes and, according to one embodiment, be approximately 700 Å thick. A conventional anisotropic nitride etch process may then be used to form sidewall spacer 42 and sidewall spacer 43 that will further serve to separate oxide layer 25 from any further materials formed overlying select gate 37 as shown in cross section in FIG. 10 .
FIG. 11 is a cross sectional view of the resulting structure in accordance with the second embodiment of the present invention. The structure of FIG. 10 has been further processed to form select gate silicide 47 , control gate silicide 45 , and silicided source and drain areas 24 .
FIG. 12 is a cross section of a third embodiment of the present invention showing a 2-bit memory cell. The structure of FIG. 4 has been etched in a manner similar to that described for FIG. 5 . In this embodiment, however, the process step that removes the nanoclusters 29 , oxide 25 , and control gate 33 is performed in a manner that recesses control gates 33 below select gate 37 . In a preferred embodiment, the select gate 37 has been masked to allow for the anisotropic etch of control gates 33 as well as nanoclusters 29 and oxide 25 . A combination of anisotropic etch with isotropic etch may also be performed. The subsequent formation of a blanket nitride layer is followed by an anisotropic etch. This results in sidewall spacers 44 and 41 . In this embodiment, sidewall spacers 44 overlie the nanoclusters 29 and oxide layer 25 while sidewall spacers 41 overlie control gates 33 . In a preferred embodiment, spacers 41 overly only a small portion of control gate 33 . Further processing is performed whereby a layer of metal such as titanium, tungsten, cobalt, nickel, an alloy or other like material is blanket deposited. An anneal reacts the metal with any exposed silicon to form a silicide. Any unreacted metal is subsequently removed. A final anneal can then be performed. The result is a memory device with silicided control gates that are recessed with respect to silicided select gates.
One of skill in the art would realize that a single bit memory cell could also be formed in the manner described in FIG. 12 for the 2-bit memory cell. For the single bit memory cell, the result of processing would be a single spacer on one side of the select gate as opposed to the double spacer as shown in FIG. 12 .
FIGS. 13 and 14 are cross sectional views of a memory device according to a fourth embodiment of the present invention. Beginning with the structure of FIG. 4 , a polish process such as chemical mechanical polishing (CMP) is used to planarize the second layer of polysilicon 31 as well as remove nanoclusters 29 and oxide 27 overlying nitride 21 . Multiple slurries may be used to achieve the best planarity of the structure. Polishing is stopped when nitride layer 21 is cleared of polysilicon layer 31 . A blanket etchback process is also contemplated for the planarization of the second layer of polysilicon 31 .
FIG. 14 shows a cross sectional view of a memory device according to the fourth embodiment of the present invention. Lithographic and etch processes define control gates 33 and select gates 37 . An anisotropic polysilicon etch is preferred. At this point, the processes as described for the first embodiment and shown in FIGS. 6-8 may be performed. The resulting structure is an essentially planar silicided control gate 33 with recessed and silicided select gates 37 .
FIGS. 15-20 are cross sectional views of a memory device according to a fifth embodiment of the present invention. Turning first to FIG. 15 , a gate oxide layer 17 is formed overlying a substrate 12 . Typically oxide layer 17 is on the order of approximately 50-70 Å and has been thermally grown. Layer 17 can also be formed by other methods including chemical vapor deposition and can also be formed from another dielectric such as silicon oxynitride, hafnium oxide, aluminum oxide, or the like. Nanoclusters 29 are then formed by island growth during CVD, by aerosol deposition techniques, by spin on coating techniques, by self assembly techniques such as e.g. annealing a thin film to form the nanoclusters, or the like. Typical nanoclusters include Si, SiGe, Al, Au, a silicon and germanium alloy, or other types of conductive material or doped or undoped semiconductive material. The nanoclusters are formed at the preferred densities in the range of 5×10 11 cm −2 to 1.1×10 12 cm −2 and an undoped diameter of 50-150 Å or larger and with a coverage of approximately 25% or less. A layer of dielectric 27 is then deposited which will serve as the oxide separating the subsequently deposited nanoclusters 29 from the control gate. Dielectric layer 27 is typically SiO 2 and is deposited to a thickness of 80-120 Å. A first layer of polysilicon 19 is formed over nanoclusters 29 . Polysilicon 19 will serve as the conductive layer for the control gate portion of the NVM device. In one embodiment, polysilicon layer 19 is approximately 1500 Å thick. An oxide layer is formed overlying polysilicon layer 19 . Oxide layer 49 may be deposited by CVD or may be thermally grown. A preferred thickness is approximately 700-1000 Å. A nitride layer 21 is formed overlying oxide layer 49 . Nitride layer 21 may be used as an etch stop layer for subsequent processing steps as discussed later. In other embodiments, layer 21 may include silicon nitride, silicon oxynitride, silicon rich oxynitride, or the like. Nitride layer 21 is approximately 700-1000 Å or thicker and is formed by conventional processes including CVD.
Turning now to FIG. 16 , lithographic and etch processes have been performed resulting in a patterned first gate structure. This structure may go on to form the control gate for the memory device.
FIG. 17 is a cross sectional view after further processing on the structure from FIG. 16 . A layer of oxide, 51 , is deposited using a CVD or similar technique. A subsequent anisotropic etch is used to form oxide sidewall spacers on control gate polysilicon structure, 19 . A layer of oxide 53 is formed by either a thermal growth, by CVD or the like. A preferred thickness is 20-50 Å. Layer 53 can also be formed by other methods well known in the art for formation of oxides Layer 53 can also be formed from another dielectric such as silicon oxynitride, hafnium oxide, aluminum oxide, or the like. A second layer of polysilicon 55 is then formed. Polysilicon 55 will serve as the conductive layer for the select gate portion of the NVM device. In one embodiment, polysilicon layer 55 is approximately 1500 Å thick and may include a p-type dopant. A polish process, such as CMP, is then used to planarize the structure.
Polysilicon layer 55 is then patterned and etched to form select gates 55 . An anti-reflective coating (ARC) may be formed over the entire structure at this time to facilitate fine mask patterning. In a preferred embodiment nitride layer 49 , oxide layer 21 , polysilicon layer 19 , nanoclusters 29 , and oxide layer 17 are simultaneously patterned and etched to define what will become the control gate portion of the memory device. A patterning and etching process for the control gate portion of the memory device occurring subsequent to the definition of the select gate is also contemplated. The resulting cross sectional view is shown in FIG. 18 .
FIG. 19 is a cross sectional view of the memory device after further processing has occurred. Nitride layer 21 has been removed, preferably by using an isotropic wet etch in hot phosphoric acid or an anisotropic dry etch. Oxide layer 49 is also removed and may be removed in a similar manner as nitride layer 21 . The resulting structure is one in which the control gate portion of the memory device is recessed with respect to the select gate portion of the memory device. A blanket nitride layer is then formed which is then anisotropically etched to form sidewalls 59 and 61 for the control gate, as well as sidewalls 57 for the select gates. At this time, source and drain areas 23 may be formed by ion implantation or other techniques.
FIG. 20 is a cross sectional view of the memory device after processing has been done to form silicided select gates 47 , silicided control gates 45 , and silicided source and drain areas 24 . A process as described previously may be done to accomplish the silicidation.
The memory device after formation of a contact plug is shown in cross section in FIG. 21 . The cross sectional view is based on the method provided to form the silicided sidewall spacer control gates 33 and recessed silicided select gates 37 from FIG. 8 . In a preferred embodiment, a dielectric layer is first formed overlying the structure as shown in FIG. 20 . The dielectric may be SiO 2 , BPSG, PSG, a spin-on dielectric or the like. Planarization of the dielectric may be performed prior to the lithographic and etch processes. A conventional process is used to define a contact hole in the dielectric which will contact the underlying silicide of the control gate. Metallization of the contact is then done. This may include a barrier deposition and a CVD tungsten fill, followed by a CMP process to remove the overburden of tungsten. A selective tungsten process is also contemplated as is other metallization techniques known in the art. As noted previously, careful selection of the patterning of the control gates 33 will enable the contact to the control gates 33 as shown.
In one embodiment, a 2-bitcell memory device includes a split gate device that uses nanoclusters for charge storage in which both the select gates and the control gates have been silicided and whereby the select gates are recessed with respect to the control gates. The silicides for the control gates and select gates are separated from one another by at least a spacer material that overlies the conductive portion of the select gate. The nanoclusters are underlying the control gate portion of the memory device.
In another embodiment, a single bitcell memory device that uses nanoclusters for charge storage in which both the select gate and the control gate have been silicided and whereby the select gate is recessed with respect to the control gate is shown. The silicides for the control gate and select gate are separated from one another by at least a spacer material that overlies the conductive portion of the select gate. The nanoclusters are underlying the control gate portion of the memory device.
In another embodiment, a 2-bit storage cell that uses nanoclusters for charge storage in which both the select gate and the control gates have been silicided is shown. The control gates are recessed with respect to the select gate. The silicides for the control gates and select gate are separated from one another by at least a spacer material that overlies the nanoclusters. The nanoclusters are underlying the control gate portion of the memory device.
In another embodiment, a polish process is used to planarize a conductive layer for the control gates and select gates. Further processing recesses the select gates with respect to the control gates. Both select gates and control gates are silicided. At least a spacer material separates the silicide of the select gate from the silicide for the control gate. The nanoclusters are underlying the control gate portion of the memory device.
In yet another embodiment, a polish process is used to planarize a conductive layer for the selective gate portion of the memory device. The nanoclusters are formed underlying the control gate portion of the memory device. Again, both select gates and control gates are silicided and are separated from one another by at least a spacer material. In this embodiment, the control gates are recessed with respect to the select gate portions.
Although the invention has been described with respect to specific conductivity types or polarity of potentials, skilled artisans appreciated that conductivity types and polarities of potentials may be reversed.
In the foregoing specification, the invention has been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims. As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. | A memory device is formed on a semiconductor substrate. A select gate electrode and a control gate electrode are formed adjacent to one another. One of either the select gate electrode or the control gate electrodes is recessed with respect to the other. The recess allows for a manufacturable process with which to form silicided surfaces on both the select gate electrode and the control gate electrode. | Concisely explain the essential features and purpose of the invention. | [
"FIELD OF THE INVENTION The present disclosure relates, in general, to memory devices, and more particularly, to a nonvolatile memory device and methods of siliciding both select and control gates of the device.",
"RELATED ART It has been shown that non-volatile memory single-transistor bitcells having a dielectric with embedded nanoclusters for use as discrete charge storage elements, can be charged with electrons using hot carrier injection (HCI injection), HCI injection with reverse well/source bias, Fowler-Nordheim (FN) tunneling, or source side injection (SSI).",
"HCI and SSI programming result in an efficient bitcell and fast programming, but the programming current for SSI programming is 10-100 times smaller than for HCI programming.",
"While HCI programming can be achieved in a 1-transistor bitcell, SSI programming requires a bitcell with two gates in close proximity having a control gate and a select gate.",
"Such a bitcell is known as a split gate bitcell.",
"Bitcell programming times are 1-10 μsec, but read access times for nonvolatile memory embedded in a microcontroller are much faster, 10-20 nsec.",
"Because of the very fast read access time, control of the RC delay on the control and select gates is becoming of higher importance.",
"This is especially true for gates that may not be connected to metal lines for long distances.",
"One way to reduce this RC delay is by silicidation of not only the select gate portion of the memory device but by silicidation of the control gate portions of the memory device as well.",
"Accordingly, a method of forming a memory device whereby control gates and select gates are silicided is needed.",
"Additionally, methods for separating the control gate silicide from the select gate silicide are needed.",
"BRIEF DESCRIPTION OF THE DRAWINGS The present invention is illustrated by way of example and not limited by the accompanying figures, in which like references indicate similar elements, and in which: FIG. 1 is a cross-sectional view of a nonvolatile memory device showing the portion to be used for the memory including a shallow trench isolation according to one embodiment of the present disclosure;",
"FIG. 2 is a cross-sectional view of a nonvolatile memory device having a select gate oxide with a first polysilicon layer and a nitride layer disposed above according to an embodiment of the present disclosure;",
"FIG. 3 is a cross-sectional view of a nonvolatile memory device after the first polysilicon layer has been patterned and etched according to an embodiment of the present disclosure;",
"FIG. 4 is a cross-sectional view of a nonvolatile memory device after formation of nanoclusters for charge storage and a second polysilicon layer for formation of the control gate to an embodiment of the present disclosure;",
"FIG. 5 is a cross-sectional view of a nonvolatile memory device after the control gate has been patterned and etched to an embodiment of the present disclosure;",
"FIG. 6 is a cross-sectional view of a nonvolatile memory device after the select gate has been patterned and etched to an embodiment of the present disclosure;",
"FIG. 7 is a cross-sectional view of a nonvolatile memory device after nitride spacers have been formed according to an embodiment of the present disclosure;",
"FIG. 8 is a cross-sectional view of a nonvolatile memory device after the control gate and the select gate have been silicided according to an embodiment of the present disclosure;",
"FIG. 9 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure after the structure in FIG. 5 has undergone a patterning and etching of one bitcell control gate;",
"FIG. 10 is a cross-sectional view of a nonvolatile memory device after the processes of FIG. 9 , and after the device has had nitride sidewall spacers and nitride spacers formed;",
"FIG. 11 is a cross-sectional view of a nonvolatile memory device after the processes of FIG. 10 and after the control gate and the select gate have been silicided;",
"FIG. 12 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure after the processes of FIG. 4 showing silicided control and select gates for a 2-bit storage cell;",
"FIG. 13 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure after the processes of FIG. 4 and after the polysilicon has been polished to form a control gate;",
"FIG. 14 is a cross-sectional view of the nonvolatile memory device of FIG. 13 after formation of the select gate and silicidation of both control gate and select gates;",
"FIG. 15 is a cross-sectional view of a nonvolatile memory device according to another embodiment of the present disclosure whereby the nanoclusters are deposited prior to forming the first polysilicon layer;",
"FIG. 16 is a cross-sectional view of the non-volatile memory device from FIG. 15 after the layers have been patterned and etched;",
"FIG. 17 is a cross-sectional view of the non-volatile memory device from FIG. 16 after formation of oxide sidewall spacers and deposition of a second polysilicon layer;",
"FIG. 18 is a cross-sectional view of the non-volatile memory device from FIG. 17 after the control gates and the select gates have been patterned and etched;",
"FIG. 19 is a cross-sectional view of the non-volatile memory device from FIG. 18 after formation of nitride sidewall spacers and nitride spacers for the select gates and control gates;",
"FIG. 20 is a cross-sectional view of the non-volatile memory device from FIG. 19 after silicidation of the select gates and control gates;",
"and FIG. 21 is a cross-sectional view of a non-volatile memory device according to another embodiment of the present disclosure showing a contact to multiple silicided control gates.",
"Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.",
"For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present disclosure.",
"DETAILED DESCRIPTION FIGS. 1-8 show cross-sectional views of a semiconductor device during the various stages of manufacture of a memory device including nanoclusters and silicided select gates and control gates according to a first embodiment of the present invention.",
"FIG. 1 is a cross-sectional view of a nonvolatile memory (NVM) device 10 according to one embodiment of the present disclosure.",
"Memory device 10 includes a substrate 12 that contains bitcell wells of a first conductivity type that may overlie a deep well of a second conductivity type, opposite the first conductivity type.",
"In one embodiment, the first conductivity type includes p-type and the second conductivity type includes n-type dopant.",
"These are not shown for clarity but are known to those of skill in the art.",
"Memory device also includes an isolation structure 13 such as shallow trench isolation.",
"Other isolation structures such as LOCOS are also contemplated.",
"FIG. 2 shows the memory device 10 after the gate oxide layer 17 has been formed.",
"Typically this oxide is on the order of approximately 20-50 Å and has been thermally grown.",
"Layer 17 can also be formed by other methods including chemical vapor deposition and can also be formed from another dielectric such as silicon oxynitride, hafnium oxide, aluminum oxide, or the like.",
"A first layer of polysilicon 19 is then formed over oxide layer 17 .",
"Polysilicon layer 19 will serve as the conductive layer for the select gate portion of the NVM device.",
"In one embodiment, polysilicon layer 19 is approximately 1000 Å thick and includes an n-type dopant.",
"Nitride layer 21 is deposited over polysilicon layer 19 .",
"Nitride layer 21 may be used as an etch stop layer for subsequent processing steps as discussed later.",
"In other embodiments, layer 21 may include silicon nitride, silicon oxynitride, silicon rich oxynitride, or the like.",
"Nitride layer 21 is approximately 700-1000 Å or thicker and is formed by conventional processes including chemical vapor deposition (CVD).",
"FIG. 3 is a cross-sectional view of the NVM device after polysilicon layer 19 has been patterned and etched using conventional lithographic and etch methods.",
"At this time, the well doping under the area that will become the control gate can be differentiated from the well doping under the select gate with a well implant layer 23 .",
"This additional well implant can be n-type or p-type, depending on the relative values of the control and select gate threshold voltages.",
"FIG. 4 is a cross-sectional view of the memory device after formation of a layer of oxide 25 .",
"The oxide layer 25 is formed to a thickness of approximately 50-70 Å and is thermally grown.",
"Oxide layer 25 can also be another dielectric material such as silicon oxynitride or a high dielectric constant (high K) and may be formed by other methods including CVD, atomic layer deposition (ALD), or the like.",
"Nanoclusters 29 can be formed by CVD, by aerosol deposition techniques, by spin on coating techniques, by self assembly techniques such as e.g. annealing a thin film to form the nanoclusters, or the like.",
"Typical nanoclusters include Si, SiGe, Al, Au, a silicon and germanium alloy, or other types of conductive material or doped or undoped semiconductive material.",
"The nanoclusters are formed at the preferred densities in the range of 5×10 11 cm −2 to 1.0×10 12 cm −2 and a diameter of 50-150 Å or larger and with a coverage of approximately 25%.",
"A layer of dielectric 27 may then be deposited to serve as the dielectric separating the previously deposited nanoclusters 29 from the control gate.",
"Dielectric layer 27 is typically SiO 2 and may be deposited to a thickness of 80-120 Å.",
"Dielectric layer 27 can also be a layer of higher permittivity such as aluminum oxide.",
"A second layer of polysilicon 31 is formed over dielectric 27 .",
"Polysilicon 31 will serve as the conductive layer for the control gate portion of the NVM device.",
"In one embodiment, polysilicon layer 31 is approximately 1500 Å thick and may include a p-type dopant.",
"The thickness of polysilicon layer 31 will be dependent on the required length of the control gate so may be either less than or greater than 1500 Å thick.",
"Turning now to FIG. 5 , a cross sectional view of the memory device is shown after etch processes have been performed to form the control gate 33 in a sidewall spacer configuration.",
"In one embodiment, an anisotropic dry etch is used.",
"A further process may then be used to remove the nanoclusters and oxide from the top surface of nitride layer 21 while retaining the nanoclusters and oxide that separate the control gate portion of the device from the select gate portion of the device.",
"This may be done by a dry etch or a combination of dry and wet etch processes and can also remove nitride layer 21 .",
"Lithographic and etch processes are then used to form the select gates 37 as shown in FIG. 6 .",
"Select gate 37 is comprised of both polysilicon layer 19 as well as oxide layer 17 .",
"Nitride layer 21 is now nitride layers 39 over the separate select gate regions 37 .",
"In a preferred embodiment, nitride layers 39 are then removed.",
"This may be performed using an isotropic wet etch in hot phosphoric acid without using a mask.",
"At this time source and drain extensions may be formed by well know implantation techniques.",
"The extensions may be doped n-type.",
"A layer of nitride or like material is then formed over the entire structure.",
"The nitride may be formed by CVD or like processes and, according to one embodiment, be approximately 700 Å thick.",
"A conventional anisotropic nitride etch process may then be used to form sidewall spacers 41 adjacent the control gates 33 , sidewall spacers 42 separating the select gates 37 , and sidewall spacers 43 that will further serve to separate oxide layer 25 from any further materials formed overlying select gates 37 .",
"Sidewall spacers 41 , 42 , and 43 are shown in FIG. 7 .",
"FIG. 8 is a cross sectional view of the resulting structure in accordance with the first embodiment of the present invention.",
"The structure of FIG. 7 has been processed to form select gate silicide 47 , control gate silicide 45 , and silicided source and drain areas 24 .",
"In a preferred embodiment, a layer of metal such as titanium, tungsten, cobalt, nickel, an alloy or other like material is blanket deposited.",
"An anneal reacts the metal with any exposed silicon to form a silicide.",
"Any unreacted metal is subsequently removed.",
"A final anneal can then be performed.",
"The result is a memory device with silicided control gates and select gates whereby the silicided areas are electrically isolated from one another by dielectric materials.",
"Sidewall spacers 41 , 42 , and 43 are silicide resistant areas and will, therefore, remain essentially unchanged.",
"It is noted that one of ordinary skill would see that by careful patterning of the select gate area, it would be possible to contact the control gate area in a way that no extra masking step for the control gate would be necessary to define the control gate contact area.",
"The masking layer used to define select gate 37 , is shaped such that the subsequent sidewall spacer control gates, 33 , are contiguous and provide sufficient area to permit a lithographically defined contact to be patterned.",
"This is more easily seen in FIG. 21 whereby a single contact 100 is seen to contact the control gates 33 prepared in the sidewall spacer method of the aforementioned embodiment.",
"FIGS. 9-11 show cross-sectional views of a semiconductor device during the various stages of manufacture of a memory device including nanoclusters and a silicided select gate and control gate according to a second embodiment of the present invention.",
"Turning now to FIG. 9 , a structure is shown after the structure of FIG. 5 has been patterned and etched according to a preferred embodiment resulting in a single bitcell device with control gate 33 .",
"Conventional masking techniques are used subsequent to the formation of the spacer control gate to form the single bitcell.",
"A conventional dry etch process, a wet etch or a combination of both may be used to attain the structure shown in FIG. 9 .",
"Nitride layer 21 may then be removed using a masked or unmasked isotropic wet etch in hot phosphoric acid, or an anisotropic dry etch with conventional masking techniques.",
"A layer of nitride or like material is then formed over the entire structure.",
"The nitride may be formed by CVD or like processes and, according to one embodiment, be approximately 700 Å thick.",
"A conventional anisotropic nitride etch process may then be used to form sidewall spacer 42 and sidewall spacer 43 that will further serve to separate oxide layer 25 from any further materials formed overlying select gate 37 as shown in cross section in FIG. 10 .",
"FIG. 11 is a cross sectional view of the resulting structure in accordance with the second embodiment of the present invention.",
"The structure of FIG. 10 has been further processed to form select gate silicide 47 , control gate silicide 45 , and silicided source and drain areas 24 .",
"FIG. 12 is a cross section of a third embodiment of the present invention showing a 2-bit memory cell.",
"The structure of FIG. 4 has been etched in a manner similar to that described for FIG. 5 .",
"In this embodiment, however, the process step that removes the nanoclusters 29 , oxide 25 , and control gate 33 is performed in a manner that recesses control gates 33 below select gate 37 .",
"In a preferred embodiment, the select gate 37 has been masked to allow for the anisotropic etch of control gates 33 as well as nanoclusters 29 and oxide 25 .",
"A combination of anisotropic etch with isotropic etch may also be performed.",
"The subsequent formation of a blanket nitride layer is followed by an anisotropic etch.",
"This results in sidewall spacers 44 and 41 .",
"In this embodiment, sidewall spacers 44 overlie the nanoclusters 29 and oxide layer 25 while sidewall spacers 41 overlie control gates 33 .",
"In a preferred embodiment, spacers 41 overly only a small portion of control gate 33 .",
"Further processing is performed whereby a layer of metal such as titanium, tungsten, cobalt, nickel, an alloy or other like material is blanket deposited.",
"An anneal reacts the metal with any exposed silicon to form a silicide.",
"Any unreacted metal is subsequently removed.",
"A final anneal can then be performed.",
"The result is a memory device with silicided control gates that are recessed with respect to silicided select gates.",
"One of skill in the art would realize that a single bit memory cell could also be formed in the manner described in FIG. 12 for the 2-bit memory cell.",
"For the single bit memory cell, the result of processing would be a single spacer on one side of the select gate as opposed to the double spacer as shown in FIG. 12 .",
"FIGS. 13 and 14 are cross sectional views of a memory device according to a fourth embodiment of the present invention.",
"Beginning with the structure of FIG. 4 , a polish process such as chemical mechanical polishing (CMP) is used to planarize the second layer of polysilicon 31 as well as remove nanoclusters 29 and oxide 27 overlying nitride 21 .",
"Multiple slurries may be used to achieve the best planarity of the structure.",
"Polishing is stopped when nitride layer 21 is cleared of polysilicon layer 31 .",
"A blanket etchback process is also contemplated for the planarization of the second layer of polysilicon 31 .",
"FIG. 14 shows a cross sectional view of a memory device according to the fourth embodiment of the present invention.",
"Lithographic and etch processes define control gates 33 and select gates 37 .",
"An anisotropic polysilicon etch is preferred.",
"At this point, the processes as described for the first embodiment and shown in FIGS. 6-8 may be performed.",
"The resulting structure is an essentially planar silicided control gate 33 with recessed and silicided select gates 37 .",
"FIGS. 15-20 are cross sectional views of a memory device according to a fifth embodiment of the present invention.",
"Turning first to FIG. 15 , a gate oxide layer 17 is formed overlying a substrate 12 .",
"Typically oxide layer 17 is on the order of approximately 50-70 Å and has been thermally grown.",
"Layer 17 can also be formed by other methods including chemical vapor deposition and can also be formed from another dielectric such as silicon oxynitride, hafnium oxide, aluminum oxide, or the like.",
"Nanoclusters 29 are then formed by island growth during CVD, by aerosol deposition techniques, by spin on coating techniques, by self assembly techniques such as e.g. annealing a thin film to form the nanoclusters, or the like.",
"Typical nanoclusters include Si, SiGe, Al, Au, a silicon and germanium alloy, or other types of conductive material or doped or undoped semiconductive material.",
"The nanoclusters are formed at the preferred densities in the range of 5×10 11 cm −2 to 1.1×10 12 cm −2 and an undoped diameter of 50-150 Å or larger and with a coverage of approximately 25% or less.",
"A layer of dielectric 27 is then deposited which will serve as the oxide separating the subsequently deposited nanoclusters 29 from the control gate.",
"Dielectric layer 27 is typically SiO 2 and is deposited to a thickness of 80-120 Å.",
"A first layer of polysilicon 19 is formed over nanoclusters 29 .",
"Polysilicon 19 will serve as the conductive layer for the control gate portion of the NVM device.",
"In one embodiment, polysilicon layer 19 is approximately 1500 Å thick.",
"An oxide layer is formed overlying polysilicon layer 19 .",
"Oxide layer 49 may be deposited by CVD or may be thermally grown.",
"A preferred thickness is approximately 700-1000 Å.",
"A nitride layer 21 is formed overlying oxide layer 49 .",
"Nitride layer 21 may be used as an etch stop layer for subsequent processing steps as discussed later.",
"In other embodiments, layer 21 may include silicon nitride, silicon oxynitride, silicon rich oxynitride, or the like.",
"Nitride layer 21 is approximately 700-1000 Å or thicker and is formed by conventional processes including CVD.",
"Turning now to FIG. 16 , lithographic and etch processes have been performed resulting in a patterned first gate structure.",
"This structure may go on to form the control gate for the memory device.",
"FIG. 17 is a cross sectional view after further processing on the structure from FIG. 16 .",
"A layer of oxide, 51 , is deposited using a CVD or similar technique.",
"A subsequent anisotropic etch is used to form oxide sidewall spacers on control gate polysilicon structure, 19 .",
"A layer of oxide 53 is formed by either a thermal growth, by CVD or the like.",
"A preferred thickness is 20-50 Å.",
"Layer 53 can also be formed by other methods well known in the art for formation of oxides Layer 53 can also be formed from another dielectric such as silicon oxynitride, hafnium oxide, aluminum oxide, or the like.",
"A second layer of polysilicon 55 is then formed.",
"Polysilicon 55 will serve as the conductive layer for the select gate portion of the NVM device.",
"In one embodiment, polysilicon layer 55 is approximately 1500 Å thick and may include a p-type dopant.",
"A polish process, such as CMP, is then used to planarize the structure.",
"Polysilicon layer 55 is then patterned and etched to form select gates 55 .",
"An anti-reflective coating (ARC) may be formed over the entire structure at this time to facilitate fine mask patterning.",
"In a preferred embodiment nitride layer 49 , oxide layer 21 , polysilicon layer 19 , nanoclusters 29 , and oxide layer 17 are simultaneously patterned and etched to define what will become the control gate portion of the memory device.",
"A patterning and etching process for the control gate portion of the memory device occurring subsequent to the definition of the select gate is also contemplated.",
"The resulting cross sectional view is shown in FIG. 18 .",
"FIG. 19 is a cross sectional view of the memory device after further processing has occurred.",
"Nitride layer 21 has been removed, preferably by using an isotropic wet etch in hot phosphoric acid or an anisotropic dry etch.",
"Oxide layer 49 is also removed and may be removed in a similar manner as nitride layer 21 .",
"The resulting structure is one in which the control gate portion of the memory device is recessed with respect to the select gate portion of the memory device.",
"A blanket nitride layer is then formed which is then anisotropically etched to form sidewalls 59 and 61 for the control gate, as well as sidewalls 57 for the select gates.",
"At this time, source and drain areas 23 may be formed by ion implantation or other techniques.",
"FIG. 20 is a cross sectional view of the memory device after processing has been done to form silicided select gates 47 , silicided control gates 45 , and silicided source and drain areas 24 .",
"A process as described previously may be done to accomplish the silicidation.",
"The memory device after formation of a contact plug is shown in cross section in FIG. 21 .",
"The cross sectional view is based on the method provided to form the silicided sidewall spacer control gates 33 and recessed silicided select gates 37 from FIG. 8 .",
"In a preferred embodiment, a dielectric layer is first formed overlying the structure as shown in FIG. 20 .",
"The dielectric may be SiO 2 , BPSG, PSG, a spin-on dielectric or the like.",
"Planarization of the dielectric may be performed prior to the lithographic and etch processes.",
"A conventional process is used to define a contact hole in the dielectric which will contact the underlying silicide of the control gate.",
"Metallization of the contact is then done.",
"This may include a barrier deposition and a CVD tungsten fill, followed by a CMP process to remove the overburden of tungsten.",
"A selective tungsten process is also contemplated as is other metallization techniques known in the art.",
"As noted previously, careful selection of the patterning of the control gates 33 will enable the contact to the control gates 33 as shown.",
"In one embodiment, a 2-bitcell memory device includes a split gate device that uses nanoclusters for charge storage in which both the select gates and the control gates have been silicided and whereby the select gates are recessed with respect to the control gates.",
"The silicides for the control gates and select gates are separated from one another by at least a spacer material that overlies the conductive portion of the select gate.",
"The nanoclusters are underlying the control gate portion of the memory device.",
"In another embodiment, a single bitcell memory device that uses nanoclusters for charge storage in which both the select gate and the control gate have been silicided and whereby the select gate is recessed with respect to the control gate is shown.",
"The silicides for the control gate and select gate are separated from one another by at least a spacer material that overlies the conductive portion of the select gate.",
"The nanoclusters are underlying the control gate portion of the memory device.",
"In another embodiment, a 2-bit storage cell that uses nanoclusters for charge storage in which both the select gate and the control gates have been silicided is shown.",
"The control gates are recessed with respect to the select gate.",
"The silicides for the control gates and select gate are separated from one another by at least a spacer material that overlies the nanoclusters.",
"The nanoclusters are underlying the control gate portion of the memory device.",
"In another embodiment, a polish process is used to planarize a conductive layer for the control gates and select gates.",
"Further processing recesses the select gates with respect to the control gates.",
"Both select gates and control gates are silicided.",
"At least a spacer material separates the silicide of the select gate from the silicide for the control gate.",
"The nanoclusters are underlying the control gate portion of the memory device.",
"In yet another embodiment, a polish process is used to planarize a conductive layer for the selective gate portion of the memory device.",
"The nanoclusters are formed underlying the control gate portion of the memory device.",
"Again, both select gates and control gates are silicided and are separated from one another by at least a spacer material.",
"In this embodiment, the control gates are recessed with respect to the select gate portions.",
"Although the invention has been described with respect to specific conductivity types or polarity of potentials, skilled artisans appreciated that conductivity types and polarities of potentials may be reversed.",
"In the foregoing specification, the invention has been described with reference to specific embodiments.",
"However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below.",
"Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention.",
"Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments.",
"However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims.",
"As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus."
] |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of corrosion-inhibiting pigments and is particularly concerned with such pigments comprising both zinc and chromium in chemical combination.
2. Prior Art
Metal protective pigments have long been used as components of coating compositions applied to metallic surfaces. Certain of these pigments have been, at least partially, effective in providing a specific inhibiting or passivating action at the surface of the metal. Among the useful pigments in this category are red lead and certain chromium containing pigments.
Among the better known chromium-containing pigments suggested for use in metal protecting coatings are zinc yellow or so called "zinc chromate" and zinc tetroxy chromate. These, among other pigments, are described in Kirk-Othmer: Encyclopedia of Chemical Technology, 2d. ed., Vol. 5 at pages 507-510; and by V. H. Chalupski in the monograph appearing in UDY: Chemistry of Chromium and its Compounds, Vol. 1 (Rheinhold Publishing Co., 1956) beginning at Page 357, particularly at pages 375-381. A further modified method for preparing zinc yellow is described in U.S. Pat. No. 2,410,916.
Zinc chromates have been used for many years as corrosion-inhibitive pigments. These pigments are used in formulations of paint and coating systems to protect metals against corrosion. The zinc chromate pigment may be used with other pigments such as red lead and ferric oxide pigments and/or with pigment extenders which may be applied as metal primers, such as, for example, in structural steel priming, on ships, aircraft, automotive bodies, etc.
The "zinc chromate" in present commercial use, or zinc yellow pigment as it is referred to in the trade, is a basic potassium zinc chromate, stated to have the empirical formula 4ZnO.4CrO 3 . K 2 O.3H 2 O. It can be made by a variety of processes, all based on the reaction of zinc and chromate compounds in aqueous solution and in the presence of potassium salts. Thus, it may be prepared by the reaction of acidified zinc oxide with potassium dichromate. The procedure described in U.S. Pat. No. 2,410,916 involves precipitation of a zinc salt with a solution of a chromate in the presence of potassium ions and hydroxyl ions. Other procedures described in the literature include initial treatment of the zinc oxide with KOH to render it reactive, followed by addition of the chromate solution in the form of potassium tetrachromate, (Kirk-Othmer, op. cit., Vol. V, pages 509-510).
Another commercial process involves the dispersion of zinc oxide in water, adding thereto a solution of potassium dichromate following by hydrochloric acid. The reaction may be expressed by the following equation:
4ZnO+2K.sub.2 Cr.sub.2 O.sub.7 +2HCl→4ZnO. 4CrO.sub.3.K.sub.2 O. 3H.sub.2 O+2KCl
Among other chromium pigments asserted to possess corrosion inhibitive properties are included chromates of alkaline earth metals and respectively of lead and iron, which pigments may also include alkali metal cation (potassium). A number of these have been exploited commercially to some extent.
In U.S. Pat. No. 2,387,528 there are described alkaline earth metal chromates containing trivalent as well as hexavalent chromium, such as basic calcium chromito-chromate. These pigments, because of various drawbacks, have not attained commercial significance; UDY: op. cit. at page 381; Kirk-Othmer, op. cit. at page 510. These are prepared, according to the patent, by roasting a mixture of the alkaline earth metal chromate and an alkaline earth metal compound which is heat decomposable to the oxide, in designated proportions and grinding the resulting product.
Solutions of chromates have also been applied to metal surfaces or to "conversion coatings" on such metals to improve corrosion resistance and paint bonding characteristics. Thus, U.S. Pat. No. 2,902,394 describes metal protecting compositions for application to zinc surfaces, prepared by intimate admixture of chromic acid with aqueous nitric, sulfuric and acetic acids and with a sulfite-type reducing agent capable of reducing a minor portion of the hexavalent chromium to trivalent state.
An earlier patent of the present inventor, U.S. Pat. No. 3,063,877, describes aqueous solutions for treating metal surfaces to impart improved corrosion resistance, which solutions are prepared by partially reducing a dissolved hexavalent chromium compound with formaldehyde, under conditions such that at least 5% and preferably at least 20% of the total chromium is present in reduced state.
U.S. Pat. No. 3,279,958 describes rinsing of phosphate, chromate, and other chemical conversion coatings on metal surfaces with a dilute aqueous acidic solution of a chromium chromate complex, followed by a water rinse. The complex is prepared by treating aqueous chromic acid solution with an organic reducing agent which contains an active hydroxyl, aldehyde or carboxyl group, to reduce a portion of the hexavalent chromium to the trivalent state.
SUMMARY OF THE INVENTION
In accordance with the present invention, novel corrosion-inhibiting pigments are provided which comprise a complex of zinc associated with chromium, wherein the chromium is present in both trivalent and hexavalent state.
The novel pigments of the invention are produced by interaction of zinc oxide with a solution of a chromium chromate complex prepared by partial reduction of an aqueous solution of chromium trioxide with a soluble organic oxidizable compound containing an active hydroxyl, aldehyde or carboxyl group, followed by drying and grinding to desired pigment size particles.
The pigments thus obtained, when applied in conventional vehicles for coating metal surfaces, have a passivating effect on such surfaces and impart pronounced capacity for resisting corrosion.
DETAILED DESCRIPTION
A wide selection of oxidizable organic compounds is applicable for partial reduction of the chromic acid; e.g. formaldehyde, methanol, ethanol, citric acid, sucrose, furfural, etc. From the standpoint of convenience, economy, and performance, the preferred reducing agents are methanol, formaldehyde and furfural.
In a preferred procedure, the zinc oxide is dispersed in water or is made into an aqueous paste. A solution containing the chromium chromate complex is then added to the zinc oxide dispersion or paste, slowly while stirring.
Since neither alkali metal salts nor other extraneous substances are employed in making the pigment of the invention, expensive purification steps, which otherwise would be required to free the pigment of by-products and particularly of deleterious by-products, is avoided. The obtained zinc chromium chromate pigment is free of extraneous metal ions and does not contain chloride, sulfate or other acidic anions that may be deleterious to the corrosion inhibiting properties of the pigment.
The relative content of zinc and chromium in the pigment will, of course, depend upon the proportions of these in the reacting mixture. The ratio of trivalent to hexavalent chromium in the pigment will be substantially that of the chromium chromate complex in the solution reacted. The empirical formula of the obtained pigment can be expressed by the formula:
xZnO.yCrO.sub.3.zCr.sub.2 O.sub.3
The mol ratio of x:(y+z) may be in the range of 5:1 to 1:3. Of the total chrome content of the pigment, 5 to 70% and preferably 25 to 65% should be present in the reduced state (Cr III ). The pigment may also contain associated water, depending upon conditions of preparation.
Th primary purpose of the zinc chromate pigment thus produced is not as a colorant but as a material which provides useful corrosion-inhibiting action when incorporated in paints and coating compositions applied to metal surfaces.
The chromium chromate solution may be prepared by methods described in U.S. Pat. No. 3,063,877 or by the methods described in my companion application Ser. No. 883,507 for CORROSION INHIBITIVE PIGMENT, filed Mar. 6, 1978. For example, a 20 to 50% by weight aqueous solution of chromic acid is reacted with the desired organic reducing agent of the type described employing less than 1 mol reductant per mol of chromium compound, to assure only partial reduction of the latter.
In a preferred procedure, a 33% by weight aqueous solution of chromic acid is employed, to which the selected reducing agent is added with vigorous stirring, using one mol of the reducing agent for 3 mols of chromic acid. The reaction is highly exothermic and slow addition of the reductant with vigorous stirring is necessary during the entire period of addition to permit close control of temperature and reaction rate. The temperature should be kept below 95° C., preferably below 85° C. When addition of reductant has been completed, stirring is continued until no further reaction is evident (by gas evolution). The obtained solution, as such, may be reacted with zinc oxide, if desired, with adjustment of water content to preferred extent in the reaction mixture.
EXAMPLE 1
Solution A
150 pounds (68.04 kg.) of chromium trioxide are dissolved in 40 gallons (151.4 liters) of water. 42 pounds (19.05 kg.) of commercial formalin (36.6%) dissolved in 18 gallons (68.1 liters) of water, are added to the chromium trioxide solution, slowly with stirring. The addition rate is controlled to maintain the reaction temperature below 85° C. When the reaction subsides, water is added to make a total of 100 gallons (378.5 liters) of concentrate. This concentrate contains 1.5 pounds of total chromium oxides per gallon (180 gm/liter) with in the order of about 42% of the total chromium being present in reduced state.
Slurry B
122 pounds (55.3 kg.) of zinc oxide are dispersed in 32 gallons (121 liters) of water to form a slurry.
Pigment preparation
Solution A is added slowly with vigorous stirring into Slurry B and the mixture agitated for 4 hours with heating at a temperature of 120°-125° C. to remove excess water. The obtained product is then further dried in an oven at about 175° C., and subsequently ground in a pebble mill to pigment size. The pigment will contain zinc to total chromium in about equal molar amounts.
The novel dry pigments of the invention may be used alone or together with other pigments in paints and coating compositions in the same manner as the already known commercial chromium-containing corrosive-inhibiting pigments such as, for example, zinc yellow, zinc tetroxychromate (4ZnO.ZnCrO 4 .xH 2 O). Pigment E (barium potassium chromate), Pigment M-50 (composite of basic lead chromate coated onto a lead silicate-silica base). These known corrosion inhibiting pigments are conventionally made up into metal coating and painting compositions with typical oleoresinous vehicles such as drying and semi-drying oils or with certain latex emulsions including synthetic resin polymers. The pigments of the present invention may be used in like manner. | Zinc oxide is interacted with an aqueous solution containing a chromium chromate complex obtained through partial reduction of an aqueous solution of chromic acid with an organic reducing agent. The resulting product is dried and the residual solid ground to suitable size for use as a pigment. | Concisely explain the essential features and purpose of the invention. | [
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention The present invention relates generally to the field of corrosion-inhibiting pigments and is particularly concerned with such pigments comprising both zinc and chromium in chemical combination.",
"Prior Art Metal protective pigments have long been used as components of coating compositions applied to metallic surfaces.",
"Certain of these pigments have been, at least partially, effective in providing a specific inhibiting or passivating action at the surface of the metal.",
"Among the useful pigments in this category are red lead and certain chromium containing pigments.",
"Among the better known chromium-containing pigments suggested for use in metal protecting coatings are zinc yellow or so called "zinc chromate"",
"and zinc tetroxy chromate.",
"These, among other pigments, are described in Kirk-Othmer: Encyclopedia of Chemical Technology, 2d.",
"ed.",
", Vol. 5 at pages 507-510;",
"and by V. H. Chalupski in the monograph appearing in UDY: Chemistry of Chromium and its Compounds, Vol. 1 (Rheinhold Publishing Co., 1956) beginning at Page 357, particularly at pages 375-381.",
"A further modified method for preparing zinc yellow is described in U.S. Pat. No. 2,410,916.",
"Zinc chromates have been used for many years as corrosion-inhibitive pigments.",
"These pigments are used in formulations of paint and coating systems to protect metals against corrosion.",
"The zinc chromate pigment may be used with other pigments such as red lead and ferric oxide pigments and/or with pigment extenders which may be applied as metal primers, such as, for example, in structural steel priming, on ships, aircraft, automotive bodies, etc.",
"The "zinc chromate"",
"in present commercial use, or zinc yellow pigment as it is referred to in the trade, is a basic potassium zinc chromate, stated to have the empirical formula 4ZnO[.",
"].4CrO 3 .",
"K 2 O[.",
"].3H 2 O. It can be made by a variety of processes, all based on the reaction of zinc and chromate compounds in aqueous solution and in the presence of potassium salts.",
"Thus, it may be prepared by the reaction of acidified zinc oxide with potassium dichromate.",
"The procedure described in U.S. Pat. No. 2,410,916 involves precipitation of a zinc salt with a solution of a chromate in the presence of potassium ions and hydroxyl ions.",
"Other procedures described in the literature include initial treatment of the zinc oxide with KOH to render it reactive, followed by addition of the chromate solution in the form of potassium tetrachromate, (Kirk-Othmer, op.",
"cit.",
", Vol. V, pages 509-510).",
"Another commercial process involves the dispersion of zinc oxide in water, adding thereto a solution of potassium dichromate following by hydrochloric acid.",
"The reaction may be expressed by the following equation: 4ZnO+2K.",
"sub[.",
"].2 Cr.",
"sub[.",
"].2 O.sub[.",
"].7 +2HCl→4ZnO.",
"4CrO.",
"sub[.",
"].3.",
"sub[.",
"].2 O. 3H.",
"sub[.",
"].2 O+2KCl Among other chromium pigments asserted to possess corrosion inhibitive properties are included chromates of alkaline earth metals and respectively of lead and iron, which pigments may also include alkali metal cation (potassium).",
"A number of these have been exploited commercially to some extent.",
"In U.S. Pat. No. 2,387,528 there are described alkaline earth metal chromates containing trivalent as well as hexavalent chromium, such as basic calcium chromito-chromate.",
"These pigments, because of various drawbacks, have not attained commercial significance;",
"UDY: op.",
"cit.",
"at page 381;",
"Kirk-Othmer, op.",
"cit.",
"at page 510.",
"These are prepared, according to the patent, by roasting a mixture of the alkaline earth metal chromate and an alkaline earth metal compound which is heat decomposable to the oxide, in designated proportions and grinding the resulting product.",
"Solutions of chromates have also been applied to metal surfaces or to "conversion coatings"",
"on such metals to improve corrosion resistance and paint bonding characteristics.",
"Thus, U.S. Pat. No. 2,902,394 describes metal protecting compositions for application to zinc surfaces, prepared by intimate admixture of chromic acid with aqueous nitric, sulfuric and acetic acids and with a sulfite-type reducing agent capable of reducing a minor portion of the hexavalent chromium to trivalent state.",
"An earlier patent of the present inventor, U.S. Pat. No. 3,063,877, describes aqueous solutions for treating metal surfaces to impart improved corrosion resistance, which solutions are prepared by partially reducing a dissolved hexavalent chromium compound with formaldehyde, under conditions such that at least 5% and preferably at least 20% of the total chromium is present in reduced state.",
"U.S. Pat. No. 3,279,958 describes rinsing of phosphate, chromate, and other chemical conversion coatings on metal surfaces with a dilute aqueous acidic solution of a chromium chromate complex, followed by a water rinse.",
"The complex is prepared by treating aqueous chromic acid solution with an organic reducing agent which contains an active hydroxyl, aldehyde or carboxyl group, to reduce a portion of the hexavalent chromium to the trivalent state.",
"SUMMARY OF THE INVENTION In accordance with the present invention, novel corrosion-inhibiting pigments are provided which comprise a complex of zinc associated with chromium, wherein the chromium is present in both trivalent and hexavalent state.",
"The novel pigments of the invention are produced by interaction of zinc oxide with a solution of a chromium chromate complex prepared by partial reduction of an aqueous solution of chromium trioxide with a soluble organic oxidizable compound containing an active hydroxyl, aldehyde or carboxyl group, followed by drying and grinding to desired pigment size particles.",
"The pigments thus obtained, when applied in conventional vehicles for coating metal surfaces, have a passivating effect on such surfaces and impart pronounced capacity for resisting corrosion.",
"DETAILED DESCRIPTION A wide selection of oxidizable organic compounds is applicable for partial reduction of the chromic acid;",
"e.g. formaldehyde, methanol, ethanol, citric acid, sucrose, furfural, etc.",
"From the standpoint of convenience, economy, and performance, the preferred reducing agents are methanol, formaldehyde and furfural.",
"In a preferred procedure, the zinc oxide is dispersed in water or is made into an aqueous paste.",
"A solution containing the chromium chromate complex is then added to the zinc oxide dispersion or paste, slowly while stirring.",
"Since neither alkali metal salts nor other extraneous substances are employed in making the pigment of the invention, expensive purification steps, which otherwise would be required to free the pigment of by-products and particularly of deleterious by-products, is avoided.",
"The obtained zinc chromium chromate pigment is free of extraneous metal ions and does not contain chloride, sulfate or other acidic anions that may be deleterious to the corrosion inhibiting properties of the pigment.",
"The relative content of zinc and chromium in the pigment will, of course, depend upon the proportions of these in the reacting mixture.",
"The ratio of trivalent to hexavalent chromium in the pigment will be substantially that of the chromium chromate complex in the solution reacted.",
"The empirical formula of the obtained pigment can be expressed by the formula: xZnO.",
"yCrO.",
"sub[.",
"].3.",
"zCr.",
"sub[.",
"].2 O.sub[.",
"].3 The mol ratio of x:(y+z) may be in the range of 5:1 to 1:3.",
"Of the total chrome content of the pigment, 5 to 70% and preferably 25 to 65% should be present in the reduced state (Cr III ).",
"The pigment may also contain associated water, depending upon conditions of preparation.",
"Th primary purpose of the zinc chromate pigment thus produced is not as a colorant but as a material which provides useful corrosion-inhibiting action when incorporated in paints and coating compositions applied to metal surfaces.",
"The chromium chromate solution may be prepared by methods described in U.S. Pat. No. 3,063,877 or by the methods described in my companion application Ser.",
"No. 883,507 for CORROSION INHIBITIVE PIGMENT, filed Mar. 6, 1978.",
"For example, a 20 to 50% by weight aqueous solution of chromic acid is reacted with the desired organic reducing agent of the type described employing less than 1 mol reductant per mol of chromium compound, to assure only partial reduction of the latter.",
"In a preferred procedure, a 33% by weight aqueous solution of chromic acid is employed, to which the selected reducing agent is added with vigorous stirring, using one mol of the reducing agent for 3 mols of chromic acid.",
"The reaction is highly exothermic and slow addition of the reductant with vigorous stirring is necessary during the entire period of addition to permit close control of temperature and reaction rate.",
"The temperature should be kept below 95° C., preferably below 85° C. When addition of reductant has been completed, stirring is continued until no further reaction is evident (by gas evolution).",
"The obtained solution, as such, may be reacted with zinc oxide, if desired, with adjustment of water content to preferred extent in the reaction mixture.",
"EXAMPLE 1 Solution A 150 pounds (68.04 kg.) of chromium trioxide are dissolved in 40 gallons (151.4 liters) of water.",
"42 pounds (19.05 kg.) of commercial formalin (36.6%) dissolved in 18 gallons (68.1 liters) of water, are added to the chromium trioxide solution, slowly with stirring.",
"The addition rate is controlled to maintain the reaction temperature below 85° C. When the reaction subsides, water is added to make a total of 100 gallons (378.5 liters) of concentrate.",
"This concentrate contains 1.5 pounds of total chromium oxides per gallon (180 gm/liter) with in the order of about 42% of the total chromium being present in reduced state.",
"Slurry B 122 pounds (55.3 kg.) of zinc oxide are dispersed in 32 gallons (121 liters) of water to form a slurry.",
"Pigment preparation Solution A is added slowly with vigorous stirring into Slurry B and the mixture agitated for 4 hours with heating at a temperature of 120°-125° C. to remove excess water.",
"The obtained product is then further dried in an oven at about 175° C., and subsequently ground in a pebble mill to pigment size.",
"The pigment will contain zinc to total chromium in about equal molar amounts.",
"The novel dry pigments of the invention may be used alone or together with other pigments in paints and coating compositions in the same manner as the already known commercial chromium-containing corrosive-inhibiting pigments such as, for example, zinc yellow, zinc tetroxychromate (4ZnO.",
"ZnCrO 4 .",
"xH 2 O).",
"Pigment E (barium potassium chromate), Pigment M-50 (composite of basic lead chromate coated onto a lead silicate-silica base).",
"These known corrosion inhibiting pigments are conventionally made up into metal coating and painting compositions with typical oleoresinous vehicles such as drying and semi-drying oils or with certain latex emulsions including synthetic resin polymers.",
"The pigments of the present invention may be used in like manner."
] |
This is a divisional application of Application No. 100,068, filed Sept. 23, 1987, now U.S. Pat. No. 4,791,261.
BACKGROUND OF THE INVENTION
This invention relates generally to material deposition apparatus, and more particularly to an evaporation source used in a RF evaporation apparatus and to a process for the self fractionation deposition of a metallic layer on a workpiece.
Evaporation apparatus is well known in the art. U.S. Pat. No. 3,401,055 to J. L. Langdon et al, issued Sept. 10, 1968, and assigned to the IBM Corporation, describes how such evaporation apparatus is used in semiconductor integrated circuit processing technology. Specifically, this patent teaches a method of depositing a metal such as a solder onto a plurality of small areas simultaneously on a semiconductor device.
As semiconductor integrated circuit chips have become denser, i.e., a million or more semiconductor devices per chip, evaporated films must meet more exacting criteria. Specifically, the films must have a thickness that does not appreciably vary either across one wafer or wafer to wafer, and the amount of conductivity-detracting impurities such as oxides must be kept at a minimum.
Using the evaporation apparatus and techniques of the prior art, for example as in the above identified U.S. Pat. No. 3,401,055, fabrication of a uniform formation of high quality thin films of low vapor pressure materials (e.g. copper) is extremely difficult. Thus, there is a need in the art for an evaporation apparatus that can efficiently deposit low vapor pressure metallic films.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of this invention to eliminate the disadvantages associated with prior art evaporation apparatus so as to provide uniform high quality evaporated thin films as required by dense semiconductor integrated circuit chips.
A more particular object of the invention is to provide an evaporation source for use in an RF evaporation apparatus which results in the deposition of high quality, uniform thin films.
The invention is directed toward a unique evaporation source for evaporating high quality, uniform metallic films onto a semiconductor workpiece (e.g. a wafer). The evaporation source of the present invention comprises an RF coupling susceptor having a volume commensurate with or greater than the amount of charge disposed within an overlaying crucible. More particularly, the source of the invention includes a pair of coaxial, cupped heat shields surrounding a flared lip crucible that is supported away from the base of the innermost heat shield by a thermal isolator and a non-metallic susceptor. The flared lip of the crucible overlaps and covers the exposed edges of the heat shields. By utilizing the source of the invention, the charge being evaporated from within the crucible can be rapidly heated to promote self-fractionation, thus eliminating conductivity-detracting impurities from the deposited film while providing a film of uniform thickness.
The foregoing and other objects, features and advantages of this invention will be apparent from the following more particular description of a preferred embodiment of the invention as illustrated in the accompanying drawings, wherein:
DESCRIPTION OF THE DRAWINGS
FIG. 1 (Prior Art) shows a cross-sectional schematic of a conventional evaporation apparatus.
FIG. 2 shows in detailed cross-section the crucible of the present invention.
FIG. 3 shows a plot of the time/temperature cycle used in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 (Prior Art) shows, in some detail, the general structures associated with conventional evaporation apparatus. A vacuum chamber 10 has a base 11 and a porthole 12 which is connected to a source of vacuum 14. Seated on a pedestal 15 affixed to base 11 is a crucible 16 containing a charge 19 of material to be evaporated. Wrapped around crucible 16 and connected to a suitable RF source 18 (such as 3 kilowatt power supply) are a plurality of RF heating coils 22. One suitable power supply is a EN1 PS 300 as sold by the EN1 Corporation of Rochester, New York. A holder 23, which can be rotated, if desired, is supported by a rod 21 descending from the top of the chamber 10, and a plurality of workpieces 24 are disposed on the holder 23. Each workpiece 24 is, for example, a semiconductor wafer, such as silicon, having a plurality of previously created chip sites that are to be coated with metallic layers. Each wafer may bear a protective coating, such as photoresist or the like, that clearly delineates the metallic pattern to be deposited on the semiconductor surface. Alternatively, the metallic material may be deposited on the wafers in the absence of such protective coating, in which case the pattern will be defined by subsequent subtractive etching.
An interposing shutter 25 comprising a solid plate of stainless steel can be selectively positioned between the substrates 24 and the crucible 16 by motor 26. The shutter 25 can be moved to the left to block the partially or totally emission of evaporant from the crucible 16. During the evaporation phase the path of the evaporant is generally cone shaped as if the evaporant came form a point source, as indicated by dashed lines 30.
If desired, the evaporation source can be disposed in an entirely separate chamber below the evaporation chamber 10. In this manner the sources may be heated independently of the workpieces. An example of this system is the Balzers SCS 800 isolated source load lock evaporation system. Such portioned apparatus is well known to the prior art. It is preferred to provide the evaporation source of the invention to this type of evaporation system.
A mechanism 27 is provided within the evaporation chamber 10 for automatically feeding a wire, of the material in the crucible being evaporated, into the crucible to automatically replenish the charge 19 as it becomes diminished by evaporation.
It should be noted that such an evaporation apparatus is presently well known and commercially available and is described above in only the most rudimentary form.
In the prior art, when depositing a low vapor pressure metal such as copper, it was found that during the initial heating and melting phase any impurities contained within the charge would, during the evaporation thereof, emit particles of impurity material (e.g. oxide) from the molten evaporant source. This phenomenon (known as "spitting") results in large particles of the evaporant and oxide in a solid, liquid or semisolid state being transmitted to the workpiece. These impurity particles of materials cause irregularities, such as large spheres, lumps, or voids, to appear in the evaporated film. These irregularities reduce the conductivity of the film, causing electrical defects and the like that result in a lower production yield of finished work.
In addition, prior art evaporant crucibles were generally designed to be relatively deep with respect to their diameter, i.e., their depth was generally at least twice their diameter. This causes, as the charge becomes diminished, a narrowing of the stream of evaporant material, as shown by dashed lines 31. Because of this narrowing of evaporant the center workpieces 24 accumulate a significantly larger amount of material than does any of the workpieces on the perimeter of the holder 23, also leading to a lack of uniformity of deposit.
The present inventors succeeded in overcoming these disadvantages of the prior art by redesigning the evaporation source. Specifically, the inventors found that when the charge is quickly heated to a temperature at which it self-fractionates (i.e., pure metal is separated from the oxide impurities), and thereafter is deposited onto the workpieces, the oxide impurities are eliminated from the film as-deposited. An evaporation source that is compatible with such a self-fractionation heating process will be described in detail below in conjunction with FIG. 2.
The evaporation source 50, shown in FIG. 2, is designed to be substituted for the post 15 and crucible 16 in FIG. 1, and basically comprises a thermally isolating column or spacer 52 on base 11, which in turn supports an outer heat shield 53. Contained within the outer heat shield 53 is a second thermally isolating spacer 54 which supports and thermally isolates an inner heat shield 55 from the outer heat shield 53. Within the inner heat shield 55 there is disposed a third thermally isolating spacer 56 upon which there is disposed a susceptor 57 which in turn supports a crucible 58. This crucible is provided with a flared lip 59 which extends from the inner edge of the crucible above the lips or upper edges of the two heat shields 53 and 55. A multiplicity of RF coils 22 matched to the power supply, as is well known in the RF heating industry, surround the above described structure.
As shown in FIG. 2, there is also provided an outer casing 60 coupled to the outer heat shield 53 to surround and enclose the coils 22. The casing 60 prevents any of the evaporated material from depositing on the coils 22, the outer heat shield 53, or the thermal isolating column 52. This casing need not be used and can be eliminated, but because it aids in extending the life of the coils 22 and eliminates the need of cleaning the column and outer heat shield after every evaporation run, it is very desirable.
In operation, when the RF power supply 18 is activated, the coils 22 emit RF energy which is concentrated within the confines of the coil. This energy is absorbed by the material adjacent the coil, and the material begins to heat due to eddy currents developed therein by the emitted frequencies.
Because it is necessary to heat the charge 19 to controlled temperatures at which it will self-fractionate and evaporate in a relatively short time, and since it is desirable that this be accomplished with the lowest possible energy expenditure, it is necessary to select both the configurations and compositions of the susceptor 57 and crucible 58 so as to absorb the maximum amount of energy and convert it into heat, and to transfer the heat by radiation and conduction to the material 19 within the crucible 58. The other components of the source 50 are selected to minimize this RF absorption so that the level to which they become heated is minimized.
The susceptor 57 is made of a solid, columnar block of graphite carbon 11/8 inches in diameter and 1/2 inches high. The crucible 58 is 1 3/16 inches in diameter and 11/16 inches deep, and is made of a material (e.g. molybdenum) that has a lower vapor pressure than the material to be evaporated (e.g. copper). The crucible is filled with approximately 30 grams of material, such that it is partially filled (i.e., the material within the crucible forms a pool approximately 5/16 inches high). The inventors found that when the initial volume of charge to be deposited is commensurate with (e.g. 5/8) the volume of the suceptor 57, the charge can be completely self-fractionated. The self-fractionation efficiency increases as the amount of charge decreases (i.e. as the charge/susceptor volume ratio decreases). On the other hand, if the charge/susceptor volume ratio is increased by increasing the charge size or charge volume, or decreasing the susceptor, or a combination of both, the self-fractionation process will not be as efficient. At very high charge/susceptor ratios, self-fractionation does not occur to an extent sufficient to improve the properties of the film as-deposited.
The susceptor 57, being a relatively large mass and being very receptive to heating by RF frequencies, assures that the charge 19 contained within the crucible 58 is heated to the desired levels necessary to melt and evaporate the charge 19 in the crucible 58. Such susceptors are especially required when the charge is a low vapor pressure material (e.g. copper or gold) that is not very absorbant of RF energies.
The base 11, upon which the unit under discussion is mounted, is usually metallic and relatively large. It is therefore very radiative (i.e., it acts as a heat sink). Since it is necessary to heat the contents of the crucible rapidly, a quartz thermal insulator 52, in the form of a hollow column having an outside diameter of 11/2 inches, a height of 13/8 inches, and an inner diameter of 11/4 inches, is disposed to support the outer heat shield 53 from the base 11. This outer heat shield 53 is a cup formed of high density silica having a wall thickness of 1/8 inch on outer diameter of 1 11/16 inches and a height of 13/4 inches. Similarly, the quartz spacer 54 also in the form of a 1/16 inch ring 1 5/16 inches in diameter and 3/16 inches in height is disposed in the bottom of the cup shaped outer shield 53 to maintain and thermally isolate the inner heat shield 55 from the outer heat shield 53. This inner heat shield is formed of pyrolytic boron nitride and has an outer diameter of 13/8 inches in diameter, a height of 1 9/16 inches and a wall thickness of 1/16 inches. Quartz and pyrolytic boron nitride are used for most of the thermal isolators and the inner heat shield because such materials are transparent to radio frequencies emitted by the coil 22 and thus becomes heated very slowly. Other material having similar properties could be used. Also, such materials can be made in very pure form such that they do not provide any contaminants in the system.
The outer heat shield 53 is formed of silica which has improved thermal characteristics over those of quartz. The inner shield 55 is formed of pyrolytic boron nitride.
Pyrolytic boron nitride is used as the inner heat shield because it prevents infrared radiation from being emitted from either the susceptor or the crucible. In this way the inner shield acts to retain heat within itself, i.e. in the crucible area and susceptor area, while shielding the outer shield 53 from infrared radiation.
A boron nitride support ring 56, 15/16 inches in diameter which is 1/2 inch in height and 1/16 inches thick is disposed within the inner heat shield 55 to support a carbon susceptor 57 which in turn supports the crucible 58. Pyrolytic boron nitride is used for this support ring 56 not only because it is a good thermal isolator but also because it is formed with the highest purity and does not interact with the carbon of the susceptor 57 at the high temperatures at which source is operated.
It should be noted that the crucible 58 has an outwardly directed flared lip 59. This lip 59 protects the top exposed edges of the shields 53 and 55 and prevent any of the material being evaporated from within the crucible from depositing on the inner edges of the heat shield 55. Moreover, note that the depth of the crucible is less than its diameter. If the depth/diameter ratio is increased to the point where the depth is greater than twice the diameter, the above-described uniformity problems result.
With reference now to FIG. 3, there is shown the RF power curve (solid line 61) and the temperature curve (dotted line 62) associated with the self-fractionation and deposition processes that can be carried out using the evaporation source of the invention. A 3 kilowatt RF power supply was used, and a charge of 30 grams of copper was disposed within the crucible. At the beginning of the cycle, the workpieces are located in the vacuum chamber and the chamber is evacuated. Four hundred fifty watts of RF power, as shown by that portion of the power curve marked 63, is then applied to the coils. The susceptor 57 begins to heat and to transfer this heat by a radiation and conduction process into the charge in the crucible, and the charge begins to melt with little or no evaporation occurring. This power level is maintained until the temperature of the charge stabilizes at 1200° C., as shown by that portion of the temperature curve marked 63A. During this time, to protect the workpieces from any undesired evaporation or contamination, the shutter 26 is moved to the left from the position. When the workpieces are to be coated, the RF power is ramped to between 2 kilowatts and 2.1 kilowatts, and is maintained there for approximately 135 seconds. This is shown by that portion of the power curve marked 64. Subsequently the power level is reduced to 780 watts (portion 66). During this time the temperature of the charge 19 is increased and self-fractionation, i.e. fractional distillation, of the charge 19 occurs. As this fractional distillation begins, any contaminants in the charge (such as oxides or the like) adhere to the surface of the melt to form a slag-like surface layer. As the RF power is increased, the temperature of the charge also increases and the fractional distillation continues until the contaminants collected on the liquid surface of the melted charge become either sublimed or vapored due to limits set by respective vapor pressures of the material used in the charge and its oxides and other contaminants. The impurities migrate to the edge of the crucible where they are drawn up the side of the crucible. In copper, this occurs because a high vapor pressure of copper evaporant is created, which pushes the surface contaminants and the like to the sidewalls of the crucible (which are at a temperature slightly higher than that of the melted charge). Once this fractionation process is completed the temperature of the crucible has peaked at 1900° C. (reference numeral 65 on curve 62). The RF power is then decreased to a power level of 780 watts as indicated by numeral 66 on curve 61. This power level corresponds to the desired rate of deposition of 4 angstroms per second of the charged material on the surface of the workpieces 24 when the workpiece is 28 inches away from the crucible 58. Forty-five seconds after this decrease in RF power, when the temperature of the charge 19 stabilizes at about 1510° C., as indicated by numeral 67 on curve 62, the evaporant shield or shutter 24 is withdrawn from in front of the workpiece to permit the evaporant to coat the workpiece. This power level is maintained for an additional 150 seconds at which time the shutter 24 is then positioned in front of the workpiece to prevent further deposition on the workpieces. Simultaneously with the shutter 24 closing, the power level is raised to 1000 watts as indicated by reference numeral 68, and is maintained at this level for 90 seconds. This causes a slight rise in temperature of the charge 19 as indicated by numeral 69 on curve 62. Twenty-four seconds after the shutter closes and the power level rises, wire is fed from the wire feed 27 into the crucible to replenish the charge therein. As the wire melts and replenishes the charge the temperature of the charge decreases as indicated by numeral 70 on curve 62.
At the end of 90 seconds the power is again decreased to the standby power level of 450 watts and the temperature of the charge continues to decline to 1200° C. at which temperature it again stabilizes.
By supporting all of the units of the invention within the coils 22, as described above, the crucible 58 is heated in a thermally controlled manner to provide self-fractionation. This self-fractionation phenomenon eliminates any spitting of copper or copper oxides and eliminates the need for utilizing ultra pure material as a source. Self-fractionation of the charge is particularly important when the material of the charge has a large amount of impurities that are introduced during its replenishment.
By utilizing the present invention as described above, copper films free of voids or inclusions and with less than 0.001% by weight of non-metallic contaminants contained therein have been successfully deposited on semiconductor wafers.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that the forgoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. | A process for the evaporation deposition of a layer of metal on a workpiece is described in which a charge of a metal is placed in a crucible formed of a material having a vapor pressure lower than the vapor pressure of the metal at a selected temperature, a shield is placed between the workpiece and the crucible, and the crucible is then heated to a first temperature sufficient to melt said charge, but insufficient to cause substantial evaporation of said charge following which the crucible is heated to a second temperature level for a time sufficient to fractionally distill the charge and sublime or vaporize any non-metallic contaminants in said charge and finally the crucible is heated to a third temperature sufficient to evaporate the charge at a selected rate at which time the shield is removed from between the cricuble and the workpiece to permit evaporant from the charge to coat the workpiece. | Concisely explain the essential features and purpose of the invention. | [
"This is a divisional application of Application No. 100,068, filed Sept.",
"23, 1987, now U.S. Pat. No. 4,791,261.",
"BACKGROUND OF THE INVENTION This invention relates generally to material deposition apparatus, and more particularly to an evaporation source used in a RF evaporation apparatus and to a process for the self fractionation deposition of a metallic layer on a workpiece.",
"Evaporation apparatus is well known in the art.",
"U.S. Pat. No. 3,401,055 to J. L. Langdon et al, issued Sept.",
"10, 1968, and assigned to the IBM Corporation, describes how such evaporation apparatus is used in semiconductor integrated circuit processing technology.",
"Specifically, this patent teaches a method of depositing a metal such as a solder onto a plurality of small areas simultaneously on a semiconductor device.",
"As semiconductor integrated circuit chips have become denser, i.e., a million or more semiconductor devices per chip, evaporated films must meet more exacting criteria.",
"Specifically, the films must have a thickness that does not appreciably vary either across one wafer or wafer to wafer, and the amount of conductivity-detracting impurities such as oxides must be kept at a minimum.",
"Using the evaporation apparatus and techniques of the prior art, for example as in the above identified U.S. Pat. No. 3,401,055, fabrication of a uniform formation of high quality thin films of low vapor pressure materials (e.g. copper) is extremely difficult.",
"Thus, there is a need in the art for an evaporation apparatus that can efficiently deposit low vapor pressure metallic films.",
"SUMMARY OF THE INVENTION Accordingly, it is a general object of this invention to eliminate the disadvantages associated with prior art evaporation apparatus so as to provide uniform high quality evaporated thin films as required by dense semiconductor integrated circuit chips.",
"A more particular object of the invention is to provide an evaporation source for use in an RF evaporation apparatus which results in the deposition of high quality, uniform thin films.",
"The invention is directed toward a unique evaporation source for evaporating high quality, uniform metallic films onto a semiconductor workpiece (e.g. a wafer).",
"The evaporation source of the present invention comprises an RF coupling susceptor having a volume commensurate with or greater than the amount of charge disposed within an overlaying crucible.",
"More particularly, the source of the invention includes a pair of coaxial, cupped heat shields surrounding a flared lip crucible that is supported away from the base of the innermost heat shield by a thermal isolator and a non-metallic susceptor.",
"The flared lip of the crucible overlaps and covers the exposed edges of the heat shields.",
"By utilizing the source of the invention, the charge being evaporated from within the crucible can be rapidly heated to promote self-fractionation, thus eliminating conductivity-detracting impurities from the deposited film while providing a film of uniform thickness.",
"The foregoing and other objects, features and advantages of this invention will be apparent from the following more particular description of a preferred embodiment of the invention as illustrated in the accompanying drawings, wherein: DESCRIPTION OF THE DRAWINGS FIG. 1 (Prior Art) shows a cross-sectional schematic of a conventional evaporation apparatus.",
"FIG. 2 shows in detailed cross-section the crucible of the present invention.",
"FIG. 3 shows a plot of the time/temperature cycle used in the present invention.",
"DETAILED DESCRIPTION OF THE INVENTION FIG. 1 (Prior Art) shows, in some detail, the general structures associated with conventional evaporation apparatus.",
"A vacuum chamber 10 has a base 11 and a porthole 12 which is connected to a source of vacuum 14.",
"Seated on a pedestal 15 affixed to base 11 is a crucible 16 containing a charge 19 of material to be evaporated.",
"Wrapped around crucible 16 and connected to a suitable RF source 18 (such as 3 kilowatt power supply) are a plurality of RF heating coils 22.",
"One suitable power supply is a EN1 PS 300 as sold by the EN1 Corporation of Rochester, New York.",
"A holder 23, which can be rotated, if desired, is supported by a rod 21 descending from the top of the chamber 10, and a plurality of workpieces 24 are disposed on the holder 23.",
"Each workpiece 24 is, for example, a semiconductor wafer, such as silicon, having a plurality of previously created chip sites that are to be coated with metallic layers.",
"Each wafer may bear a protective coating, such as photoresist or the like, that clearly delineates the metallic pattern to be deposited on the semiconductor surface.",
"Alternatively, the metallic material may be deposited on the wafers in the absence of such protective coating, in which case the pattern will be defined by subsequent subtractive etching.",
"An interposing shutter 25 comprising a solid plate of stainless steel can be selectively positioned between the substrates 24 and the crucible 16 by motor 26.",
"The shutter 25 can be moved to the left to block the partially or totally emission of evaporant from the crucible 16.",
"During the evaporation phase the path of the evaporant is generally cone shaped as if the evaporant came form a point source, as indicated by dashed lines 30.",
"If desired, the evaporation source can be disposed in an entirely separate chamber below the evaporation chamber 10.",
"In this manner the sources may be heated independently of the workpieces.",
"An example of this system is the Balzers SCS 800 isolated source load lock evaporation system.",
"Such portioned apparatus is well known to the prior art.",
"It is preferred to provide the evaporation source of the invention to this type of evaporation system.",
"A mechanism 27 is provided within the evaporation chamber 10 for automatically feeding a wire, of the material in the crucible being evaporated, into the crucible to automatically replenish the charge 19 as it becomes diminished by evaporation.",
"It should be noted that such an evaporation apparatus is presently well known and commercially available and is described above in only the most rudimentary form.",
"In the prior art, when depositing a low vapor pressure metal such as copper, it was found that during the initial heating and melting phase any impurities contained within the charge would, during the evaporation thereof, emit particles of impurity material (e.g. oxide) from the molten evaporant source.",
"This phenomenon (known as "spitting") results in large particles of the evaporant and oxide in a solid, liquid or semisolid state being transmitted to the workpiece.",
"These impurity particles of materials cause irregularities, such as large spheres, lumps, or voids, to appear in the evaporated film.",
"These irregularities reduce the conductivity of the film, causing electrical defects and the like that result in a lower production yield of finished work.",
"In addition, prior art evaporant crucibles were generally designed to be relatively deep with respect to their diameter, i.e., their depth was generally at least twice their diameter.",
"This causes, as the charge becomes diminished, a narrowing of the stream of evaporant material, as shown by dashed lines 31.",
"Because of this narrowing of evaporant the center workpieces 24 accumulate a significantly larger amount of material than does any of the workpieces on the perimeter of the holder 23, also leading to a lack of uniformity of deposit.",
"The present inventors succeeded in overcoming these disadvantages of the prior art by redesigning the evaporation source.",
"Specifically, the inventors found that when the charge is quickly heated to a temperature at which it self-fractionates (i.e., pure metal is separated from the oxide impurities), and thereafter is deposited onto the workpieces, the oxide impurities are eliminated from the film as-deposited.",
"An evaporation source that is compatible with such a self-fractionation heating process will be described in detail below in conjunction with FIG. 2. The evaporation source 50, shown in FIG. 2, is designed to be substituted for the post 15 and crucible 16 in FIG. 1, and basically comprises a thermally isolating column or spacer 52 on base 11, which in turn supports an outer heat shield 53.",
"Contained within the outer heat shield 53 is a second thermally isolating spacer 54 which supports and thermally isolates an inner heat shield 55 from the outer heat shield 53.",
"Within the inner heat shield 55 there is disposed a third thermally isolating spacer 56 upon which there is disposed a susceptor 57 which in turn supports a crucible 58.",
"This crucible is provided with a flared lip 59 which extends from the inner edge of the crucible above the lips or upper edges of the two heat shields 53 and 55.",
"A multiplicity of RF coils 22 matched to the power supply, as is well known in the RF heating industry, surround the above described structure.",
"As shown in FIG. 2, there is also provided an outer casing 60 coupled to the outer heat shield 53 to surround and enclose the coils 22.",
"The casing 60 prevents any of the evaporated material from depositing on the coils 22, the outer heat shield 53, or the thermal isolating column 52.",
"This casing need not be used and can be eliminated, but because it aids in extending the life of the coils 22 and eliminates the need of cleaning the column and outer heat shield after every evaporation run, it is very desirable.",
"In operation, when the RF power supply 18 is activated, the coils 22 emit RF energy which is concentrated within the confines of the coil.",
"This energy is absorbed by the material adjacent the coil, and the material begins to heat due to eddy currents developed therein by the emitted frequencies.",
"Because it is necessary to heat the charge 19 to controlled temperatures at which it will self-fractionate and evaporate in a relatively short time, and since it is desirable that this be accomplished with the lowest possible energy expenditure, it is necessary to select both the configurations and compositions of the susceptor 57 and crucible 58 so as to absorb the maximum amount of energy and convert it into heat, and to transfer the heat by radiation and conduction to the material 19 within the crucible 58.",
"The other components of the source 50 are selected to minimize this RF absorption so that the level to which they become heated is minimized.",
"The susceptor 57 is made of a solid, columnar block of graphite carbon 11/8 inches in diameter and 1/2 inches high.",
"The crucible 58 is 1 3/16 inches in diameter and 11/16 inches deep, and is made of a material (e.g. molybdenum) that has a lower vapor pressure than the material to be evaporated (e.g. copper).",
"The crucible is filled with approximately 30 grams of material, such that it is partially filled (i.e., the material within the crucible forms a pool approximately 5/16 inches high).",
"The inventors found that when the initial volume of charge to be deposited is commensurate with (e.g. 5/8) the volume of the suceptor 57, the charge can be completely self-fractionated.",
"The self-fractionation efficiency increases as the amount of charge decreases (i.e. as the charge/susceptor volume ratio decreases).",
"On the other hand, if the charge/susceptor volume ratio is increased by increasing the charge size or charge volume, or decreasing the susceptor, or a combination of both, the self-fractionation process will not be as efficient.",
"At very high charge/susceptor ratios, self-fractionation does not occur to an extent sufficient to improve the properties of the film as-deposited.",
"The susceptor 57, being a relatively large mass and being very receptive to heating by RF frequencies, assures that the charge 19 contained within the crucible 58 is heated to the desired levels necessary to melt and evaporate the charge 19 in the crucible 58.",
"Such susceptors are especially required when the charge is a low vapor pressure material (e.g. copper or gold) that is not very absorbant of RF energies.",
"The base 11, upon which the unit under discussion is mounted, is usually metallic and relatively large.",
"It is therefore very radiative (i.e., it acts as a heat sink).",
"Since it is necessary to heat the contents of the crucible rapidly, a quartz thermal insulator 52, in the form of a hollow column having an outside diameter of 11/2 inches, a height of 13/8 inches, and an inner diameter of 11/4 inches, is disposed to support the outer heat shield 53 from the base 11.",
"This outer heat shield 53 is a cup formed of high density silica having a wall thickness of 1/8 inch on outer diameter of 1 11/16 inches and a height of 13/4 inches.",
"Similarly, the quartz spacer 54 also in the form of a 1/16 inch ring 1 5/16 inches in diameter and 3/16 inches in height is disposed in the bottom of the cup shaped outer shield 53 to maintain and thermally isolate the inner heat shield 55 from the outer heat shield 53.",
"This inner heat shield is formed of pyrolytic boron nitride and has an outer diameter of 13/8 inches in diameter, a height of 1 9/16 inches and a wall thickness of 1/16 inches.",
"Quartz and pyrolytic boron nitride are used for most of the thermal isolators and the inner heat shield because such materials are transparent to radio frequencies emitted by the coil 22 and thus becomes heated very slowly.",
"Other material having similar properties could be used.",
"Also, such materials can be made in very pure form such that they do not provide any contaminants in the system.",
"The outer heat shield 53 is formed of silica which has improved thermal characteristics over those of quartz.",
"The inner shield 55 is formed of pyrolytic boron nitride.",
"Pyrolytic boron nitride is used as the inner heat shield because it prevents infrared radiation from being emitted from either the susceptor or the crucible.",
"In this way the inner shield acts to retain heat within itself, i.e. in the crucible area and susceptor area, while shielding the outer shield 53 from infrared radiation.",
"A boron nitride support ring 56, 15/16 inches in diameter which is 1/2 inch in height and 1/16 inches thick is disposed within the inner heat shield 55 to support a carbon susceptor 57 which in turn supports the crucible 58.",
"Pyrolytic boron nitride is used for this support ring 56 not only because it is a good thermal isolator but also because it is formed with the highest purity and does not interact with the carbon of the susceptor 57 at the high temperatures at which source is operated.",
"It should be noted that the crucible 58 has an outwardly directed flared lip 59.",
"This lip 59 protects the top exposed edges of the shields 53 and 55 and prevent any of the material being evaporated from within the crucible from depositing on the inner edges of the heat shield 55.",
"Moreover, note that the depth of the crucible is less than its diameter.",
"If the depth/diameter ratio is increased to the point where the depth is greater than twice the diameter, the above-described uniformity problems result.",
"With reference now to FIG. 3, there is shown the RF power curve (solid line 61) and the temperature curve (dotted line 62) associated with the self-fractionation and deposition processes that can be carried out using the evaporation source of the invention.",
"A 3 kilowatt RF power supply was used, and a charge of 30 grams of copper was disposed within the crucible.",
"At the beginning of the cycle, the workpieces are located in the vacuum chamber and the chamber is evacuated.",
"Four hundred fifty watts of RF power, as shown by that portion of the power curve marked 63, is then applied to the coils.",
"The susceptor 57 begins to heat and to transfer this heat by a radiation and conduction process into the charge in the crucible, and the charge begins to melt with little or no evaporation occurring.",
"This power level is maintained until the temperature of the charge stabilizes at 1200° C., as shown by that portion of the temperature curve marked 63A.",
"During this time, to protect the workpieces from any undesired evaporation or contamination, the shutter 26 is moved to the left from the position.",
"When the workpieces are to be coated, the RF power is ramped to between 2 kilowatts and 2.1 kilowatts, and is maintained there for approximately 135 seconds.",
"This is shown by that portion of the power curve marked 64.",
"Subsequently the power level is reduced to 780 watts (portion 66).",
"During this time the temperature of the charge 19 is increased and self-fractionation, i.e. fractional distillation, of the charge 19 occurs.",
"As this fractional distillation begins, any contaminants in the charge (such as oxides or the like) adhere to the surface of the melt to form a slag-like surface layer.",
"As the RF power is increased, the temperature of the charge also increases and the fractional distillation continues until the contaminants collected on the liquid surface of the melted charge become either sublimed or vapored due to limits set by respective vapor pressures of the material used in the charge and its oxides and other contaminants.",
"The impurities migrate to the edge of the crucible where they are drawn up the side of the crucible.",
"In copper, this occurs because a high vapor pressure of copper evaporant is created, which pushes the surface contaminants and the like to the sidewalls of the crucible (which are at a temperature slightly higher than that of the melted charge).",
"Once this fractionation process is completed the temperature of the crucible has peaked at 1900° C. (reference numeral 65 on curve 62).",
"The RF power is then decreased to a power level of 780 watts as indicated by numeral 66 on curve 61.",
"This power level corresponds to the desired rate of deposition of 4 angstroms per second of the charged material on the surface of the workpieces 24 when the workpiece is 28 inches away from the crucible 58.",
"Forty-five seconds after this decrease in RF power, when the temperature of the charge 19 stabilizes at about 1510° C., as indicated by numeral 67 on curve 62, the evaporant shield or shutter 24 is withdrawn from in front of the workpiece to permit the evaporant to coat the workpiece.",
"This power level is maintained for an additional 150 seconds at which time the shutter 24 is then positioned in front of the workpiece to prevent further deposition on the workpieces.",
"Simultaneously with the shutter 24 closing, the power level is raised to 1000 watts as indicated by reference numeral 68, and is maintained at this level for 90 seconds.",
"This causes a slight rise in temperature of the charge 19 as indicated by numeral 69 on curve 62.",
"Twenty-four seconds after the shutter closes and the power level rises, wire is fed from the wire feed 27 into the crucible to replenish the charge therein.",
"As the wire melts and replenishes the charge the temperature of the charge decreases as indicated by numeral 70 on curve 62.",
"At the end of 90 seconds the power is again decreased to the standby power level of 450 watts and the temperature of the charge continues to decline to 1200° C. at which temperature it again stabilizes.",
"By supporting all of the units of the invention within the coils 22, as described above, the crucible 58 is heated in a thermally controlled manner to provide self-fractionation.",
"This self-fractionation phenomenon eliminates any spitting of copper or copper oxides and eliminates the need for utilizing ultra pure material as a source.",
"Self-fractionation of the charge is particularly important when the material of the charge has a large amount of impurities that are introduced during its replenishment.",
"By utilizing the present invention as described above, copper films free of voids or inclusions and with less than 0.001% by weight of non-metallic contaminants contained therein have been successfully deposited on semiconductor wafers.",
"While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that the forgoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention."
] |
BACKGROUND
The present invention relates to product handling systems and, more particularly, to systems for receiving bulk quantities of individual product items and arranging the product items uniformly to be deposited on product conveyors.
In product manufacturing operations, the product items typically are produced in bulk quantities, but in many instances are packed and shipped in packages of a selected number and orientation. This requires that the bulk of product items produced be organized and arranged uniformly so that the items can be placed into packages of a uniform count and orientation.
Typical of such product production operations is the production of cooked products such as frankfurters. Such cooked product items are produced in bulk, yet are packed and shipped in packages of discreet numbers and arrays, such as a package of eight frankfurters, arranged in stacked rows of four frankfurters each.
Accordingly, there is a need for a system for receiving bulk quantities of product items, and ultimately orienting the items uniformly to be placed on conveyors which deliver the items to packing machinery.
SUMMARY OF THE INVENTION
The present invention is a system for receiving bulk quantities of product items and organizing and orienting the items uniformly to be placed on a product conveyor. The product alignment system of the present invention includes a product receiving component, which receives bulk quantities of product, a product orienting component, which receives product items from the receiving component at a measured rate and orients the products uniformly and a product launching component for placing the oriented product items on a bucket conveyor.
The product receiving component includes a hopper shaped to receive bulk quantities of product items. The hopper includes a hopper conveyor which extends across the bed of the conveyor, and a hopper nose conveyor, which projects sidewardly from an open side of the hopper and is fed by the hopper conveyor. The hopper nose conveyor includes a powered rake spaced above its load carrying surface, which spreads out the product items over the surface of the conveyor. The receiving component also includes a scale conveyor, oriented at an angle to the hopper nose conveyor, for receiving product from the hopper nose conveyor and depositing it at a substantially uniform rate onto the product orienting component. The scale conveyor also includes a powered rake spaced above its load carrying surface which provides substantially a continuous, single layer of product.
Both the hopper nose conveyor and the scale conveyor include load sensors at their upstream ends beneath the load carrying surfaces of those conveyors. The load sensors include analog proximity switches and are connected to a computer control and are adjusted to detect an accumulation of product whose weight exceeds a certain preselected level. The accumulation of weight results from the advancement of the hopper conveyor, combined with the action of the powered rakes, which tend to kick product items rearwardly toward the upstream end of the conveyors, while allowing only a single layer or layers of product to pass beneath. When the overload condition is detected by the load sensor associated with the hopper nose conveyor, an analog signal is generated which is read by a computer control which automatically begins to decrease the speed of the motor powering the hopper conveyor, thereby reducing the speed of the conveyor which reduces the rate at which product items are conveyed from the hopper to the hopper nose conveyor. This speed reduction, which is directly proportional to the weight of material on the hopper nose conveyor, continues until the accumulation of product at the upstream end of the hopper nose conveyor is reduced below the threshold level.
Similarly, an accumulation of product items on the upstream end of the scale conveyor triggers the load sensor associated with that conveyor, and generates a signal which is read by the computer control. Consequently, the computer control slows the motor driving the hopper nose conveyor to reduce the rate at which product items are deposited on the upstream end of the scale conveyor. This reduced speed operation, also proportional to the weight of product on the scale conveyor, continues until the amount of product on the scale conveyor is reduced below a threshold amount.
The product orienting component includes a first group of product conveying belts which are made of urethane molded into a V-shape in cross section. The belts are positioned to alternate with a second group of product aligning belts, having an O-ring shape. The product conveying belts are powered to run at a speed which is greater than that of the product aligning belts, so that product items bridging between the product supporting belts and the product aligning belts are rotated into the product supporting belts by the speed differential.
The product aligning belts are powered such that adjacent ones of the product aligning belts run at different speeds, so that product items which may bridge across adjacent aligning belts are rotated to fall into the product supporting belts by the speed differential of the adjacent product aligning belts. Furthermore, the product aligning belts are supported on pulleys which elevate the product contacting surfaces of the product aligning belts above the product support surface of the product supporting belts. Accordingly, there is a tendency for product items to fall downwardly by gravity into the bottom of the V-shaped product supporting belts. The product conveying belt system also includes sets of powered rakes which are spaced above the belts to ensure that only a single layer of product passes beneath.
The product launching component is located downstream of the arrangement of alternating product aligning belts and product supporting belts and includes a group of product launching belts, which also have a V-shape and are in registry with the product conveying belts. In a preferred embodiment, the product launching belts alternate in length so that they will feed evenly a pair of product conveyors which are oriented substantially normal to the direction of travel of the product launching belts.
Accordingly, it is an object of the present invention to provide a product aligning system which is capable of receiving bulk quantities of product items and orienting and aligning the items for placement onto a bucket product conveyor; a product aligning system in which products are automatically fed at an even rate from a hopper onto a product orienting component; a product aligning system which automatically orients oblong product items to lay along product conveying belts; a product aligning system which has a relatively small footprint; and a product aligning system which is relatively easy to maintain and construct.
Other objects and advantages will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic, top plan view of the product aligning system of the present invention, shown feeding a bucket conveyor;
FIG. 2 is a schematic, side elevation of the system shown in FIG. 1;
FIG. 3 is a schematic, side elevation of an alternate embodiment of the present invention;
FIG. 4 is a detail showing the product supporting belts and product aligning belts of the system of FIG. 1;
FIG. 5 is a detail in section of the pulleys supporting the product supporting belts and product aligning belts shown in FIG. 4;
FIG. 6 is a detail showing a top plan view of the hopper nose conveyor of the system of FIG. 1;
FIG. 7 is a schematic, side elevation of the hopper nose conveyor of FIG. 6;
FIG. 8 is a schematic, side elevation of the detail of FIG. 7 in which the load sensor has been actuated;
FIG. 9 is a schematic, top plan view of the scale conveyor of the system of FIG. 1;
FIG. 10 is a schematic, side elevation of the scale conveyor of FIG. 9;
FIG. 11 is a schematic, side elevation of the conveyor of FIG. 10, in which the load sensor is actuated; and
FIG. 12 is a top plan view of the upstream portion of the product launcher apparatus of the system of FIG. 1.
DETAILED DESCRIPTION
As shown in FIGS. 1 and 2, the product aligning system of the present invention, generally designated 10, is designed to receive large quantities of product items, such as cooked frankfurters 12, in bulk, and organize and align the frankfurters for placement onto twin bucket conveyors 14, 16. The aligning system includes a product receiving component 18, a product orienting component 20, and a product launching component 22 which ultimately deposits the items 12 on the conveyors 14, 16.
Product Receiving Component
The product receiving component 18 includes a hopper 24 having an open top and bottom, side walls 26, 28, and an end wall 30. The hopper 24 includes an open end 34 and a hopper conveyor 36 driven by AC motor 38. The hopper conveyor 36 extends substantially the entire length of the bottom wall 32 of the hopper 18.
A hopper nose conveyor 40 extends outwardly from the open end 34 of the hopper 18 and includes a belt assembly 42 driven an AC motor 44. The hopper nose conveyor 40 includes long and short side walls 46, 48 which support a counter-rotating rake 50 driven by motor 44. The hopper nose conveyor 40 and hopper 18 are supported by a wheeled frame 52 so that the entire unit is portable and easily positionable.
As shown in FIGS. 6, 7 and 8, the hopper nose conveyor 40 includes conveyor belts 54, 56, 58, 60 positioned adjacent to each other. Belts 54-60 each vary in length in stairstep fashion. The counter-rotating rake 50 is positioned above the belts 54-60 a distance sufficient so that large piles 62 (see FIG. 2) of cooked items deposited on the belts 54-60 are smoothed out so that only a relatively level layer 64 of items passes downstream of the rake. Preferably, rake 50 is oriented substantially normal to the direction of product flow on conveyor 40.
The hopper nose conveyor 40 includes a load sensor shown in FIGS. 6, 7 and 8. The load sensor apparatus, generally designated 66, includes a fulcrum axle 68 which is pivotally mounted in walls 46, 48 and supports upstream lever arm 70 that, in turn, supports load sensor bars 72, which are joined on a common load sensor axle 74 at an upstream end of the conveyors 54-60, and are supported at a downstream end on pivot axle 68. The load sensor 66 also includes a forward lever arm 76 which is displaced outwardly away from the conveyor 60 and includes a contact surface 78 that touches a force adjusting device 79, spring loaded tension button 80 mounted in a sleeve 82. The downward force of the tension button 80 is adjustable by a threaded wheel 84. An analog proximity switch 86 is mounted on the sleeve 82 and, as shown in FIG. 2, is connected to a computer control 88.
As shown in FIGS. 7 and 8, should an accumulation of product items (such as pile 62 shown in FIG. 2) exceed a certain, preselected threshold weight, the downward force of the pile, represented by arrow A in FIG. 8, deflects the contact 72 downwardly, causing the forward lever arm 76 to pivot upwardly in the direction of arrow B, thereby depressing the button 80 and actuating the proximity switch 86, which sends an analog signal to computer control 88 proportional to the weight of the pile 62.
The hopper nose conveyor 40 deposits product items 12 onto a scale conveyor, generally designated 90. As shown in FIG. 1, the scale conveyor 90 is oriented at an angle to hopper nose conveyor 40, receives product items 12 from the hopper nose conveyor, and conveys them to the product orienting component 20. The particular angle of the scale conveyor 90 relative to the hopper nose conveyor 40 may be varied to suit the space provided for the aligning system 10. As shown in FIGS. 9, 10 and 11, the scale conveyor 90 includes a hopper 92 which encloses the sides and rear of the conveyor and an array of conveyor elements 94, 96, 98, 100, 102, 104, 106, 108, 110 and 112. The conveyor elements 94-112 are driven by a common AC drive motor 114 which, like motor 44, is actuated by computer control 88. The drive motor 114 also drives a counter-rotating rake 116.
The scale conveyor 90 also includes a load sensor, generally designated 118. Load sensor 118 includes a pivot arm 120 which is attached to a pivot axis 122 supported in the hopper 92 by bearings (not shown). The pivot axis 122 supports lever arms 124 which extend beneath the load carrying surfaces 126 of the belts 128 of the conveyors 94-112. The lever arms 124 are joined by a common lever arm shaft 130 at the upstream end of the conveyors 94-112.
As shown in FIGS. 10 and 11, should the product 12 accumulate on the upstream end of the scale conveyor 90 to a weight which exceeds a predetermined threshold value, the downward force of the weight of the accumulated articles, represented by arrow C, pivots the arms 124 downwardly, thereby pivoting the lever arm 120 downwardly as well. Lever arm 120 depresses the spring-loaded tension button 132 of a force adjusting device 133 similar to that shown in FIG. 7, having a sleeve 134 and force adjusting wheel 136. The proximity of the lever arm 120 to proximity switch 138 generates an analog signal, proportional to the force C, to computer control 88, which is connected to proximity switch 138, as shown in FIG. 2.
The operation of the product receiving component 18 is as follows. Cooked food product items 12 are dumped in bulk into hopper 26, where they are displaced sidewardly (see FIGS. 1 and 2) by hopper conveyor 36 and deposited on the upstream end of the hopper nose conveyor 40. The counter-rotating rake 50, which is powered and in synchronization with motor 44, kicks back product items 12 which are stacked above a predetermined height on the load carrying surface 140 of the conveyor 42. Should the pile 62 of product items accumulating on the upstream end of the conveyor 42 exceed a certain threshold weight, the load sensor 66 will detect the overload condition and signal computer control 88. Computer control 88 will then reduce the speed of motor 38 proportionally to the weight of pile 62, which controls conveyor 36 to slow the rate of product flow from the hopper 26 to the hopper nose conveyor 40.
The hopper nose conveyor will, nevertheless, continue to deposit cooked product items 12 on the scale conveyor 90, evenly distributing the product across conveyor elements 94-112. The counter-rotating rake 116 of scale conveyor 90 kicks back cooked items so that substantially a single layer of cooked items flows downstream of the rake 116 to the product aligning component 22. Should the product items accumulate in the upstream portion of the scale conveyor 90 above a predetermined weight, the load sensor 118 will detect the overload condition and signal computer control 88. Computer control 88 will slow down hopper nose conveyor drive motor proportionally to the weight of the pile until the condition is corrected, with the weight of accumulated product items falling below the threshold level. Consequently, the need for operator supervision of these components is substantially reduced, as is the need for operator intervention in preventing overload conditions.
Product Orienting Component
The product orienting component 20 is shown in FIGS. 1 and 12 and includes an array 142 of product conveying belts 144 and an array 146 of product aligning belts 148. The product aligning belts 148 are O-ring belts and are oriented in alternating relation with the product conveying belts 144.
The product conveying belts 144 are made of urethane and, as shown in FIGS. 4 and 5, are molded to have a V-shape. The belts 144 are supported on intermediate conveyor rollers 150 (see also FIG. 12) which are formed to have a V-shape complementary to the belts 144. The upstream and downstream end rollers 152, 154, however, are standard crowned rollers, so that the belts 144 are self-aligning despite their V-shape. The product aligning belts 148 are mounted on pulleys 156. The upstream end of the product aligning belts 148 is supported on upstream axle 158, and the downstream end of the product aligning belts are mounted on downstream axle 160. Axles 158, 160 also support intermediate rollers 150 of the product conveying belts 144, which rotate freely on axles 158, 160.
Upstream support rollers 156' are ridgedly fixed to the axle 158, while the rollers 156 intermediate these rollers are not, and therefore rotate freely on the axle. Conversely, rollers 156" are ridgedly mounted on axle 160 directly downstream of rollers 156, and therefore are alternating with rollers 156 which are supported on, but not attached and driven by, axle 160. Axle 158 is driven by drive sprocket 162, which is of a larger diameter than drive sprocket 164 on axle 160. Both sprockets 162, 164 are driven by conveyor drive motor 166, so that the drive rollers 156' are, at all times, driven at a speed which is less than the speed of drive rollers 156". This ensures that, at all times, the belts 148 are travel at different speeds so that there is a differential in belt speed between any two adjacent ones of the belts 148. Further, the drive axis 168 for the product conveying belts 144 is also driven by motor 166, and the drive sprocket 170 is sized such that the speed of belts 144 at all times exceeds the speeds of belts 148.
As shown in FIG. 4, should a product item 12' bridge a product conveying 144 and an adjacent product aligning belt 148, the speed differential between the belts 144, 148 will cause the product to rotate and align itself to the position shown as 12", in which the product lies in the crotch or lower portion of the V-shaped belt. Should a product 12'" bridge between two adjacent product aligning belts 148, as shown in FIG. 4, the speed differential between those two belts will also cause the item to rotate, first to the position shown as 12', then ultimately to the orientation shown as 12". In order to accomplish this aligning task, it is preferable that the diameters of the pulleys 156 be greater than the greatest diameter of the rollers 150. With such dimensioning, the rotation of product items 12 to the orientation shown as 12" is aided by gravity.
Product Launching Component
As shown in FIG. 1, a product launching component 22 is positioned immediately downstream from the product aligning component 20, and comprises an array 172 of product launching belts 174, 176. Belts 174, 176 are urethane belts molded to form a V-shape, identical to that shown in FIGS. 4 and 5. Further, the extreme upstream and downstream end rollers (not shown) are also crowned, as with rollers 152, 154, so that the conveyors perform a self-aligning function.
The belts 174 terminate a shorter distance than belts 176, and are oriented in alternating relation with belts 176. With this orientation, product items 12 are loaded evenly onto conveyors 14, 16, even if the product is not distributed evenly across the component 22. The belts 174, 176 are powered by drive motor 166, and therefore are synchronized in speed with the belts 144. Belts 174, 176 convey the food product items 12 (best shown in FIG. 1) to the conveyors 14, 16 and the speed of the belts 174, 176 is sufficient to "launch" the products to fall into transfer buckets (not shown) of the conveyors 14, 16 so that product 12 is oriented in transverse, parallel relation as it travels down conveyors 14, 16.
In order to prevent an orientation of product in which the items 12 are stacked more than one high on the belts 144, a series of counter-rotating rakes 178, 180 is provided. As shown in FIG. 5, rakes 178, 180 are provided with fingers 182 which are shorter than fingers 184 to accommodate the variation elevation of the product supporting surfaces and product contacting surfaces of the product conveying belts 144 and product aligning belts 148.
As shown in FIG. 5, the fingers 184 of the rakes 178, 180 kick back product items 12 that may tend to accumulate in layers more than one product item high.
System Operation
The operation of the system 10 is as follows. The computer control 88 is powered up by the operator, and the motors 38, 44, 114 and 166 are activated. A bulk load of product 12 is dumped into the hopper 26 and is conveyed sidewardly (see FIG. 1) onto hopper nose conveyor 40. The rake 50 of hopper nose conveyor 40 levels out the product 12 and prevents lumps and piles of product from depositing onto the scale conveyor 90. Product deposited on scale conveyor 90 is likewise conveyed downstream to the upstream end of the product aligning conveyor 20. Should an accumulation of product 12 build up on hopper nose conveyor 40, the load sensor 66 will detect the condition, analog proximity switch 86 will signal computer control 88, and the speed of motor 38 will vary accordingly, speeding up or slowing down gradually to ensure an even flow of product.
Similarly, should product accumulate on the upstream end of scale conveyor 90, the analog proximity switch 138 will signal the computer 88 to vary the speed of motor 44 accordingly. If necessary, the speed of motor 38 will be varied, depending whether the slowdown of motor 44 causes an excessive build-up of product 62. Therefore, the leveling system has a cascade effect in which the speed of motor 144 determines, indirectly, the speeds of drive motors 44 and 38, and therefore the speeds of their associated hopper nose conveyor 42 and hopper conveyor 36.
The product items 12 are deposited onto the upstream end of product aligning component 20, where it falls in disorganized fashion on belts 144 and 148. As described previously, the differentials in speeds between belts 144 and 148, and between adjacent ones of 148, cause the product items 12 to rotate and orient themselves in the crotches of the V-belts 144. Excessive layers of such aligned products are removed as the V-belts 144 convey products have passed the powered rake assemblies 178, 180. The aligned products are then deposited onto the launching component 122, and are conveyed to the bucket conveyors 14, 16 which, in turn, convey the product 12 to packing apparatus, shown in FIG. 1 generally as 190. The packing apparatus 190 includes a filler head which is shown and described in copending application Ser. No. 08/532,221 (attorney docket 024793.501), the disclosure of which is incorporated herein by reference.
Accordingly, the product aligning system 10 of the present invention provides a compact, efficient and automated system for receiving product items in bulk, metering the flow of product items onto a product item orienting and aligning component, then depositing the aligned product items onto a bucket conveyor for further handling. By providing a closed loop, computer-controlled metering system, the wide variations in product flow into the hopper are accommodated by varying the speeds of the several conveyors that convey the product to the aligning apparatus.
An alternate embodiment of the present invention is shown in FIG. 3, in which a hopper 18' includes a hopper conveyor 36' which is positioned below the hopper (not shown) of the scale conveyor 90'. The scale conveyor 90' is substantially identical in construction to the conveyors 94-112 of the embodiment of FIG. 1. The hopper nose conveyor 40' has been modified to convey the product items 12 upwardly from the hopper conveyor 36 to the scale conveyor. Consequently, it is not necessary to include load sensing apparatus in the hopper nose conveyor 40'. The product aligning component 20' and product launching component 22' of the embodiment of FIG. 2 are substantially identical to their counterparts in the embodiment of FIG. 1.
While the forms of apparatus herein described constitute preferred embodiments of the invention, it is to be understood that the present invention is not limited to these precise forms of apparatus, and that variations may be made without departing from the scope of the invention. | A product aligning system specially adapted for receiving and aligning product items in bulk quantity, includes a hopper for receiving masses of product items in bulk and including a hopper conveyor extending across the bottom of the hopper, a hopper nose conveyor for receiving product items conveyed by the hopper conveyor and extending outwardly from the hopper, and a scale conveyor for receiving items from the hopper nose conveyor. The hopper nose conveyor and scale conveyor each include powered rakes positioned above the item supporting surfaces of those conveyors such that substantially only a single layer of items passes therebeneath. The hopper nose and scale conveyors each include load sensing apparatus which detects an accumulation of product items on those conveyors and signals a computer control which slows the speeds of the hopper and hopper nose conveyors sufficiently to allow the accumulation of products to reduce. The system also includes a product orienting component which includes an array of V-shaped belts positioned in alternating relation with an array of O-ring belts. The O-ring belts are driven at a slower speed than the V-shaped belts, and further, are driven at varying speeds, so that individual product items which bridge between adjacent O-ring belts, or between a V-shaped belt and an adjacent O-ring belt, are rotated as a result of the speed differential to lay substantially in alignment with the V-shaped product supporting belts. Powered rakes are positioned above the V-shaped belts so that substantially only a single layer of aligned product is conveyed from the downstream ends of the belts. | Condense the core contents of the given document. | [
"BACKGROUND The present invention relates to product handling systems and, more particularly, to systems for receiving bulk quantities of individual product items and arranging the product items uniformly to be deposited on product conveyors.",
"In product manufacturing operations, the product items typically are produced in bulk quantities, but in many instances are packed and shipped in packages of a selected number and orientation.",
"This requires that the bulk of product items produced be organized and arranged uniformly so that the items can be placed into packages of a uniform count and orientation.",
"Typical of such product production operations is the production of cooked products such as frankfurters.",
"Such cooked product items are produced in bulk, yet are packed and shipped in packages of discreet numbers and arrays, such as a package of eight frankfurters, arranged in stacked rows of four frankfurters each.",
"Accordingly, there is a need for a system for receiving bulk quantities of product items, and ultimately orienting the items uniformly to be placed on conveyors which deliver the items to packing machinery.",
"SUMMARY OF THE INVENTION The present invention is a system for receiving bulk quantities of product items and organizing and orienting the items uniformly to be placed on a product conveyor.",
"The product alignment system of the present invention includes a product receiving component, which receives bulk quantities of product, a product orienting component, which receives product items from the receiving component at a measured rate and orients the products uniformly and a product launching component for placing the oriented product items on a bucket conveyor.",
"The product receiving component includes a hopper shaped to receive bulk quantities of product items.",
"The hopper includes a hopper conveyor which extends across the bed of the conveyor, and a hopper nose conveyor, which projects sidewardly from an open side of the hopper and is fed by the hopper conveyor.",
"The hopper nose conveyor includes a powered rake spaced above its load carrying surface, which spreads out the product items over the surface of the conveyor.",
"The receiving component also includes a scale conveyor, oriented at an angle to the hopper nose conveyor, for receiving product from the hopper nose conveyor and depositing it at a substantially uniform rate onto the product orienting component.",
"The scale conveyor also includes a powered rake spaced above its load carrying surface which provides substantially a continuous, single layer of product.",
"Both the hopper nose conveyor and the scale conveyor include load sensors at their upstream ends beneath the load carrying surfaces of those conveyors.",
"The load sensors include analog proximity switches and are connected to a computer control and are adjusted to detect an accumulation of product whose weight exceeds a certain preselected level.",
"The accumulation of weight results from the advancement of the hopper conveyor, combined with the action of the powered rakes, which tend to kick product items rearwardly toward the upstream end of the conveyors, while allowing only a single layer or layers of product to pass beneath.",
"When the overload condition is detected by the load sensor associated with the hopper nose conveyor, an analog signal is generated which is read by a computer control which automatically begins to decrease the speed of the motor powering the hopper conveyor, thereby reducing the speed of the conveyor which reduces the rate at which product items are conveyed from the hopper to the hopper nose conveyor.",
"This speed reduction, which is directly proportional to the weight of material on the hopper nose conveyor, continues until the accumulation of product at the upstream end of the hopper nose conveyor is reduced below the threshold level.",
"Similarly, an accumulation of product items on the upstream end of the scale conveyor triggers the load sensor associated with that conveyor, and generates a signal which is read by the computer control.",
"Consequently, the computer control slows the motor driving the hopper nose conveyor to reduce the rate at which product items are deposited on the upstream end of the scale conveyor.",
"This reduced speed operation, also proportional to the weight of product on the scale conveyor, continues until the amount of product on the scale conveyor is reduced below a threshold amount.",
"The product orienting component includes a first group of product conveying belts which are made of urethane molded into a V-shape in cross section.",
"The belts are positioned to alternate with a second group of product aligning belts, having an O-ring shape.",
"The product conveying belts are powered to run at a speed which is greater than that of the product aligning belts, so that product items bridging between the product supporting belts and the product aligning belts are rotated into the product supporting belts by the speed differential.",
"The product aligning belts are powered such that adjacent ones of the product aligning belts run at different speeds, so that product items which may bridge across adjacent aligning belts are rotated to fall into the product supporting belts by the speed differential of the adjacent product aligning belts.",
"Furthermore, the product aligning belts are supported on pulleys which elevate the product contacting surfaces of the product aligning belts above the product support surface of the product supporting belts.",
"Accordingly, there is a tendency for product items to fall downwardly by gravity into the bottom of the V-shaped product supporting belts.",
"The product conveying belt system also includes sets of powered rakes which are spaced above the belts to ensure that only a single layer of product passes beneath.",
"The product launching component is located downstream of the arrangement of alternating product aligning belts and product supporting belts and includes a group of product launching belts, which also have a V-shape and are in registry with the product conveying belts.",
"In a preferred embodiment, the product launching belts alternate in length so that they will feed evenly a pair of product conveyors which are oriented substantially normal to the direction of travel of the product launching belts.",
"Accordingly, it is an object of the present invention to provide a product aligning system which is capable of receiving bulk quantities of product items and orienting and aligning the items for placement onto a bucket product conveyor;",
"a product aligning system in which products are automatically fed at an even rate from a hopper onto a product orienting component;",
"a product aligning system which automatically orients oblong product items to lay along product conveying belts;",
"a product aligning system which has a relatively small footprint;",
"and a product aligning system which is relatively easy to maintain and construct.",
"Other objects and advantages will be apparent from the following description, the accompanying drawings and the appended claims.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a somewhat schematic, top plan view of the product aligning system of the present invention, shown feeding a bucket conveyor;",
"FIG. 2 is a schematic, side elevation of the system shown in FIG. 1;",
"FIG. 3 is a schematic, side elevation of an alternate embodiment of the present invention;",
"FIG. 4 is a detail showing the product supporting belts and product aligning belts of the system of FIG. 1;",
"FIG. 5 is a detail in section of the pulleys supporting the product supporting belts and product aligning belts shown in FIG. 4;",
"FIG. 6 is a detail showing a top plan view of the hopper nose conveyor of the system of FIG. 1;",
"FIG. 7 is a schematic, side elevation of the hopper nose conveyor of FIG. 6;",
"FIG. 8 is a schematic, side elevation of the detail of FIG. 7 in which the load sensor has been actuated;",
"FIG. 9 is a schematic, top plan view of the scale conveyor of the system of FIG. 1;",
"FIG. 10 is a schematic, side elevation of the scale conveyor of FIG. 9;",
"FIG. 11 is a schematic, side elevation of the conveyor of FIG. 10, in which the load sensor is actuated;",
"and FIG. 12 is a top plan view of the upstream portion of the product launcher apparatus of the system of FIG. 1. DETAILED DESCRIPTION As shown in FIGS. 1 and 2, the product aligning system of the present invention, generally designated 10, is designed to receive large quantities of product items, such as cooked frankfurters 12, in bulk, and organize and align the frankfurters for placement onto twin bucket conveyors 14, 16.",
"The aligning system includes a product receiving component 18, a product orienting component 20, and a product launching component 22 which ultimately deposits the items 12 on the conveyors 14, 16.",
"Product Receiving Component The product receiving component 18 includes a hopper 24 having an open top and bottom, side walls 26, 28, and an end wall 30.",
"The hopper 24 includes an open end 34 and a hopper conveyor 36 driven by AC motor 38.",
"The hopper conveyor 36 extends substantially the entire length of the bottom wall 32 of the hopper 18.",
"A hopper nose conveyor 40 extends outwardly from the open end 34 of the hopper 18 and includes a belt assembly 42 driven an AC motor 44.",
"The hopper nose conveyor 40 includes long and short side walls 46, 48 which support a counter-rotating rake 50 driven by motor 44.",
"The hopper nose conveyor 40 and hopper 18 are supported by a wheeled frame 52 so that the entire unit is portable and easily positionable.",
"As shown in FIGS. 6, 7 and 8, the hopper nose conveyor 40 includes conveyor belts 54, 56, 58, 60 positioned adjacent to each other.",
"Belts 54-60 each vary in length in stairstep fashion.",
"The counter-rotating rake 50 is positioned above the belts 54-60 a distance sufficient so that large piles 62 (see FIG. 2) of cooked items deposited on the belts 54-60 are smoothed out so that only a relatively level layer 64 of items passes downstream of the rake.",
"Preferably, rake 50 is oriented substantially normal to the direction of product flow on conveyor 40.",
"The hopper nose conveyor 40 includes a load sensor shown in FIGS. 6, 7 and 8.",
"The load sensor apparatus, generally designated 66, includes a fulcrum axle 68 which is pivotally mounted in walls 46, 48 and supports upstream lever arm 70 that, in turn, supports load sensor bars 72, which are joined on a common load sensor axle 74 at an upstream end of the conveyors 54-60, and are supported at a downstream end on pivot axle 68.",
"The load sensor 66 also includes a forward lever arm 76 which is displaced outwardly away from the conveyor 60 and includes a contact surface 78 that touches a force adjusting device 79, spring loaded tension button 80 mounted in a sleeve 82.",
"The downward force of the tension button 80 is adjustable by a threaded wheel 84.",
"An analog proximity switch 86 is mounted on the sleeve 82 and, as shown in FIG. 2, is connected to a computer control 88.",
"As shown in FIGS. 7 and 8, should an accumulation of product items (such as pile 62 shown in FIG. 2) exceed a certain, preselected threshold weight, the downward force of the pile, represented by arrow A in FIG. 8, deflects the contact 72 downwardly, causing the forward lever arm 76 to pivot upwardly in the direction of arrow B, thereby depressing the button 80 and actuating the proximity switch 86, which sends an analog signal to computer control 88 proportional to the weight of the pile 62.",
"The hopper nose conveyor 40 deposits product items 12 onto a scale conveyor, generally designated 90.",
"As shown in FIG. 1, the scale conveyor 90 is oriented at an angle to hopper nose conveyor 40, receives product items 12 from the hopper nose conveyor, and conveys them to the product orienting component 20.",
"The particular angle of the scale conveyor 90 relative to the hopper nose conveyor 40 may be varied to suit the space provided for the aligning system 10.",
"As shown in FIGS. 9, 10 and 11, the scale conveyor 90 includes a hopper 92 which encloses the sides and rear of the conveyor and an array of conveyor elements 94, 96, 98, 100, 102, 104, 106, 108, 110 and 112.",
"The conveyor elements 94-112 are driven by a common AC drive motor 114 which, like motor 44, is actuated by computer control 88.",
"The drive motor 114 also drives a counter-rotating rake 116.",
"The scale conveyor 90 also includes a load sensor, generally designated 118.",
"Load sensor 118 includes a pivot arm 120 which is attached to a pivot axis 122 supported in the hopper 92 by bearings (not shown).",
"The pivot axis 122 supports lever arms 124 which extend beneath the load carrying surfaces 126 of the belts 128 of the conveyors 94-112.",
"The lever arms 124 are joined by a common lever arm shaft 130 at the upstream end of the conveyors 94-112.",
"As shown in FIGS. 10 and 11, should the product 12 accumulate on the upstream end of the scale conveyor 90 to a weight which exceeds a predetermined threshold value, the downward force of the weight of the accumulated articles, represented by arrow C, pivots the arms 124 downwardly, thereby pivoting the lever arm 120 downwardly as well.",
"Lever arm 120 depresses the spring-loaded tension button 132 of a force adjusting device 133 similar to that shown in FIG. 7, having a sleeve 134 and force adjusting wheel 136.",
"The proximity of the lever arm 120 to proximity switch 138 generates an analog signal, proportional to the force C, to computer control 88, which is connected to proximity switch 138, as shown in FIG. 2. The operation of the product receiving component 18 is as follows.",
"Cooked food product items 12 are dumped in bulk into hopper 26, where they are displaced sidewardly (see FIGS. 1 and 2) by hopper conveyor 36 and deposited on the upstream end of the hopper nose conveyor 40.",
"The counter-rotating rake 50, which is powered and in synchronization with motor 44, kicks back product items 12 which are stacked above a predetermined height on the load carrying surface 140 of the conveyor 42.",
"Should the pile 62 of product items accumulating on the upstream end of the conveyor 42 exceed a certain threshold weight, the load sensor 66 will detect the overload condition and signal computer control 88.",
"Computer control 88 will then reduce the speed of motor 38 proportionally to the weight of pile 62, which controls conveyor 36 to slow the rate of product flow from the hopper 26 to the hopper nose conveyor 40.",
"The hopper nose conveyor will, nevertheless, continue to deposit cooked product items 12 on the scale conveyor 90, evenly distributing the product across conveyor elements 94-112.",
"The counter-rotating rake 116 of scale conveyor 90 kicks back cooked items so that substantially a single layer of cooked items flows downstream of the rake 116 to the product aligning component 22.",
"Should the product items accumulate in the upstream portion of the scale conveyor 90 above a predetermined weight, the load sensor 118 will detect the overload condition and signal computer control 88.",
"Computer control 88 will slow down hopper nose conveyor drive motor proportionally to the weight of the pile until the condition is corrected, with the weight of accumulated product items falling below the threshold level.",
"Consequently, the need for operator supervision of these components is substantially reduced, as is the need for operator intervention in preventing overload conditions.",
"Product Orienting Component The product orienting component 20 is shown in FIGS. 1 and 12 and includes an array 142 of product conveying belts 144 and an array 146 of product aligning belts 148.",
"The product aligning belts 148 are O-ring belts and are oriented in alternating relation with the product conveying belts 144.",
"The product conveying belts 144 are made of urethane and, as shown in FIGS. 4 and 5, are molded to have a V-shape.",
"The belts 144 are supported on intermediate conveyor rollers 150 (see also FIG. 12) which are formed to have a V-shape complementary to the belts 144.",
"The upstream and downstream end rollers 152, 154, however, are standard crowned rollers, so that the belts 144 are self-aligning despite their V-shape.",
"The product aligning belts 148 are mounted on pulleys 156.",
"The upstream end of the product aligning belts 148 is supported on upstream axle 158, and the downstream end of the product aligning belts are mounted on downstream axle 160.",
"Axles 158, 160 also support intermediate rollers 150 of the product conveying belts 144, which rotate freely on axles 158, 160.",
"Upstream support rollers 156'",
"are ridgedly fixed to the axle 158, while the rollers 156 intermediate these rollers are not, and therefore rotate freely on the axle.",
"Conversely, rollers 156"",
"are ridgedly mounted on axle 160 directly downstream of rollers 156, and therefore are alternating with rollers 156 which are supported on, but not attached and driven by, axle 160.",
"Axle 158 is driven by drive sprocket 162, which is of a larger diameter than drive sprocket 164 on axle 160.",
"Both sprockets 162, 164 are driven by conveyor drive motor 166, so that the drive rollers 156'",
"are, at all times, driven at a speed which is less than the speed of drive rollers 156".",
"This ensures that, at all times, the belts 148 are travel at different speeds so that there is a differential in belt speed between any two adjacent ones of the belts 148.",
"Further, the drive axis 168 for the product conveying belts 144 is also driven by motor 166, and the drive sprocket 170 is sized such that the speed of belts 144 at all times exceeds the speeds of belts 148.",
"As shown in FIG. 4, should a product item 12'",
"bridge a product conveying 144 and an adjacent product aligning belt 148, the speed differential between the belts 144, 148 will cause the product to rotate and align itself to the position shown as 12", in which the product lies in the crotch or lower portion of the V-shaped belt.",
"Should a product 12'"",
"bridge between two adjacent product aligning belts 148, as shown in FIG. 4, the speed differential between those two belts will also cause the item to rotate, first to the position shown as 12', then ultimately to the orientation shown as 12".",
"In order to accomplish this aligning task, it is preferable that the diameters of the pulleys 156 be greater than the greatest diameter of the rollers 150.",
"With such dimensioning, the rotation of product items 12 to the orientation shown as 12"",
"is aided by gravity.",
"Product Launching Component As shown in FIG. 1, a product launching component 22 is positioned immediately downstream from the product aligning component 20, and comprises an array 172 of product launching belts 174, 176.",
"Belts 174, 176 are urethane belts molded to form a V-shape, identical to that shown in FIGS. 4 and 5.",
"Further, the extreme upstream and downstream end rollers (not shown) are also crowned, as with rollers 152, 154, so that the conveyors perform a self-aligning function.",
"The belts 174 terminate a shorter distance than belts 176, and are oriented in alternating relation with belts 176.",
"With this orientation, product items 12 are loaded evenly onto conveyors 14, 16, even if the product is not distributed evenly across the component 22.",
"The belts 174, 176 are powered by drive motor 166, and therefore are synchronized in speed with the belts 144.",
"Belts 174, 176 convey the food product items 12 (best shown in FIG. 1) to the conveyors 14, 16 and the speed of the belts 174, 176 is sufficient to "launch"",
"the products to fall into transfer buckets (not shown) of the conveyors 14, 16 so that product 12 is oriented in transverse, parallel relation as it travels down conveyors 14, 16.",
"In order to prevent an orientation of product in which the items 12 are stacked more than one high on the belts 144, a series of counter-rotating rakes 178, 180 is provided.",
"As shown in FIG. 5, rakes 178, 180 are provided with fingers 182 which are shorter than fingers 184 to accommodate the variation elevation of the product supporting surfaces and product contacting surfaces of the product conveying belts 144 and product aligning belts 148.",
"As shown in FIG. 5, the fingers 184 of the rakes 178, 180 kick back product items 12 that may tend to accumulate in layers more than one product item high.",
"System Operation The operation of the system 10 is as follows.",
"The computer control 88 is powered up by the operator, and the motors 38, 44, 114 and 166 are activated.",
"A bulk load of product 12 is dumped into the hopper 26 and is conveyed sidewardly (see FIG. 1) onto hopper nose conveyor 40.",
"The rake 50 of hopper nose conveyor 40 levels out the product 12 and prevents lumps and piles of product from depositing onto the scale conveyor 90.",
"Product deposited on scale conveyor 90 is likewise conveyed downstream to the upstream end of the product aligning conveyor 20.",
"Should an accumulation of product 12 build up on hopper nose conveyor 40, the load sensor 66 will detect the condition, analog proximity switch 86 will signal computer control 88, and the speed of motor 38 will vary accordingly, speeding up or slowing down gradually to ensure an even flow of product.",
"Similarly, should product accumulate on the upstream end of scale conveyor 90, the analog proximity switch 138 will signal the computer 88 to vary the speed of motor 44 accordingly.",
"If necessary, the speed of motor 38 will be varied, depending whether the slowdown of motor 44 causes an excessive build-up of product 62.",
"Therefore, the leveling system has a cascade effect in which the speed of motor 144 determines, indirectly, the speeds of drive motors 44 and 38, and therefore the speeds of their associated hopper nose conveyor 42 and hopper conveyor 36.",
"The product items 12 are deposited onto the upstream end of product aligning component 20, where it falls in disorganized fashion on belts 144 and 148.",
"As described previously, the differentials in speeds between belts 144 and 148, and between adjacent ones of 148, cause the product items 12 to rotate and orient themselves in the crotches of the V-belts 144.",
"Excessive layers of such aligned products are removed as the V-belts 144 convey products have passed the powered rake assemblies 178, 180.",
"The aligned products are then deposited onto the launching component 122, and are conveyed to the bucket conveyors 14, 16 which, in turn, convey the product 12 to packing apparatus, shown in FIG. 1 generally as 190.",
"The packing apparatus 190 includes a filler head which is shown and described in copending application Ser.",
"No. 08/532,221 (attorney docket 024793.501), the disclosure of which is incorporated herein by reference.",
"Accordingly, the product aligning system 10 of the present invention provides a compact, efficient and automated system for receiving product items in bulk, metering the flow of product items onto a product item orienting and aligning component, then depositing the aligned product items onto a bucket conveyor for further handling.",
"By providing a closed loop, computer-controlled metering system, the wide variations in product flow into the hopper are accommodated by varying the speeds of the several conveyors that convey the product to the aligning apparatus.",
"An alternate embodiment of the present invention is shown in FIG. 3, in which a hopper 18'",
"includes a hopper conveyor 36'",
"which is positioned below the hopper (not shown) of the scale conveyor 90'.",
"The scale conveyor 90'",
"is substantially identical in construction to the conveyors 94-112 of the embodiment of FIG. 1. The hopper nose conveyor 40'",
"has been modified to convey the product items 12 upwardly from the hopper conveyor 36 to the scale conveyor.",
"Consequently, it is not necessary to include load sensing apparatus in the hopper nose conveyor 40'.",
"The product aligning component 20'",
"and product launching component 22'",
"of the embodiment of FIG. 2 are substantially identical to their counterparts in the embodiment of FIG. 1. While the forms of apparatus herein described constitute preferred embodiments of the invention, it is to be understood that the present invention is not limited to these precise forms of apparatus, and that variations may be made without departing from the scope of the invention."
] |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention pertains to the installation of computer units in desks or similar platforms where the confusion of multiple wires and cords are minimized as opposed to installations in which power cables, network cables and other similar wires are indiscriminately run from one unit to another with the net result of a good deal of confusion and entanglement of cords.
The relatively recent advent of personal computers at multiple locations throughout an office with the computers net-worked together by cables, each computer including a power cord, monitor, power and signal connections and cords for a mouse, key board, and printer, as well as from a central processing unit has resulted in installation on the floor or on desks or in cubicles with severely jumbled cables and cords either behind the desk or under or alongside the desk. The result is both an unsightly entanglement of wires and difficult repair or replacement circumstances in which wires and cables must be sorted out and traced through the tangle so that the correct wire or cable may be handled for the replacement.
Also, the placement of the processing unit on the floor is frequently difficult to access. Usually it is desirable to get the box out of the way, but that leads to a condition of inaccessibility when service or repair is necessary. Frequently, in such situations, furniture must be moved or sometimes even dismantled in order to get at the interior of the container in which the electronics are located.
By the present invention an installation may be made in which the cable can be run to a given point at which computer components may be located while at the same time, the cable is enclosed systematically within a desk corridor or component. Some individual separation of computer components maybe indicated for more convenient installation of the computer both for convenience, cleanliness and security if desired, these components maybe retractable into separate compartments. The convenience of ready access will be obvious. It may also be apparent that security may be enhanced by the easy provision of locked containers for the processor especially.
It is also apparent that by this invention, added protection to the processing unit is available because of improved location away from a position of being bumped or kicked on the floor. Further the improved location of the processor farther from the drives provides for better cooling and improved circulation of air around the processor. Dust prevention for both the processor and the drives is also enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a desk incorporating the system of the invention.
FIG. 2 is a front elevational view of the desk of FIG. 1.
FIG. 3 is a sectional view from line 3--3 of FIG. 2.
FIG. 4 is a partial view similar to FIG. 3 showing the processor container in an open position.
FIG. 5 is a partial top plan view of an alternative type desk.
FIG. 6 is a front elevational view of the alternative shown in FIG. 5.
FIG. 7 is a sectional view from line 7--7 of FIG. 6.
DESCRIPTION
Briefly the invention comprises a system for providing necessary wiring arrangements for a computer in connection with a desk. The computer does not necessarily become part of the desk, but various components may be separately located on the desk.
More specifically and with reference to the drawings, the system is used in connection with a desk 10 or other computer platform which typically would be an L-shaped device adapted to be placed in a corner of an office or work cubicle. Computers are often set on such desks and trail electrical cords or cables to other networked computers or to electrical outlets or to other components of the computer--all of which leads to a tangle or jumble of cords and wires which must be traced or untangled when components are to be repaired or replaced.
In the current device, the desk includes a specific container 11 for the central processor. This container is preferably hinged to the rear part of the desk at a lower corner 12 of the container. Thus, a server or a processing unit can be carried within this container 11 and tipped forward for renewal or replacement when necessary. It is obvious that a drawer or slide arrangement might be readily substituted for the hinged container.
Cables and cords 15 from this unit are threaded through a conduit 16 and from this conduit may lead to a monitor (not shown) on the top of the desk and to a power source (also not shown), or perhaps to a printer. Principally, however, the cables are designed to lead to the disk drive units 17 and a control panel unit 18. These units maybe mounted by any convenient device to the lower surface of the desk top at a conveniently accessible location. The conduit 16 is preferably built into the desk at an upper rear corner so as to be out of the way. Thus, the wires and cables are all contained in a location where they will not be tangled and will not get underfoot.
As shown in FIG. 4, some excess cable and wires maybe required in order to tilt down the container 11. Provision is made for storage of those short excess amounts within that container. Thus, as the container 11 is returned to its upper or closed position that excess can be tucked into the container to get the cords out of the way. It will be obvious to those skilled in the art that a drawer or similar container could be substituted for the hinged arrangement shown in the figures.
An alternative embodiment of the system is shown in FIGS. 5-7. In this embodiment, the cords and wires to the processing unit and its container 11 are handled in the same way. However, the disk drives 17 instead of being mounted on the front edge of the desk 10 are separately mounted on platforms 20. Each platform is mounted so that it can be raised or lowered by some kind of elevator unit. Illustrated is a piston and cylinder device 21 which may be operated hydraulically or pneumatically. However, electrically operated devices, cable and pulley devices, or any other mechanisms may be used to provide the lifting. This mechanism provides convenient compact means for hiding the drives so that they will not interfere in any way with the use of the desk. It will be apparent that by mounting these lifts 20 and the drive units 17 at the rear of the desk, and by making the top of the drive unit fit the opening in the desk so that the unit can be lowered to be flush with the desk surface, the use of the desk is not interfered with.
Suitable security devices of any acceptable type may be used on the controls of the lifts so that unauthorized use of the device may be avoided.
It is apparent that by this invention a compact and convenient installation of a computer on a desk may be provided. The installation will be not only be compact and convenient but can be easily accessed for repair and replacement, and will be relatively secure physically. | A system of mounting a computer mechanism to avoid tangled cords and to protect the equipment conveniently within a desk or similar work surfaces. The system includes a desk having units of the computer and a harness of the wires and cables necessary for operation thereof either built into the desk or added to the desk. | Identify the most important claim in the given context and summarize it | [
"BACKGROUND AND SUMMARY OF THE INVENTION This invention pertains to the installation of computer units in desks or similar platforms where the confusion of multiple wires and cords are minimized as opposed to installations in which power cables, network cables and other similar wires are indiscriminately run from one unit to another with the net result of a good deal of confusion and entanglement of cords.",
"The relatively recent advent of personal computers at multiple locations throughout an office with the computers net-worked together by cables, each computer including a power cord, monitor, power and signal connections and cords for a mouse, key board, and printer, as well as from a central processing unit has resulted in installation on the floor or on desks or in cubicles with severely jumbled cables and cords either behind the desk or under or alongside the desk.",
"The result is both an unsightly entanglement of wires and difficult repair or replacement circumstances in which wires and cables must be sorted out and traced through the tangle so that the correct wire or cable may be handled for the replacement.",
"Also, the placement of the processing unit on the floor is frequently difficult to access.",
"Usually it is desirable to get the box out of the way, but that leads to a condition of inaccessibility when service or repair is necessary.",
"Frequently, in such situations, furniture must be moved or sometimes even dismantled in order to get at the interior of the container in which the electronics are located.",
"By the present invention an installation may be made in which the cable can be run to a given point at which computer components may be located while at the same time, the cable is enclosed systematically within a desk corridor or component.",
"Some individual separation of computer components maybe indicated for more convenient installation of the computer both for convenience, cleanliness and security if desired, these components maybe retractable into separate compartments.",
"The convenience of ready access will be obvious.",
"It may also be apparent that security may be enhanced by the easy provision of locked containers for the processor especially.",
"It is also apparent that by this invention, added protection to the processing unit is available because of improved location away from a position of being bumped or kicked on the floor.",
"Further the improved location of the processor farther from the drives provides for better cooling and improved circulation of air around the processor.",
"Dust prevention for both the processor and the drives is also enhanced.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of a desk incorporating the system of the invention.",
"FIG. 2 is a front elevational view of the desk of FIG. 1. FIG. 3 is a sectional view from line 3--3 of FIG. 2. FIG. 4 is a partial view similar to FIG. 3 showing the processor container in an open position.",
"FIG. 5 is a partial top plan view of an alternative type desk.",
"FIG. 6 is a front elevational view of the alternative shown in FIG. 5. FIG. 7 is a sectional view from line 7--7 of FIG. 6. DESCRIPTION Briefly the invention comprises a system for providing necessary wiring arrangements for a computer in connection with a desk.",
"The computer does not necessarily become part of the desk, but various components may be separately located on the desk.",
"More specifically and with reference to the drawings, the system is used in connection with a desk 10 or other computer platform which typically would be an L-shaped device adapted to be placed in a corner of an office or work cubicle.",
"Computers are often set on such desks and trail electrical cords or cables to other networked computers or to electrical outlets or to other components of the computer--all of which leads to a tangle or jumble of cords and wires which must be traced or untangled when components are to be repaired or replaced.",
"In the current device, the desk includes a specific container 11 for the central processor.",
"This container is preferably hinged to the rear part of the desk at a lower corner 12 of the container.",
"Thus, a server or a processing unit can be carried within this container 11 and tipped forward for renewal or replacement when necessary.",
"It is obvious that a drawer or slide arrangement might be readily substituted for the hinged container.",
"Cables and cords 15 from this unit are threaded through a conduit 16 and from this conduit may lead to a monitor (not shown) on the top of the desk and to a power source (also not shown), or perhaps to a printer.",
"Principally, however, the cables are designed to lead to the disk drive units 17 and a control panel unit 18.",
"These units maybe mounted by any convenient device to the lower surface of the desk top at a conveniently accessible location.",
"The conduit 16 is preferably built into the desk at an upper rear corner so as to be out of the way.",
"Thus, the wires and cables are all contained in a location where they will not be tangled and will not get underfoot.",
"As shown in FIG. 4, some excess cable and wires maybe required in order to tilt down the container 11.",
"Provision is made for storage of those short excess amounts within that container.",
"Thus, as the container 11 is returned to its upper or closed position that excess can be tucked into the container to get the cords out of the way.",
"It will be obvious to those skilled in the art that a drawer or similar container could be substituted for the hinged arrangement shown in the figures.",
"An alternative embodiment of the system is shown in FIGS. 5-7.",
"In this embodiment, the cords and wires to the processing unit and its container 11 are handled in the same way.",
"However, the disk drives 17 instead of being mounted on the front edge of the desk 10 are separately mounted on platforms 20.",
"Each platform is mounted so that it can be raised or lowered by some kind of elevator unit.",
"Illustrated is a piston and cylinder device 21 which may be operated hydraulically or pneumatically.",
"However, electrically operated devices, cable and pulley devices, or any other mechanisms may be used to provide the lifting.",
"This mechanism provides convenient compact means for hiding the drives so that they will not interfere in any way with the use of the desk.",
"It will be apparent that by mounting these lifts 20 and the drive units 17 at the rear of the desk, and by making the top of the drive unit fit the opening in the desk so that the unit can be lowered to be flush with the desk surface, the use of the desk is not interfered with.",
"Suitable security devices of any acceptable type may be used on the controls of the lifts so that unauthorized use of the device may be avoided.",
"It is apparent that by this invention a compact and convenient installation of a computer on a desk may be provided.",
"The installation will be not only be compact and convenient but can be easily accessed for repair and replacement, and will be relatively secure physically."
] |
BACKGROUND
1. Technical Field
The present disclosure relates to imaging systems and, particularly, to a computational imaging system.
2. Description of Related Art
Generally, an image of an object captured by conventional imaging systems is in focus only over a limited object distance range which is known as depth of field (DOF). Therefore, it is difficult to sharply capture object scenes that span large distances. To obtain an extended DOF, one attempt has been made that deliberately blurs an intermediate image captured by an imaging system by placing a coded aperture in the aperture of the imaging system and then digitally removes the blur using reconstruction algorithms. The coded aperture is patterned according to a modulation transfer function (e.g., a delta function). As such, reconstruction algorithms can effectively deconvolute the modulation transfer function and restores the image to a more recognizable likeness of the object with a greater DOF than what that would have been otherwise obtainable. This is known as coded aperture imaging and is one kind of computational imaging system. See Zand, J., “Coded Aperture Imaging in High Energy Astronomy”, NASA Laboratory for High Energy Astrophysics (LHEA) at NASA's GSFC (1996); Levin, A., Fergus, R., Durand, F., Freeman, B., “Image and Depth from a Conventional Camera with a Coded Aperture”, ACM Transactions on Graphics (Proc. SIGGRAPH) (2007); Veeraraghavan, A., Raskar, R., Agrawal, A., Mohan, A., Tumblin, J., “Dappled Photography: Mask Enhanced Cameras for Heterodyned Light Fields and Coded Aperture Refocusing”, ACM Transactions on Graphics (Proc. SIGGRAPH) (2007); and Liang, C. K., Lin, T. H., Wong, B. Y., Liu, C., Chen, H. H., “Programmable Aperture Photography: Multiplexed Light Field Acquisition”, ACM Transactions on Graphics (Proc. SIGGRAPH), Vol. 27, No. 3, Article No. 55 (2008). However, to blur the intermediate image, the coded aperture (e.g., the pattern formed on the coded aperture) also blocks large amounts of light rays incident on the aperture, resulting in large amount of light loss.
Therefore, it is desirable to provide a computational imaging system, which can overcome the abovementioned shortcomings.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present computational imaging system should be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present computational imaging system. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a schematic view of a computational imaging system, according to a first exemplary embodiment.
FIG. 2 is a planar view of a liquid crystal (LC) element of the computational imaging system of FIG. 1 .
FIG. 3 is a planar view of the LC element, according to a second embodiment.
FIG. 4 is a planar view of the LC element, according to a third embodiment.
FIG. 5 is a planar view of the LC element, according to a fourth embodiment.
DETAILED DESCRIPTION
Embodiments of the present computational imaging system will now be described in detail with reference to the drawings.
Referring to FIGS. 1 and 2 , a computational imaging system 100 , according to a first embodiment, includes a lens 10 , an image sensor 20 , an LC element 30 , and a digital focus processor 40 .
The lens 10 and the image sensor 20 constitute an imaging sub-system. The LC element 30 functions as the aperture of the imaging sub-system constituted by the lens 10 and the image sensor 20 (placed in the light path of the imaging sub-system).
The LC element 30 is a transmissive LC panel that has a periodically patterned electrode 32 . The electrode 32 is patterned according to a periodical modulation transfer function (i.e., a spatial function):
H ( x,y )=cos 2π( s x x+s y y ), (1)
where an origin of the oxy coordinate system is the center of the LC element 30 , the x axis extends along the widthwise direction of the LC element 30 , the y axis extends along the lengthwise direction of the LC element 30 , s x is a spatial frequency of the electrode 32 along the x axis, and s y is a spatial frequency of the electrode 32 along the y axis. Assuming that: (i) the refractive index of the LC element 30 outside the electrode 32 is n 0 ; and (ii) the refractive index of the LC element 30 at the electrode 32 is n=n 0 +Δn, where Δn is the refractive index variance caused by applying a voltage to the electrode 32 , the refractive index of the entire LC element 30 can be expressed as a refractive index function:
n ( x,y )= n 0 +Δn ×cos 2π( s x x+s y y ). (2)
Also referring to FIG. 2 , in this embodiment, the electrode 32 is a set of concentric annuluses 322 with uniform distances between each two adjacent annuluses 322 . However, the electrode 32 is not limited to this embodiment, but can conform to other configurations, for example, a rectangular spiral line 324 as shown in FIG. 3 , a circular dot array 326 , or a rectangular block array 328 as shown in FIG. 5 .
The digital Focus processor 40 includes a Fourier transforming device 42 , a deconvolution device 44 , an inverse Fourier transforming device 46 , and a refocusing device 48 .
The Fourier transforming device 42 is configured for transforming a space domain amplitude function U I (x,y) of an intermediate image captured by the image sensor 20 into a frequency domain function U ƒ (x,y), where ƒ x , ƒ y are x and y axes variables in the frequency domain, respectively. According to Fourier optics, it can be determined that:
U f ( f x , f y ) = ⅇ [ j 1 2 f ( f x 2 + f y 2 ) ] jλ f · ∫ ∫ - ∞ ∞ U I ( x , y ) ⅇ - j 2 π λ f ( xf x + y f y ) ⅆ x ⅆ y , ( 3 )
where j is the imaginary unit, λ is a wavelength of light rays that captured by the image sensor 20 , ƒ(x,y) is a focal length function of each point (e.g., pixel) (x,y) of the image sensor 20 to bring the corresponding point (x,y) into focus.
In addition, the Fourier transforming device 42 is also used for transforming the spatial function of the electrode 32 H(x,y) into a corresponding frequency domain function: H ƒ (ƒ x ,ƒ y ).
According to complex optics, the function U ƒ (ƒ x ,ƒ y ) is the convolution of a function U S (x,y) and the function H(x,y), that is,
U I ( x,y )= U S ( x,y )· H ( x,y ), (4)
wherein the function U S (x,y) is a spatial domain amplitude function of a real (final) image of objects. As such, to obtain the real image of the objects, the function U ƒ (ƒ x ,ƒ y ) must go through deconvolution to obtain the function H ƒ (ƒ x ,ƒ y ). This is accomplished by the deconvolution device 44 . According to mathematics, it can be determined that:
U ƒ (ƒ x ,ƒ y )= F ( U S ( x,y ))· H ƒ (ƒ x ,ƒ y ), (5)
where F(U S (x,y)) is the Fourier transform of the function U S (x,y). As such, deconvoluting of the function U ƒ (ƒ x ,ƒ y ) can be expressed as:
F ( U S ( x,y ))={ F} −1 ( U ƒ (ƒ x ,ƒ y )) H ƒ (ƒ x ,ƒ y ). (6)
As such, the blur caused by the electrode 32 is digitally removed.
The inverse Fourier transforming device 46 is configured for inversely transforming the frequency domain function F(U S (x,y)) into the spatial domain amplitude function U S (x,y) to restore the real image of the objects.
According to the above, it can be determined that the resulting function U S (x,y) is a function of three variables: x, y, and ƒ(x,y). Therefore, for each point (x,y) of the real image, the unique in-focus focal length ƒ(x,y) can be determined. The refocusing device 50 is configured to determine the unique in-focus focal length for each point (x,y) of the real image to bring all points of the real image into focus. As such, an all-in-focus real image of the objects can be obtained.
By employing the LC element 30 , transmittance of the electrode 32 can be controlled by adjusting the voltage applied thereto. As such, the amount of light loss can be controlled and minimized. Typically, to reduce light loss, a transmittance of the electrode 32 is greater than about 50%.
It will be understood that the above particular embodiments and methods are shown and described by way of illustration only. The principles and the features of the present disclosure may be employed in various and numerous embodiment thereof without departing from the scope of the disclosure as claimed. The above-described embodiments illustrate the scope of the disclosure but do not restrict the scope of the disclosure. | An imaging sub-system, a liquid crystal (LC) element, and a digital focus processor are provided. The LC element is placed in the light path of the imaging sub-system, functioning as the aperture of the imaging sub-system, and includes a periodically patterned electrode which is patterned according to a periodical modulation function and configured to blur an intermediate image captured by the imaging sub-system by applying a controllable voltage thereto. The digital focus processor is configured to deconvolute the periodical modulation function to remove the blur away from the intermediate image and determine an all-in-focus real image. | Analyze the document's illustrations and descriptions to summarize the main idea's core structure and function. | [
"BACKGROUND 1.",
"Technical Field The present disclosure relates to imaging systems and, particularly, to a computational imaging system.",
"Description of Related Art Generally, an image of an object captured by conventional imaging systems is in focus only over a limited object distance range which is known as depth of field (DOF).",
"Therefore, it is difficult to sharply capture object scenes that span large distances.",
"To obtain an extended DOF, one attempt has been made that deliberately blurs an intermediate image captured by an imaging system by placing a coded aperture in the aperture of the imaging system and then digitally removes the blur using reconstruction algorithms.",
"The coded aperture is patterned according to a modulation transfer function (e.g., a delta function).",
"As such, reconstruction algorithms can effectively deconvolute the modulation transfer function and restores the image to a more recognizable likeness of the object with a greater DOF than what that would have been otherwise obtainable.",
"This is known as coded aperture imaging and is one kind of computational imaging system.",
"See Zand, J., “Coded Aperture Imaging in High Energy Astronomy”, NASA Laboratory for High Energy Astrophysics (LHEA) at NASA's GSFC (1996);",
"Levin, A., Fergus, R., Durand, F., Freeman, B., “Image and Depth from a Conventional Camera with a Coded Aperture”, ACM Transactions on Graphics (Proc.",
"SIGGRAPH) (2007);",
"Veeraraghavan, A., Raskar, R., Agrawal, A., Mohan, A., Tumblin, J., “Dappled Photography: Mask Enhanced Cameras for Heterodyned Light Fields and Coded Aperture Refocusing”, ACM Transactions on Graphics (Proc.",
"SIGGRAPH) (2007);",
"and Liang, C. K., Lin, T. H., Wong, B. Y., Liu, C., Chen, H. H., “Programmable Aperture Photography: Multiplexed Light Field Acquisition”, ACM Transactions on Graphics (Proc.",
"SIGGRAPH), Vol. 27, No. 3, Article No. 55 (2008).",
"However, to blur the intermediate image, the coded aperture (e.g., the pattern formed on the coded aperture) also blocks large amounts of light rays incident on the aperture, resulting in large amount of light loss.",
"Therefore, it is desirable to provide a computational imaging system, which can overcome the abovementioned shortcomings.",
"BRIEF DESCRIPTION OF THE DRAWINGS Many aspects of the present computational imaging system should be better understood with reference to the following drawings.",
"The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present computational imaging system.",
"Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.",
"FIG. 1 is a schematic view of a computational imaging system, according to a first exemplary embodiment.",
"FIG. 2 is a planar view of a liquid crystal (LC) element of the computational imaging system of FIG. 1 .",
"FIG. 3 is a planar view of the LC element, according to a second embodiment.",
"FIG. 4 is a planar view of the LC element, according to a third embodiment.",
"FIG. 5 is a planar view of the LC element, according to a fourth embodiment.",
"DETAILED DESCRIPTION Embodiments of the present computational imaging system will now be described in detail with reference to the drawings.",
"Referring to FIGS. 1 and 2 , a computational imaging system 100 , according to a first embodiment, includes a lens 10 , an image sensor 20 , an LC element 30 , and a digital focus processor 40 .",
"The lens 10 and the image sensor 20 constitute an imaging sub-system.",
"The LC element 30 functions as the aperture of the imaging sub-system constituted by the lens 10 and the image sensor 20 (placed in the light path of the imaging sub-system).",
"The LC element 30 is a transmissive LC panel that has a periodically patterned electrode 32 .",
"The electrode 32 is patterned according to a periodical modulation transfer function (i.e., a spatial function): H ( x,y )=cos 2π( s x x+s y y ), (1) where an origin of the oxy coordinate system is the center of the LC element 30 , the x axis extends along the widthwise direction of the LC element 30 , the y axis extends along the lengthwise direction of the LC element 30 , s x is a spatial frequency of the electrode 32 along the x axis, and s y is a spatial frequency of the electrode 32 along the y axis.",
"Assuming that: (i) the refractive index of the LC element 30 outside the electrode 32 is n 0 ;",
"and (ii) the refractive index of the LC element 30 at the electrode 32 is n=n 0 +Δn, where Δn is the refractive index variance caused by applying a voltage to the electrode 32 , the refractive index of the entire LC element 30 can be expressed as a refractive index function: n ( x,y )= n 0 +Δn ×cos 2π( s x x+s y y ).",
"(2) Also referring to FIG. 2 , in this embodiment, the electrode 32 is a set of concentric annuluses 322 with uniform distances between each two adjacent annuluses 322 .",
"However, the electrode 32 is not limited to this embodiment, but can conform to other configurations, for example, a rectangular spiral line 324 as shown in FIG. 3 , a circular dot array 326 , or a rectangular block array 328 as shown in FIG. 5 .",
"The digital Focus processor 40 includes a Fourier transforming device 42 , a deconvolution device 44 , an inverse Fourier transforming device 46 , and a refocusing device 48 .",
"The Fourier transforming device 42 is configured for transforming a space domain amplitude function U I (x,y) of an intermediate image captured by the image sensor 20 into a frequency domain function U ƒ (x,y), where ƒ x , ƒ y are x and y axes variables in the frequency domain, respectively.",
"According to Fourier optics, it can be determined that: U f ( f x , f y ) = ⅇ [ j 1 2 f ( f x 2 + f y 2 ) ] jλ f · ∫ ∫ - ∞ ∞ U I ( x , y ) ⅇ - j 2 π λ f ( xf x + y f y ) ⅆ x ⅆ y , ( 3 ) where j is the imaginary unit, λ is a wavelength of light rays that captured by the image sensor 20 , ƒ(x,y) is a focal length function of each point (e.g., pixel) (x,y) of the image sensor 20 to bring the corresponding point (x,y) into focus.",
"In addition, the Fourier transforming device 42 is also used for transforming the spatial function of the electrode 32 H(x,y) into a corresponding frequency domain function: H ƒ (ƒ x ,ƒ y ).",
"According to complex optics, the function U ƒ (ƒ x ,ƒ y ) is the convolution of a function U S (x,y) and the function H(x,y), that is, U I ( x,y )= U S ( x,y )· H ( x,y ), (4) wherein the function U S (x,y) is a spatial domain amplitude function of a real (final) image of objects.",
"As such, to obtain the real image of the objects, the function U ƒ (ƒ x ,ƒ y ) must go through deconvolution to obtain the function H ƒ (ƒ x ,ƒ y ).",
"This is accomplished by the deconvolution device 44 .",
"According to mathematics, it can be determined that: U ƒ (ƒ x ,ƒ y )= F ( U S ( x,y ))· H ƒ (ƒ x ,ƒ y ), (5) where F(U S (x,y)) is the Fourier transform of the function U S (x,y).",
"As such, deconvoluting of the function U ƒ (ƒ x ,ƒ y ) can be expressed as: F ( U S ( x,y ))={ F} −1 ( U ƒ (ƒ x ,ƒ y )) H ƒ (ƒ x ,ƒ y ).",
"(6) As such, the blur caused by the electrode 32 is digitally removed.",
"The inverse Fourier transforming device 46 is configured for inversely transforming the frequency domain function F(U S (x,y)) into the spatial domain amplitude function U S (x,y) to restore the real image of the objects.",
"According to the above, it can be determined that the resulting function U S (x,y) is a function of three variables: x, y, and ƒ(x,y).",
"Therefore, for each point (x,y) of the real image, the unique in-focus focal length ƒ(x,y) can be determined.",
"The refocusing device 50 is configured to determine the unique in-focus focal length for each point (x,y) of the real image to bring all points of the real image into focus.",
"As such, an all-in-focus real image of the objects can be obtained.",
"By employing the LC element 30 , transmittance of the electrode 32 can be controlled by adjusting the voltage applied thereto.",
"As such, the amount of light loss can be controlled and minimized.",
"Typically, to reduce light loss, a transmittance of the electrode 32 is greater than about 50%.",
"It will be understood that the above particular embodiments and methods are shown and described by way of illustration only.",
"The principles and the features of the present disclosure may be employed in various and numerous embodiment thereof without departing from the scope of the disclosure as claimed.",
"The above-described embodiments illustrate the scope of the disclosure but do not restrict the scope of the disclosure."
] |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to the filing dates of U.S. application Ser. No. 11/905,903 filed Oct. 5, 2007, U.S. Provisional Application No. 60/866,391 filed Nov. 17, 2006, and U.S. Provisional Application No. 60/916,750 filed May 8, 2007, the contents of each of which are incorporated herein by reference.
TECHNICAL FIELD
The technology herein relates to electrical connectors for video game systems, and more specifically to electromechanical connecting arrangements for connecting with video game input, peripheral and/or other devices. Still more particularly, the technology herein relates to methods, apparatus and techniques for providing reliable electrical and mechanical connectivity between 3D video game system components while preventing or discouraging incompatible and/or unauthorized device connections. The technology herein also relates to a secure lockable connector arrangement for video game system peripheral or other devices.
BACKGROUND AND SUMMARY
Video game system designers spend enormous amounts of time, effort, energy, money and other resources designing new video game systems for the consumer electronics market. A vast amount of human factor and other engineering typically goes into video game designs to make them successful and popular with consumers. For example, a video game input device such as a remote controller, handheld controller, joystick or the like should be capable of providing fine and other flexible user control inputs while at the same time being able to withstand various forms of physical abuse from small children. There are significant challenges to designing, developing and manufacturing video game consumer electronics hardware that is easy to use, very capable, highly reliable, rugged, flexible, compact, relatively low cost and a pleasure to operate.
A video game system designer may become disappointed if a competitor attempts to “knock off”, copy or otherwise attempt to develop unlicensed or unauthorized substitute input devices. Video game input devices that are cheaply made without the requisite human factor engineering tend to disappoint consumers. Furthermore, it is important for reliability, safety, avoiding damage and other reasons that only those devices intended to be connected are in fact able to be connected. It is undesirable to allow an unauthorized or unlicensed video game accessory manufacturer to get a “free ride” by selling certain types of products designed to interoperate with the video game system without first obtaining permission from or otherwise working out an agreement with the video game system manufacturer.
Some in the past have used complex electronic authentication or other elements to ensure that accessory hardware and software manufacturers obtain proper licenses and permissions. For example, many video game system software, disks and cartridges are protected by security systems that allow the system to determine whether software is authentic. The system can refuse to run software that is not authentic. While it may be possible and desirable to include electronic encryption and authentication on hardware accessory signal pathways, more fundamental approaches can also be effective.
The technology herein relates to a new and improved electromechanical connector arrangement for use in a video game system and/or other application. Exemplary illustrative non-limiting features include:
Unique shape, design and dimensions that discourage or prevent connection of non-compatible devices Male connector insertion portion defines receiving socket containing electrical contacts, and female connector socket has protrusion having electrical contact strips disposed thereon for pressure insertion into and engagement with the male connector receiving socket Connector configurations that ensure connection in a proper orientation to provide electrical compatibility and eliminate the possibility of short-circuits Quick release locking arrangement that firmly mechanically holds mating connectors together despite extensive movement of the game player's arms and hands Staged electrical contacting sequence provides proper sequence for applying signals Wrist strap tethering handheld remote controller to hand is attached to a locking connector that securely mates with a connector of the remote controller High reliability and long life Very rugged design in a compact low cost package Easy to manipulate and operate to insert and release Positive coupling with tactile feel so users know when connection is successful Positive interlock securely fastens and holds connectors together despite active motion by users holding onto handheld controllers the connector is used to couple together Good strain resistance preventing cable from being forceably pulled out of connector Combination insertion/receiving interlocking portions on both male and female connectors provide mechanical strength when connectors are mated Other advantageous non-limiting features
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages will be better and more completely understood by referring to the following detailed description of exemplary non-limiting illustrative implementations in conjunction with the drawings of which:
FIG. 1 is an elevated front right perspective view of an exemplary illustrative non-limiting male connector plug as seen from near the connector's insertion end;
FIG. 2 is an elevated rear left perspective view of the FIG. 1 male connector plug inverted and as seen from behind the connector's cable receiving portion;
FIGS. 2A & 2B show the FIG. 1 male connector plug being squeezed between a finger and thumb to partially retract locking nibs used to lock the connector in a mating position;
FIG. 2C shows fully retracted locking nibs;
FIG. 2D shows exemplary illustrative non-limiting retractable locking nibs in more detail;
FIG. 2D-1 shows an exemplary illustrative non-limiting implementation of how retractable nibs of the FIG. 1 male connector can engage with exemplary female mating connector nib retaining slots;
FIGS. 2E-2P show an exemplary illustrative non-limiting plug and socket connector mating sequence (and, if viewed in reverse, an unmating/release sequence) from different perspectives;
FIG. 3 shows a top view in plan of the FIG. 1 exemplary illustrative non-limiting male connector showing exemplary illustrative non-limiting dimensions in millimeters for an exemplary illustrative plug cable assembly;
FIG. 4 shows a side elevation of the FIG. 3 exemplary male connector and cable assembly including dimensions in millimeters;
FIG. 5 shows further exemplary illustrative non-limiting cable assembly dimensions in millimeters;
FIG. 6 shows a plan view of an exemplary illustrative non-limiting male plug six pin electrical contact arrangement;
FIGS. 6A and 6B show perspective views of an exemplary illustrative non-limiting female connector socket contact arrangement;
FIG. 7A is an exemplary illustrative non-limiting cross-section view of an exemplary illustrative non-limiting corresponding female plug connector showing exemplary electrical pin assignments;
FIG. 7B is an exemplary illustrative non-limiting electrical circuit connection diagram;
FIG. 8 is a cross-sectional more detailed view of an exemplary illustrative non-limiting locking mechanism showing the retractable locking nibs operated by finger-depressible actuators;
FIG. 8A shows in detail an exemplary illustrative non-limiting internal locking mechanism structure portion of the FIG. 1 connector;
FIGS. 9 and 10 show exemplary electrical contacting arrangements including dimensions in millimeters;
FIG. 11 shows a top exemplary illustrative non-limiting female connector metallic or other conductive socket shield;
FIG. 12 is a side elevated view in plan of an exemplary illustrative non-limiting female connector in a flipped configuration as compared to FIG. 7A ;
FIG. 13 is a side elevated plan view of the FIG. 11 exemplary illustrative non-limiting socket shield;
FIG. 14 shows the exemplary illustrative non-limiting socket shield in cross-section;
FIG. 15 shows exemplary illustrative non-limiting socket shield dimensions in millimeters;
FIG. 16 show exemplary illustrative non-limiting socket shield printed circuit board contact dimensions in millimeters;
FIGS. 17A-17L show exemplary illustrative compatible or partially compatible non-limiting connector socket shapes; and
FIGS. 18A-18P show exemplary illustrative non-limiting compatible plug shapes.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of an exemplary illustrative non-limiting electrical connector plug 50 . Electrical connector plug 50 can be used, for example, to electrically connect a video game accessory including but not limited to a “nunchuk”, “classic controller” or other device to another video game unit such as for example a handheld remote control. These are exemplary illustrative non-limiting examples—connector 50 can be used to connect any device to any other device.
Exemplary illustrative non-limiting electrical connector plug 50 includes an insertion portion 52 and a manually grippable portion 54 . Insertion portion 52 in one exemplary illustrative non-limiting implementation forms a male portion of a connector that mates with a female connector receptacle or socket 100 (See FIG. 2E and following). Grippable portion 54 is intended to be gripped by human digits (fingers and thumb of the human hand) to allow a user to easily manually, and in a locking manner, insert the connector plug 50 into and to remove (unlock) the connector plug 50 from a corresponding mating female connector socket 100 .
In the exemplary illustrative non-limiting implementation shown, grippable portion 54 includes a generally box-like housing 56 including grippable side walls 58 a, 58 b. Housing 56 can be of two-piece construction with a top (upper) case portion 60 joining with a bottom (lower) case portion 62 . Upper and lower or top and bottom housing case portions 60 , 62 can be for example made of molded hard plastic, white “66Nylon” material or any other suitable durable material.
The upper and lower housing case portions 60 , 62 when coupled together (e.g., using retaining screws, adhesive, or any other convenient fastening system) encapsulate and protect internal portions of the connector assembly to make the connector plug 50 rugged and allow it to stand up to abuse from children and others. In other exemplary illustrative non-limiting implementations, housing 56 as shown could be eliminated and some other arrangement used (or omitted as desired) for electrically connecting the connectors of a cable (not shown) to the insertion portion 52 .
In the exemplary illustrative non-limiting implementation, the connector plug housing 56 is of a convenient size for grasping or gripping between a thumb and other digit (e.g., forefinger, middle finger, etc.). See FIG. 2A for example. Dimensions can be for example 17 mm wide by 23.5 mm long by 9.7 mm high in one exemplary illustrative non-limiting implementation. See for example FIGS. 3 and 4 . Such a size is convenient to be grasped by adults and small children. Other dimensions are possible.
In one exemplary illustrative non-limiting implementation, the male connector plug 50 has a wrist strap hook 59 mounted on its housing 56 . Wrist strap hook 59 can comprise for example a separate layer of clear strong durable plastic or other similar material providing a ridge 59 a and a hook structure 59 b. The purpose of ridge 59 a and hook structure 59 b in one exemplary illustrative non-limiting implementation is to retain a nylon or other durable fabric or other wrist strap (e.g., loop) so the device into which the male connector plug 50 (e.g., a handheld remote controller) can be anchored to the user's hand or wrist.
Since illustrative non-limiting implementations shown herein have a rugged, strong locking mechanism that locks the male connector plug 50 to a mating female connector socket 100 (and thus for example to a handheld device which provides the mating female connector socket), it is sufficient in the exemplary illustrative non-limiting implementation to anchor the wrist strap to the connector 50 which mates with the handheld device (direct connection of the wrist strap to the handheld device itself is thus not necessary in one exemplary illustrative non-limiting implementation). In other implementations, a wrist strap could be anchored directly to the handheld device as opposed to the connector, or it could be omitted. In some exemplary illustrative non-limiting implementations, a sensor of some sort (e.g., optical) is provided to detect whether the wrist strap is being used and in some cases to prevent games or other applications from operating unless the wrist strap is physically in place. The wrist strap could be replaced with a lanyard or any other desired arrangement.
Exemplary Illustrative Non-Limiting Secure Locking Mechanism
An exemplary illustrative non-limiting implementation includes a secure locking mechanism including control arms 64 , locking nibs or tangs 66 , and slots or other openings defined within a mating connector in registry with the locking nibs or tangs (see FIG. 2E ). In one exemplary illustrative non-limiting implementation, the thumb for example can be placed into contact with sidewall 58 a and a finger can be placed into contact with sidewall 58 b. When the user grasps connector plug 50 in the way shown in FIG. 2A and exerts pressure against the sidewalls 58 a, 58 b, the user may inwardly depress control arms 64 a, 64 b. Arms 64 a, 64 b provide a control feature for the locking mechanism. In more detail, in one exemplary illustrative non-limiting implementation, nibs 66 are normally biased to project outwardly through openings 68 . In the exemplary illustrative non-limiting implementation, locking nibs 66 have ramped, angled or inclined leading edges 70 and flat (non-angled) following edges 72 . As shown in FIG. 2C (and see also FIG. 8A internal view), these retractable nibs 66 may be integrally formed (e.g., by conventional metal cutting and bending manufacturing processes) on metal members 65 a, 65 b that integrally extend alongside the control arms 64 a, 64 b. Two such retractable nibs 66 are formed on each metal member in the exemplary illustrative non-limiting implementation, although other exemplary embodiments could have one nib, more than two nibs, some locking structure other than a nib, or no locking structure at all.
In the exemplary illustrative non-limiting implementation, control arms 64 and associated retractable nibs 66 are mechanically biased (see FIGS. 1 and 2 ) such that, at rest, the locking nibs 66 are fully extended. In the exemplary illustrative non-limiting implementation, nibs 66 can be forced to retract in two ways: (a) by the user depressing control arms 64 (for unlocking action), and (b) when the connector plug insertion portion 52 is inserted into a snugly fitting receptacle (leading up to locking action) which applies retracting pressure directly onto the nibs in a direction that is substantially perpendicular to the direction in which the associated control arm extends. In the exemplary illustrative non-limiting implementation, inserting the connector plug insertion portion 52 into a female receptacle thus causes a locking action, and user depression of control arms 64 causes an unlocking action. As FIG. 8A shows, the metal members 65 a, 65 b are part of a U-shaped structure 65 that is formed with a stiffening cross base 65 c that holds the members 65 a and 65 b in an outwardly biased position, but which allows the members (and hence the nibs 66 ) to flex inwardly when pressure is applied to the control arms 64 a, 64 b. The metallic structure 65 can serve double duty as a cable retaining structure.
In more detail, when the user grasps the connector plug housing 54 between the thumb and a finger and applies pressure to the control arms 64 and at this stage may or may not cause retractable nibs 66 to retract (see FIGS. 2A-2D ). The user may insert the plug insertion portion 52 into a corresponding conformal or other snugly fitting female connector socket 100 (see FIGS. 2E-2K ) and apply pressure onto the connector to force the connector insertion end further into the female connector socket. A point is reached (see FIG. 2L ) at which the retractable locking nibs 66 contact the outer edges of the connector socket 100 and the retractable nib biasing forces offer some resistance to further insertion. If the user continues to increase or otherwise provide applied insertion force, the socket wall will apply a side directed component of that axially directed insertion force to the retractable nibs 66 to cause the nibs to retract sufficiently to clear the socket opening (see FIG. 2M and following). Such retraction of nibs 66 can occur whether or not the user is applying pressure to the control arms 64 .
Insertion is smoother and easier if the user is applying pressure to the control arms 64 , but the force that the insertion wall of the female connector socket applies to the retractable nibs 66 will cause the nibs to retract irrespective of whether the user is applying force to control arms 64 . Even though they are partially retracted, the nibs 66 are outwardly biased in the exemplary illustrative non-limiting implementation such that they remain in close biased contact with the female socket inner wall and exert a frictional force thereon. However, in the exemplary illustrative non-limiting implementation, the contact is between smooth metal surfaces so the frictional insertion force is relatively small, so as not to substantially impede insertion progress. Meanwhile, proper registration between the plug 50 and the socket is ensured by channel 320 conformally in registry with an engaging ridge 1320 disposed on an insertion wall of the female socket.
Thus, in the exemplary illustrative non-limiting implementation shown, retractable nibs 66 serve to automatically retract as the connector insertion portion 52 is inserted into a corresponding snugly-fitting female receptacle. If corresponding locking grooves, openings or other structures in registry with locking nibs 66 are provided, the locking nibs may then automatically protrude into the corresponding structures in registration therewith, such that the trailing edges 72 abut corresponding edges of grooves, holes or the like and thereby substantially prevent the connector insertion portion 52 from being removed from a corresponding female receptacle unless either the control arms 64 are depressed to retract the nibs or a substantial amount of pressure is applied.
FIG. 2D-1 shows one such exemplary illustrative non-limiting female connector socket engaging structure including a metal housing 201 defining a pair of rectangular openings or slots 202 (only one is shown), each rectangular opening being dimensioned to accept a pair of nibs 66 , the openings being positioned so that the nibs engage with the opening when male connector plug 50 is substantially fully inserted into and thus fully mated with female connector socket 100 .
More specifically, as the user continues to supply insertion force ( FIG. 2N , FIG. 2O ), the retractable nibs 66 eventually engage with corresponding slots 202 defined in the female connector socket wall. In the exemplary illustrative non-limiting implementation, such slots are located and disposed in registry with the nib 66 positions when the male connector plug 50 is fully mated with the female connector socket 100 . Upon such mating connection, the locking nibs 66 snap outwardly with a positive “click” sound and generate a corresponding tactile snap, thereby letting the user know that the male connector plug 50 has fully mated with the female connector socket 100 ( FIG. 2P ). At this fully mated point, the body of connector 50 may be in direct contact with an outer surface 67 defined by a device housing the female socket 100 . The nib flat engaging surfaces 72 at this point engage, much as a ratchet engages with a pawl, with edges of the corresponding female socket wall slots 202 to firmly and strongly lock the connector plug into the mating connector socket 100 . When locked, the connector plug 66 can move in and out by a very small distance in the exemplary illustrative non-limiting implementation, but is in fact firmly locked in place so that attempting to pull the connector plug out by force will be unsuccessful unless a very large amount of force is applied.
The locking mechanism (the retractable nib portion of which is shown in more detail in FIG. 8 A—including the U-shaped structure 65 ) thus provides added degrees of safety and security since the accessory or other device that connector plug 50 connects to will generally not easily unintentionally separate from the corresponding female connector socket 100 . This can provide significant benefits for example when a user is holding a video game remote controller with one hand, the remote controller providing a female connector socket 100 into which a wired connector plug 50 is inserted. As the user independently swings his or her left and right arms to operate the two different devices, for example, the exemplary illustrative locking mechanism shown including retractable nibs 66 and corresponding in-registration slots, grooves or other openings or similar structures maintains a firmly-locked electrical and mechanical connection. This prevents electrical connector 50 from unexpectedly and unintentionally flying out of the corresponding female connector socket 100 during such arm movements, thereby potentially avoiding injuries, inconvenience, and other potential occurrences caused by unintended disconnection.
In one exemplary illustrative non-limiting implementation, the locking mechanism is designed so it will fail and release the connector plug 50 from the connector socket 100 when a very substantial removal force is applied. Such a removal force can for example be somewhat or substantially less than the amount of force required to pull a cable out of the connector plug so that the locking mechanism will forceably release just before the cable strain release fails. Thus, the exemplary illustrative non-limiting locking mechanism is sufficiently stiff so that the connector will not come out accidentally, but is not so stiff that the cord will break first (locking mechanism strength is less than the tensile strength of the cable connected to the male connector 50 assuming a cable based connection is used).
In normal use, the user can easily withdraw the connector plug 50 from the connector socket 100 at any time by applying pressure onto control arms 64 and thereby cause the control arms to retract inwardly into the connector plug housing. As the user applies force to the control arms 64 and exceeds the biasing force that maintains the control arms in their outwardly protruding resting positions, the retractable nibs begin to retract into housing 54 (see FIG. 2C ) and thus disengage from the female connector socket wall slots 202 or other engaging voids. As the user continues to apply more force, the control arms 64 continue to travel inwardly into the grippable portion 54 housing 56 interior. This causes locking nibs 66 to further retract into insertion portion 52 , thereby in one exemplary illustrative non-limiting implementation freeing the connector insertion portion 52 from a mating receptacle engaging slot or other engaging structure(s). Once the locking nibs 66 are sufficiently retracted to disengage from corresponding slots, the user can then pull the male connector plug 50 outwardly away from the female connector socket 100 to slide out and thereby withdraw the plug from the socket 100 .
As can be seen in FIG. 2A , the exemplary illustrative non-limiting implementation of male connector plug insertion portion 52 has one or more longitudinally defined raised portions or ribs 69 that are intended to maintain frictional contact with the female connector socket inner wall while limiting or reducing the total contact surface area between the withdrawing male connector plug insertion portion 52 and the female connector socket interior walls. Furthermore, during the operation of withdrawing the connector plug 50 from the female socket 100 , the user can continue to maintain strong pressure on the control arms 64 with the same finger and thumb that is being used to apply withdrawal force in a direction away from the female connector socket 100 , thereby maintaining the retractable nibs 66 in substantially or completely retracted positions so the nibs do not substantially add to the amount of force needed to withdraw the connector plug 50 from the connector socket 100 . Such a withdrawal operation is therefore simple, does not require much dexterity or applied force, and therefore can be performed even by a small child without difficulty.
In still other exemplary illustrative non-limiting implementations, the retractable nibs 66 could be formed in other ways and or omitted entirely. Although the exemplary illustrative non-limiting implementation shown includes a locking mechanism including retractable nibs 66 , other arrangements could be used instead. For example, in some applications, a friction fit alone might be sufficient, or the force of gravity in combination with a friction fit could be used to keep the connector insertion portion 52 mated with a corresponding female connector receptacle.
Exemplary Male and Female Multilevel Interlocking Configurations
FIG. 6 shows a forward-looking plan view looking down onto (and into) the male connector 50 . One can see the insertion portion 52 which terminates in a planar surface 300 composed of plastic or other material. The exemplary illustrative male connector 50 defines, in this planar surface 300 , a recess 302 in which the above-mentioned electrical contact strips are disposed. This recess 302 is dimensioned to receive a protrusion which is disposed within the female connector (socket). Thus, the male connector 50 in the exemplary illustration has a portion with a female receptacle for receiving a male protrusion portion of the female socket 100 . Providing a male plug 50 with a female socket portion 302 and providing the female socket 100 with a male protrusion portion enhances ruggedness, reliability and mechanical strength through the application of multiple interlocking elements that surround one another. In the exemplary illustrative non-limiting implementation, the female socket male protrusion portion is received and surrounded by the male plug recess 302 , which in turn is surrounded by the larger male projection 52 that is received within the female socket recess.
The cross-sections of the different interlocking portions can be other than those shown in the Figures discussed above. For example, FIGS. 17 a - 18 p illustrate various connector/plug configurations that include fully or partially compatible mechanical configurations in combination with compatible electrical configurations for the male projection 52 and female connector socket 100 , each or any of which may be used to establish the desired electrical connection. However, as mentioned above, entirely different locking mechanisms could be substituted, such locking mechanisms including for example:
a lever-operated locking mechanism of the type often seen holding zero insertion force connector pins a retractable spring or other biased plunger, ball or the like a pure friction fit such as commonly used by USB connectors a threaded ring or other structure that screws onto a corresponding threaded shaft or other structure threaded shafts with knurled knobs that mate and interlock with corresponding threaded screw holes, of the type for example used for personal computer parallel and serial cables side protrusions of the type used commonly for USB male and female connectors any other suitable locking, retaining or friction fully engaging structural mechanism in suitable applications, a combination of friction and the force of gravity (e.g., docking ports or the like) while connector 50 is not in physical motion and has a generally downwards orientation any other suitable arrangement (for example, a locking mechanism that engages the slots on the bottom of a FIG. 6A remote controller rather than engaging the connector itself). other
Exemplary Electrical Connection
Referring again to FIG. 1 , the exemplary illustrative non-limiting implementation of male connection plug 50 includes a keyed or slotted insertion portion 52 having a substantially planar distal surface 300 . Substantially planar distal surface 300 may define a rectangular opening 302 therein. Rectangular opening 302 may have channels 304 a, b, c, e, f and g (sometimes referred to generally as “channels 304 ”) defined therein. A portion 305 of each channel located at the front of the opening 302 is closed off with respect to the opening 302 . Electrical contact strips (e.g., copper or other conductive strips) 306 may be disposed within the channels 304 . These copper or other conductive contact strips 306 are dimensioned and disposed to make good electrical contact with corresponding electrical contacts 308 of mating female connector socket 100 . See FIG. 12 , which shows an exemplary illustrative non-limiting female connector socket 100 including a metal outer housing 402 defining an opening 404 that is dimensioned and shaped to conformally match and accept, with close frictional engagement, the male connection plug insertion portion 52 . Thus, for example, the cross-section of the male connection insertion portion 52 is the “positive” of a shape that is dimensioned to conformally match the shape and size of a “negative” or void defined within the space of opening 404 defined by the female mating connector socket metal housing 402 . Of course, metal is just one example, any type of material could be used. Metal may have some advantages in terms of durability, ruggedness, scratch and breakage-resistance and ability to provide RF and noise shielding, but other materials could be used instead or in addition.
Referring again to FIG. 12 , a channeled projection 406 is defined within the space or void 404 within the female connector socket 100 . The channeled projection 406 has channels 408 a, b, c, d, e and f (sometimes referred to generally as “channels 408 ”) defined therein, the channels each having a copper or other electrically conductive strip 308 therein. The female connector channeled projection 406 is shaped and dimensioned to be inserted within the channeled rectangular opening 302 within the male connector plug insertion portion distal surface 300 . When the male plug 50 mates with the female socket 100 , the male plug insertion portion 52 is inserted within the female socket space 404 as described above, and the female socket channeled projection 406 is in turn inserted into the male plug rectangular opening 302 . As the female socket channeled projection 406 is inserted into the male plug rectangular opening 302 , the copper or other conductive strips 306 of the male plug 50 engage in close electrically conductive sliding contact with corresponding copper or other conductive strips 308 of the female socket 100 . Such sliding contact establishes corresponding electrical connections for each of the six pairs of conductors shown. Different numbers of conductors could be used if desired. In some cases, unneeded ones of the conductive strips for particular applications can be omitted or made to be “no connection.” As many connective strips as desired may be provided. In the example shown, a total of six connective strips are provided for six independent electrical connections. In some configurations, not all connections are used (for example, there may be no need in some applications to connect to a “battery” connection). In such cases, the female socket 100 could be provided with one more (unused) electrical contact than certain configurations of male plug 50 , whereas other configurations of male plug 50 could have the same number of electrical contacts as the female socket 100 , or vice versa. Other applications can of course have other configurations.
FIGS. 6A and 6B show details of exemplary illustrative non-limiting copper or other conductive strips 308 as described above (strips 306 are similar). See also cross-sectional FIG. 8 . As shown for example in FIG. 6B , each strip 308 comprises a thin strip of copper or other conductive metal or similar having a bulging portion 309 formed longitudinally therein. Such bulging or protruding portions can provide good sliding frictional electrical contact while minimizing the amount of force necessary to establish insertion. Furthermore, FIG. 6B shows that not all of the strips 308 in the female connector socket 100 are the same length. In one exemplary illustrative non-limiting implementation, certain of the strips 308 are shorter than others so that the longer strips make contact with counterpart strips 306 (which in one exemplary illustrative non-limiting implementation are all the same size) before the shorter ones make contact. For example, in one exemplary illustrative non-limiting implementation, it may be desirable to connect power and ground before making contact between data signal lines. This exemplary illustrated non-limiting connector conductive strip configurations shown provide such staged connections.
FIGS. 7A and 7B show electrical wiring diagrams for the paired connection, and FIG. 8 shows a cross-section of an exemplary electrical connecting strip structure within male connector 50 . The electrical connecting strips in the exemplary illustrative non-limiting implementation are made of a highly ductile, relatively stiff conductive material such as copper, aluminum or other metal. As perhaps best seen in FIG. 8 , when pressure is applied to the copper strips due to engagement with additional copper strips within the female socket (see FIG. 6A ), the copper strips in the male connector 50 flex outwardly. Forward ends of the copper strips rest against the closed off portions 305 of the channels formed on the sidewalls of the opening. An angled portion 307 projecting inwardly of the male connector copper strips protruding through a slotted opening in the male connector inner contact supporting structure 310 moves outwardly upon conformal engagement with a corresponding female connector structure. However, the springiness of the copper strips ensures that an inward mechanical bias continues to be applied, resulting in a pressure contact between the male and female connector mating contact strips. Such pressure contact provides effective and reliable highly-conductive electrical conductivity even when the copper strips are worn or oxidized after long use.
One exemplary illustrative non-limiting pin assignment configuration may be as follows for a six-pin male connector:
Pin 1: Vcc (3 volts)
Pin 2: SCL (serial clock line)
Pin 3: “Attach” (connected to Vcc on the male plug 50 side, sensed on the female socket 100 side to determine whether a plug is connected or not)
Pin 4: V-Batt (can be used for supplying external power through the connectors if desired; this connection is optional in many games)
Pin 5: SDA (serial data line)
Pin 6: Ground
In one implementation shown in FIG. 6B , Vcc and Ground (1 and 6) are in an exemplary illustrative non-limiting implementation made longer than the rest of the lines. This means that power and ground will be connected first, before the other signal lines. Furthermore, in the illustrative implementation, ground shield is connected first when the male and female connectors first come into contact (see for example FIG. 2I to 2 ). One exemplary illustrative non-limiting connection sequence is thus:
(1) shielding plates make contact
(2) pins 1 and 6 (Vcc and ground) make contact simultaneously
(3) pins 2-5 (all the rest) make contact.
Other variations are of course possible, e.g., pins 2-5 make contact first and then power and ground make contact.
Such earlier or staged connection helps to eliminate power surges etc.
FIGS. 3-5 show an exemplary illustrative non-limiting cable assembly including a multi-conductor cable with a male connector 50 at one end and an associated strain reliever 1500 at an opposite end. The dimensions shown in these drawings (in millimeters) are exemplary (different dimensions could be used if desired).
Keyed Configuration
FIG. 6B shows that the exemplary illustrative non-limiting implementation of the female connector 100 channeled projection 406 is symmetrical such that if taken by itself, it could be turned upside down and still connect equally well with the male connector plug rectangular opening conductors 306 . However, FIG. 7A reveals that if the exemplary illustrative non-limiting implementation female connector channeled projection 406 were flipped in its connection orientation, then Vcc and Ground would be reversed, the clock line and the data line would be reversed, and the Attach and V-Batt lines would be reversed. This would not provide a compatible or even working connection in the exemplary illustrative non-limiting implementation. To avoid such inadvertent connection reversals, the outer profile of the male and female connector portions are keyed so they can made in only one orientation. See the longitudinal key slot, trough or channel 320 in the male connector plug 50 of FIG. 2 and the corresponding mating and engaging longitudinal plateau 450 shown in the illustrative exemplary non-limiting female connector socket 100 shown in FIG. 12 . Note also the curved corners in each connector.
While such conformal keying wherein plateau 450 slides into trough 320 provides good compatibility, it should be understood that other cross-sectional shapes and profiles could similarly provide partial compatibility and orientation control without being entirely conformal. In particular, although the exemplary illustrative non-limiting implementations shown in FIGS. 1 and 12 provide substantially 100% complete conformality between the corresponding mating shapes, less than 100% conformality in shape and/or dimension might be attempted instead to nevertheless providing proper mating orientation, retention, etc.
Different Cross-Sectional Configurations
FIGS. 17A-17L provide non-exhaustive examples of female socket insertion cavity cross-sectional shapes that may accept a FIG. 1 male connector plug 50 . FIGS. 18A-18P provide non-exhaustive examples of male connector plug cross-sectional shapes that may be accepted by the FIG. 12 female connector socket 100 . There are a very large number of potential variations and possibilities, so the examples shown in these drawings are only representative.
One can assume that an unauthorized or unlicensed hardware manufacturer would try to make his or her connector as different as possible from an authentic connector while still achieving electrical and mechanical compatibility. Elements of electrical and mechanical compatibility include for example proper electrical connection of most of the six electrical connections in the exemplary implementation (at least data and clock line connections would presumably be wanted to provide electrical compatibility, although the pluggable device might be able to provide its own power it would presumably also tie to the common ground connection or to shield but perhaps not to both); and prevention or correction in some way, shape or form from reversed orientation such that those lines are not reversed (although in some circumstances one could envision simply telling the user to try it one way or the other until it works since there are only two possibilities, so long as pin assignment is made carefully to avoid short-circuits).
Elements of mechanical compatibility depend to some extent on the particular application. Rugged, locking, conformal compatibility is probably useful for many applications. However, in applications where not much movement is involved, then perhaps the locking mechanism could be dispensed with or not used, and less conformality might be used. Less conformal might weaken ruggedness, but other precautions (e.g., additional means of attachment or stabilization) might be used to compensate. In some applications such as stationary docking port applications involving very little motion, the aspects of mechanical conformality used for compatibility might be reduced. By setting for these illustrative non-limiting shapes and examples, applicants intend to capture any and all ways to compatibly connect to either the FIG. 1 (male) connector or to the FIG. 12 (female) connector.
All dimensions herein and in the drawings are in millimeters. Tolerances are plus or minus 0.3 mm.
While the technology herein has been described in connection with exemplary illustrative non-limiting implementations, the invention is not to be limited by the disclosure. For example, other connection means including sleeves, clip down, tie downs, plunger based retaining mechanisms, discrete fingers, capacitive or inductive proximity sensors, optical couplers and other variations could be used instead of what is described above. Although the exemplary illustrative non-limiting implementation connects video game systems, other arrangements are also possible. The invention is intended to be defined by the claims and to cover all corresponding and equivalent arrangements whether or not specifically disclosed herein. | Compatible mechanical and/or electrical connections to video game system accessories provide unique shape, design and dimensions that discourage or prevent non-compatible devices from being connected, connector configurations that allow connection only in a proper orientation to ensure electrical compatibility and eliminate the possibility of short-circuits, quick release locking arrangement firmly mechanically holds mating connectors together despite extensive movement of the game player's arms and hands, staged electrical contacting sequence provides proper signal application sequence, and wrist strap to tether handheld remote controller to hand is attached to a locking connector that mates with a connector of the remote controller. | Briefly describe the main idea outlined in the provided context. | [
"CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to the filing dates of U.S. application Ser.",
"No. 11/905,903 filed Oct. 5, 2007, U.S. Provisional Application No. 60/866,391 filed Nov. 17, 2006, and U.S. Provisional Application No. 60/916,750 filed May 8, 2007, the contents of each of which are incorporated herein by reference.",
"TECHNICAL FIELD The technology herein relates to electrical connectors for video game systems, and more specifically to electromechanical connecting arrangements for connecting with video game input, peripheral and/or other devices.",
"Still more particularly, the technology herein relates to methods, apparatus and techniques for providing reliable electrical and mechanical connectivity between 3D video game system components while preventing or discouraging incompatible and/or unauthorized device connections.",
"The technology herein also relates to a secure lockable connector arrangement for video game system peripheral or other devices.",
"BACKGROUND AND SUMMARY Video game system designers spend enormous amounts of time, effort, energy, money and other resources designing new video game systems for the consumer electronics market.",
"A vast amount of human factor and other engineering typically goes into video game designs to make them successful and popular with consumers.",
"For example, a video game input device such as a remote controller, handheld controller, joystick or the like should be capable of providing fine and other flexible user control inputs while at the same time being able to withstand various forms of physical abuse from small children.",
"There are significant challenges to designing, developing and manufacturing video game consumer electronics hardware that is easy to use, very capable, highly reliable, rugged, flexible, compact, relatively low cost and a pleasure to operate.",
"A video game system designer may become disappointed if a competitor attempts to “knock off”, copy or otherwise attempt to develop unlicensed or unauthorized substitute input devices.",
"Video game input devices that are cheaply made without the requisite human factor engineering tend to disappoint consumers.",
"Furthermore, it is important for reliability, safety, avoiding damage and other reasons that only those devices intended to be connected are in fact able to be connected.",
"It is undesirable to allow an unauthorized or unlicensed video game accessory manufacturer to get a “free ride”",
"by selling certain types of products designed to interoperate with the video game system without first obtaining permission from or otherwise working out an agreement with the video game system manufacturer.",
"Some in the past have used complex electronic authentication or other elements to ensure that accessory hardware and software manufacturers obtain proper licenses and permissions.",
"For example, many video game system software, disks and cartridges are protected by security systems that allow the system to determine whether software is authentic.",
"The system can refuse to run software that is not authentic.",
"While it may be possible and desirable to include electronic encryption and authentication on hardware accessory signal pathways, more fundamental approaches can also be effective.",
"The technology herein relates to a new and improved electromechanical connector arrangement for use in a video game system and/or other application.",
"Exemplary illustrative non-limiting features include: Unique shape, design and dimensions that discourage or prevent connection of non-compatible devices Male connector insertion portion defines receiving socket containing electrical contacts, and female connector socket has protrusion having electrical contact strips disposed thereon for pressure insertion into and engagement with the male connector receiving socket Connector configurations that ensure connection in a proper orientation to provide electrical compatibility and eliminate the possibility of short-circuits Quick release locking arrangement that firmly mechanically holds mating connectors together despite extensive movement of the game player's arms and hands Staged electrical contacting sequence provides proper sequence for applying signals Wrist strap tethering handheld remote controller to hand is attached to a locking connector that securely mates with a connector of the remote controller High reliability and long life Very rugged design in a compact low cost package Easy to manipulate and operate to insert and release Positive coupling with tactile feel so users know when connection is successful Positive interlock securely fastens and holds connectors together despite active motion by users holding onto handheld controllers the connector is used to couple together Good strain resistance preventing cable from being forceably pulled out of connector Combination insertion/receiving interlocking portions on both male and female connectors provide mechanical strength when connectors are mated Other advantageous non-limiting features BRIEF DESCRIPTION OF THE DRAWINGS These and other features and advantages will be better and more completely understood by referring to the following detailed description of exemplary non-limiting illustrative implementations in conjunction with the drawings of which: FIG. 1 is an elevated front right perspective view of an exemplary illustrative non-limiting male connector plug as seen from near the connector's insertion end;",
"FIG. 2 is an elevated rear left perspective view of the FIG. 1 male connector plug inverted and as seen from behind the connector's cable receiving portion;",
"FIGS. 2A &",
"2B show the FIG. 1 male connector plug being squeezed between a finger and thumb to partially retract locking nibs used to lock the connector in a mating position;",
"FIG. 2C shows fully retracted locking nibs;",
"FIG. 2D shows exemplary illustrative non-limiting retractable locking nibs in more detail;",
"FIG. 2D-1 shows an exemplary illustrative non-limiting implementation of how retractable nibs of the FIG. 1 male connector can engage with exemplary female mating connector nib retaining slots;",
"FIGS. 2E-2P show an exemplary illustrative non-limiting plug and socket connector mating sequence (and, if viewed in reverse, an unmating/release sequence) from different perspectives;",
"FIG. 3 shows a top view in plan of the FIG. 1 exemplary illustrative non-limiting male connector showing exemplary illustrative non-limiting dimensions in millimeters for an exemplary illustrative plug cable assembly;",
"FIG. 4 shows a side elevation of the FIG. 3 exemplary male connector and cable assembly including dimensions in millimeters;",
"FIG. 5 shows further exemplary illustrative non-limiting cable assembly dimensions in millimeters;",
"FIG. 6 shows a plan view of an exemplary illustrative non-limiting male plug six pin electrical contact arrangement;",
"FIGS. 6A and 6B show perspective views of an exemplary illustrative non-limiting female connector socket contact arrangement;",
"FIG. 7A is an exemplary illustrative non-limiting cross-section view of an exemplary illustrative non-limiting corresponding female plug connector showing exemplary electrical pin assignments;",
"FIG. 7B is an exemplary illustrative non-limiting electrical circuit connection diagram;",
"FIG. 8 is a cross-sectional more detailed view of an exemplary illustrative non-limiting locking mechanism showing the retractable locking nibs operated by finger-depressible actuators;",
"FIG. 8A shows in detail an exemplary illustrative non-limiting internal locking mechanism structure portion of the FIG. 1 connector;",
"FIGS. 9 and 10 show exemplary electrical contacting arrangements including dimensions in millimeters;",
"FIG. 11 shows a top exemplary illustrative non-limiting female connector metallic or other conductive socket shield;",
"FIG. 12 is a side elevated view in plan of an exemplary illustrative non-limiting female connector in a flipped configuration as compared to FIG. 7A ;",
"FIG. 13 is a side elevated plan view of the FIG. 11 exemplary illustrative non-limiting socket shield;",
"FIG. 14 shows the exemplary illustrative non-limiting socket shield in cross-section;",
"FIG. 15 shows exemplary illustrative non-limiting socket shield dimensions in millimeters;",
"FIG. 16 show exemplary illustrative non-limiting socket shield printed circuit board contact dimensions in millimeters;",
"FIGS. 17A-17L show exemplary illustrative compatible or partially compatible non-limiting connector socket shapes;",
"and FIGS. 18A-18P show exemplary illustrative non-limiting compatible plug shapes.",
"DETAILED DESCRIPTION FIG. 1 is a perspective view of an exemplary illustrative non-limiting electrical connector plug 50 .",
"Electrical connector plug 50 can be used, for example, to electrically connect a video game accessory including but not limited to a “nunchuk”, “classic controller”",
"or other device to another video game unit such as for example a handheld remote control.",
"These are exemplary illustrative non-limiting examples—connector 50 can be used to connect any device to any other device.",
"Exemplary illustrative non-limiting electrical connector plug 50 includes an insertion portion 52 and a manually grippable portion 54 .",
"Insertion portion 52 in one exemplary illustrative non-limiting implementation forms a male portion of a connector that mates with a female connector receptacle or socket 100 (See FIG. 2E and following).",
"Grippable portion 54 is intended to be gripped by human digits (fingers and thumb of the human hand) to allow a user to easily manually, and in a locking manner, insert the connector plug 50 into and to remove (unlock) the connector plug 50 from a corresponding mating female connector socket 100 .",
"In the exemplary illustrative non-limiting implementation shown, grippable portion 54 includes a generally box-like housing 56 including grippable side walls 58 a, 58 b. Housing 56 can be of two-piece construction with a top (upper) case portion 60 joining with a bottom (lower) case portion 62 .",
"Upper and lower or top and bottom housing case portions 60 , 62 can be for example made of molded hard plastic, white “66Nylon”",
"material or any other suitable durable material.",
"The upper and lower housing case portions 60 , 62 when coupled together (e.g., using retaining screws, adhesive, or any other convenient fastening system) encapsulate and protect internal portions of the connector assembly to make the connector plug 50 rugged and allow it to stand up to abuse from children and others.",
"In other exemplary illustrative non-limiting implementations, housing 56 as shown could be eliminated and some other arrangement used (or omitted as desired) for electrically connecting the connectors of a cable (not shown) to the insertion portion 52 .",
"In the exemplary illustrative non-limiting implementation, the connector plug housing 56 is of a convenient size for grasping or gripping between a thumb and other digit (e.g., forefinger, middle finger, etc.).",
"See FIG. 2A for example.",
"Dimensions can be for example 17 mm wide by 23.5 mm long by 9.7 mm high in one exemplary illustrative non-limiting implementation.",
"See for example FIGS. 3 and 4 .",
"Such a size is convenient to be grasped by adults and small children.",
"Other dimensions are possible.",
"In one exemplary illustrative non-limiting implementation, the male connector plug 50 has a wrist strap hook 59 mounted on its housing 56 .",
"Wrist strap hook 59 can comprise for example a separate layer of clear strong durable plastic or other similar material providing a ridge 59 a and a hook structure 59 b. The purpose of ridge 59 a and hook structure 59 b in one exemplary illustrative non-limiting implementation is to retain a nylon or other durable fabric or other wrist strap (e.g., loop) so the device into which the male connector plug 50 (e.g., a handheld remote controller) can be anchored to the user's hand or wrist.",
"Since illustrative non-limiting implementations shown herein have a rugged, strong locking mechanism that locks the male connector plug 50 to a mating female connector socket 100 (and thus for example to a handheld device which provides the mating female connector socket), it is sufficient in the exemplary illustrative non-limiting implementation to anchor the wrist strap to the connector 50 which mates with the handheld device (direct connection of the wrist strap to the handheld device itself is thus not necessary in one exemplary illustrative non-limiting implementation).",
"In other implementations, a wrist strap could be anchored directly to the handheld device as opposed to the connector, or it could be omitted.",
"In some exemplary illustrative non-limiting implementations, a sensor of some sort (e.g., optical) is provided to detect whether the wrist strap is being used and in some cases to prevent games or other applications from operating unless the wrist strap is physically in place.",
"The wrist strap could be replaced with a lanyard or any other desired arrangement.",
"Exemplary Illustrative Non-Limiting Secure Locking Mechanism An exemplary illustrative non-limiting implementation includes a secure locking mechanism including control arms 64 , locking nibs or tangs 66 , and slots or other openings defined within a mating connector in registry with the locking nibs or tangs (see FIG. 2E ).",
"In one exemplary illustrative non-limiting implementation, the thumb for example can be placed into contact with sidewall 58 a and a finger can be placed into contact with sidewall 58 b. When the user grasps connector plug 50 in the way shown in FIG. 2A and exerts pressure against the sidewalls 58 a, 58 b, the user may inwardly depress control arms 64 a, 64 b. Arms 64 a, 64 b provide a control feature for the locking mechanism.",
"In more detail, in one exemplary illustrative non-limiting implementation, nibs 66 are normally biased to project outwardly through openings 68 .",
"In the exemplary illustrative non-limiting implementation, locking nibs 66 have ramped, angled or inclined leading edges 70 and flat (non-angled) following edges 72 .",
"As shown in FIG. 2C (and see also FIG. 8A internal view), these retractable nibs 66 may be integrally formed (e.g., by conventional metal cutting and bending manufacturing processes) on metal members 65 a, 65 b that integrally extend alongside the control arms 64 a, 64 b. Two such retractable nibs 66 are formed on each metal member in the exemplary illustrative non-limiting implementation, although other exemplary embodiments could have one nib, more than two nibs, some locking structure other than a nib, or no locking structure at all.",
"In the exemplary illustrative non-limiting implementation, control arms 64 and associated retractable nibs 66 are mechanically biased (see FIGS. 1 and 2 ) such that, at rest, the locking nibs 66 are fully extended.",
"In the exemplary illustrative non-limiting implementation, nibs 66 can be forced to retract in two ways: (a) by the user depressing control arms 64 (for unlocking action), and (b) when the connector plug insertion portion 52 is inserted into a snugly fitting receptacle (leading up to locking action) which applies retracting pressure directly onto the nibs in a direction that is substantially perpendicular to the direction in which the associated control arm extends.",
"In the exemplary illustrative non-limiting implementation, inserting the connector plug insertion portion 52 into a female receptacle thus causes a locking action, and user depression of control arms 64 causes an unlocking action.",
"As FIG. 8A shows, the metal members 65 a, 65 b are part of a U-shaped structure 65 that is formed with a stiffening cross base 65 c that holds the members 65 a and 65 b in an outwardly biased position, but which allows the members (and hence the nibs 66 ) to flex inwardly when pressure is applied to the control arms 64 a, 64 b. The metallic structure 65 can serve double duty as a cable retaining structure.",
"In more detail, when the user grasps the connector plug housing 54 between the thumb and a finger and applies pressure to the control arms 64 and at this stage may or may not cause retractable nibs 66 to retract (see FIGS. 2A-2D ).",
"The user may insert the plug insertion portion 52 into a corresponding conformal or other snugly fitting female connector socket 100 (see FIGS. 2E-2K ) and apply pressure onto the connector to force the connector insertion end further into the female connector socket.",
"A point is reached (see FIG. 2L ) at which the retractable locking nibs 66 contact the outer edges of the connector socket 100 and the retractable nib biasing forces offer some resistance to further insertion.",
"If the user continues to increase or otherwise provide applied insertion force, the socket wall will apply a side directed component of that axially directed insertion force to the retractable nibs 66 to cause the nibs to retract sufficiently to clear the socket opening (see FIG. 2M and following).",
"Such retraction of nibs 66 can occur whether or not the user is applying pressure to the control arms 64 .",
"Insertion is smoother and easier if the user is applying pressure to the control arms 64 , but the force that the insertion wall of the female connector socket applies to the retractable nibs 66 will cause the nibs to retract irrespective of whether the user is applying force to control arms 64 .",
"Even though they are partially retracted, the nibs 66 are outwardly biased in the exemplary illustrative non-limiting implementation such that they remain in close biased contact with the female socket inner wall and exert a frictional force thereon.",
"However, in the exemplary illustrative non-limiting implementation, the contact is between smooth metal surfaces so the frictional insertion force is relatively small, so as not to substantially impede insertion progress.",
"Meanwhile, proper registration between the plug 50 and the socket is ensured by channel 320 conformally in registry with an engaging ridge 1320 disposed on an insertion wall of the female socket.",
"Thus, in the exemplary illustrative non-limiting implementation shown, retractable nibs 66 serve to automatically retract as the connector insertion portion 52 is inserted into a corresponding snugly-fitting female receptacle.",
"If corresponding locking grooves, openings or other structures in registry with locking nibs 66 are provided, the locking nibs may then automatically protrude into the corresponding structures in registration therewith, such that the trailing edges 72 abut corresponding edges of grooves, holes or the like and thereby substantially prevent the connector insertion portion 52 from being removed from a corresponding female receptacle unless either the control arms 64 are depressed to retract the nibs or a substantial amount of pressure is applied.",
"FIG. 2D-1 shows one such exemplary illustrative non-limiting female connector socket engaging structure including a metal housing 201 defining a pair of rectangular openings or slots 202 (only one is shown), each rectangular opening being dimensioned to accept a pair of nibs 66 , the openings being positioned so that the nibs engage with the opening when male connector plug 50 is substantially fully inserted into and thus fully mated with female connector socket 100 .",
"More specifically, as the user continues to supply insertion force ( FIG. 2N , FIG. 2O ), the retractable nibs 66 eventually engage with corresponding slots 202 defined in the female connector socket wall.",
"In the exemplary illustrative non-limiting implementation, such slots are located and disposed in registry with the nib 66 positions when the male connector plug 50 is fully mated with the female connector socket 100 .",
"Upon such mating connection, the locking nibs 66 snap outwardly with a positive “click”",
"sound and generate a corresponding tactile snap, thereby letting the user know that the male connector plug 50 has fully mated with the female connector socket 100 ( FIG. 2P ).",
"At this fully mated point, the body of connector 50 may be in direct contact with an outer surface 67 defined by a device housing the female socket 100 .",
"The nib flat engaging surfaces 72 at this point engage, much as a ratchet engages with a pawl, with edges of the corresponding female socket wall slots 202 to firmly and strongly lock the connector plug into the mating connector socket 100 .",
"When locked, the connector plug 66 can move in and out by a very small distance in the exemplary illustrative non-limiting implementation, but is in fact firmly locked in place so that attempting to pull the connector plug out by force will be unsuccessful unless a very large amount of force is applied.",
"The locking mechanism (the retractable nib portion of which is shown in more detail in FIG. 8 A—including the U-shaped structure 65 ) thus provides added degrees of safety and security since the accessory or other device that connector plug 50 connects to will generally not easily unintentionally separate from the corresponding female connector socket 100 .",
"This can provide significant benefits for example when a user is holding a video game remote controller with one hand, the remote controller providing a female connector socket 100 into which a wired connector plug 50 is inserted.",
"As the user independently swings his or her left and right arms to operate the two different devices, for example, the exemplary illustrative locking mechanism shown including retractable nibs 66 and corresponding in-registration slots, grooves or other openings or similar structures maintains a firmly-locked electrical and mechanical connection.",
"This prevents electrical connector 50 from unexpectedly and unintentionally flying out of the corresponding female connector socket 100 during such arm movements, thereby potentially avoiding injuries, inconvenience, and other potential occurrences caused by unintended disconnection.",
"In one exemplary illustrative non-limiting implementation, the locking mechanism is designed so it will fail and release the connector plug 50 from the connector socket 100 when a very substantial removal force is applied.",
"Such a removal force can for example be somewhat or substantially less than the amount of force required to pull a cable out of the connector plug so that the locking mechanism will forceably release just before the cable strain release fails.",
"Thus, the exemplary illustrative non-limiting locking mechanism is sufficiently stiff so that the connector will not come out accidentally, but is not so stiff that the cord will break first (locking mechanism strength is less than the tensile strength of the cable connected to the male connector 50 assuming a cable based connection is used).",
"In normal use, the user can easily withdraw the connector plug 50 from the connector socket 100 at any time by applying pressure onto control arms 64 and thereby cause the control arms to retract inwardly into the connector plug housing.",
"As the user applies force to the control arms 64 and exceeds the biasing force that maintains the control arms in their outwardly protruding resting positions, the retractable nibs begin to retract into housing 54 (see FIG. 2C ) and thus disengage from the female connector socket wall slots 202 or other engaging voids.",
"As the user continues to apply more force, the control arms 64 continue to travel inwardly into the grippable portion 54 housing 56 interior.",
"This causes locking nibs 66 to further retract into insertion portion 52 , thereby in one exemplary illustrative non-limiting implementation freeing the connector insertion portion 52 from a mating receptacle engaging slot or other engaging structure(s).",
"Once the locking nibs 66 are sufficiently retracted to disengage from corresponding slots, the user can then pull the male connector plug 50 outwardly away from the female connector socket 100 to slide out and thereby withdraw the plug from the socket 100 .",
"As can be seen in FIG. 2A , the exemplary illustrative non-limiting implementation of male connector plug insertion portion 52 has one or more longitudinally defined raised portions or ribs 69 that are intended to maintain frictional contact with the female connector socket inner wall while limiting or reducing the total contact surface area between the withdrawing male connector plug insertion portion 52 and the female connector socket interior walls.",
"Furthermore, during the operation of withdrawing the connector plug 50 from the female socket 100 , the user can continue to maintain strong pressure on the control arms 64 with the same finger and thumb that is being used to apply withdrawal force in a direction away from the female connector socket 100 , thereby maintaining the retractable nibs 66 in substantially or completely retracted positions so the nibs do not substantially add to the amount of force needed to withdraw the connector plug 50 from the connector socket 100 .",
"Such a withdrawal operation is therefore simple, does not require much dexterity or applied force, and therefore can be performed even by a small child without difficulty.",
"In still other exemplary illustrative non-limiting implementations, the retractable nibs 66 could be formed in other ways and or omitted entirely.",
"Although the exemplary illustrative non-limiting implementation shown includes a locking mechanism including retractable nibs 66 , other arrangements could be used instead.",
"For example, in some applications, a friction fit alone might be sufficient, or the force of gravity in combination with a friction fit could be used to keep the connector insertion portion 52 mated with a corresponding female connector receptacle.",
"Exemplary Male and Female Multilevel Interlocking Configurations FIG. 6 shows a forward-looking plan view looking down onto (and into) the male connector 50 .",
"One can see the insertion portion 52 which terminates in a planar surface 300 composed of plastic or other material.",
"The exemplary illustrative male connector 50 defines, in this planar surface 300 , a recess 302 in which the above-mentioned electrical contact strips are disposed.",
"This recess 302 is dimensioned to receive a protrusion which is disposed within the female connector (socket).",
"Thus, the male connector 50 in the exemplary illustration has a portion with a female receptacle for receiving a male protrusion portion of the female socket 100 .",
"Providing a male plug 50 with a female socket portion 302 and providing the female socket 100 with a male protrusion portion enhances ruggedness, reliability and mechanical strength through the application of multiple interlocking elements that surround one another.",
"In the exemplary illustrative non-limiting implementation, the female socket male protrusion portion is received and surrounded by the male plug recess 302 , which in turn is surrounded by the larger male projection 52 that is received within the female socket recess.",
"The cross-sections of the different interlocking portions can be other than those shown in the Figures discussed above.",
"For example, FIGS. 17 a - 18 p illustrate various connector/plug configurations that include fully or partially compatible mechanical configurations in combination with compatible electrical configurations for the male projection 52 and female connector socket 100 , each or any of which may be used to establish the desired electrical connection.",
"However, as mentioned above, entirely different locking mechanisms could be substituted, such locking mechanisms including for example: a lever-operated locking mechanism of the type often seen holding zero insertion force connector pins a retractable spring or other biased plunger, ball or the like a pure friction fit such as commonly used by USB connectors a threaded ring or other structure that screws onto a corresponding threaded shaft or other structure threaded shafts with knurled knobs that mate and interlock with corresponding threaded screw holes, of the type for example used for personal computer parallel and serial cables side protrusions of the type used commonly for USB male and female connectors any other suitable locking, retaining or friction fully engaging structural mechanism in suitable applications, a combination of friction and the force of gravity (e.g., docking ports or the like) while connector 50 is not in physical motion and has a generally downwards orientation any other suitable arrangement (for example, a locking mechanism that engages the slots on the bottom of a FIG. 6A remote controller rather than engaging the connector itself).",
"other Exemplary Electrical Connection Referring again to FIG. 1 , the exemplary illustrative non-limiting implementation of male connection plug 50 includes a keyed or slotted insertion portion 52 having a substantially planar distal surface 300 .",
"Substantially planar distal surface 300 may define a rectangular opening 302 therein.",
"Rectangular opening 302 may have channels 304 a, b, c, e, f and g (sometimes referred to generally as “channels 304 ”) defined therein.",
"A portion 305 of each channel located at the front of the opening 302 is closed off with respect to the opening 302 .",
"Electrical contact strips (e.g., copper or other conductive strips) 306 may be disposed within the channels 304 .",
"These copper or other conductive contact strips 306 are dimensioned and disposed to make good electrical contact with corresponding electrical contacts 308 of mating female connector socket 100 .",
"See FIG. 12 , which shows an exemplary illustrative non-limiting female connector socket 100 including a metal outer housing 402 defining an opening 404 that is dimensioned and shaped to conformally match and accept, with close frictional engagement, the male connection plug insertion portion 52 .",
"Thus, for example, the cross-section of the male connection insertion portion 52 is the “positive”",
"of a shape that is dimensioned to conformally match the shape and size of a “negative”",
"or void defined within the space of opening 404 defined by the female mating connector socket metal housing 402 .",
"Of course, metal is just one example, any type of material could be used.",
"Metal may have some advantages in terms of durability, ruggedness, scratch and breakage-resistance and ability to provide RF and noise shielding, but other materials could be used instead or in addition.",
"Referring again to FIG. 12 , a channeled projection 406 is defined within the space or void 404 within the female connector socket 100 .",
"The channeled projection 406 has channels 408 a, b, c, d, e and f (sometimes referred to generally as “channels 408 ”) defined therein, the channels each having a copper or other electrically conductive strip 308 therein.",
"The female connector channeled projection 406 is shaped and dimensioned to be inserted within the channeled rectangular opening 302 within the male connector plug insertion portion distal surface 300 .",
"When the male plug 50 mates with the female socket 100 , the male plug insertion portion 52 is inserted within the female socket space 404 as described above, and the female socket channeled projection 406 is in turn inserted into the male plug rectangular opening 302 .",
"As the female socket channeled projection 406 is inserted into the male plug rectangular opening 302 , the copper or other conductive strips 306 of the male plug 50 engage in close electrically conductive sliding contact with corresponding copper or other conductive strips 308 of the female socket 100 .",
"Such sliding contact establishes corresponding electrical connections for each of the six pairs of conductors shown.",
"Different numbers of conductors could be used if desired.",
"In some cases, unneeded ones of the conductive strips for particular applications can be omitted or made to be “no connection.”",
"As many connective strips as desired may be provided.",
"In the example shown, a total of six connective strips are provided for six independent electrical connections.",
"In some configurations, not all connections are used (for example, there may be no need in some applications to connect to a “battery”",
"connection).",
"In such cases, the female socket 100 could be provided with one more (unused) electrical contact than certain configurations of male plug 50 , whereas other configurations of male plug 50 could have the same number of electrical contacts as the female socket 100 , or vice versa.",
"Other applications can of course have other configurations.",
"FIGS. 6A and 6B show details of exemplary illustrative non-limiting copper or other conductive strips 308 as described above (strips 306 are similar).",
"See also cross-sectional FIG. 8 .",
"As shown for example in FIG. 6B , each strip 308 comprises a thin strip of copper or other conductive metal or similar having a bulging portion 309 formed longitudinally therein.",
"Such bulging or protruding portions can provide good sliding frictional electrical contact while minimizing the amount of force necessary to establish insertion.",
"Furthermore, FIG. 6B shows that not all of the strips 308 in the female connector socket 100 are the same length.",
"In one exemplary illustrative non-limiting implementation, certain of the strips 308 are shorter than others so that the longer strips make contact with counterpart strips 306 (which in one exemplary illustrative non-limiting implementation are all the same size) before the shorter ones make contact.",
"For example, in one exemplary illustrative non-limiting implementation, it may be desirable to connect power and ground before making contact between data signal lines.",
"This exemplary illustrated non-limiting connector conductive strip configurations shown provide such staged connections.",
"FIGS. 7A and 7B show electrical wiring diagrams for the paired connection, and FIG. 8 shows a cross-section of an exemplary electrical connecting strip structure within male connector 50 .",
"The electrical connecting strips in the exemplary illustrative non-limiting implementation are made of a highly ductile, relatively stiff conductive material such as copper, aluminum or other metal.",
"As perhaps best seen in FIG. 8 , when pressure is applied to the copper strips due to engagement with additional copper strips within the female socket (see FIG. 6A ), the copper strips in the male connector 50 flex outwardly.",
"Forward ends of the copper strips rest against the closed off portions 305 of the channels formed on the sidewalls of the opening.",
"An angled portion 307 projecting inwardly of the male connector copper strips protruding through a slotted opening in the male connector inner contact supporting structure 310 moves outwardly upon conformal engagement with a corresponding female connector structure.",
"However, the springiness of the copper strips ensures that an inward mechanical bias continues to be applied, resulting in a pressure contact between the male and female connector mating contact strips.",
"Such pressure contact provides effective and reliable highly-conductive electrical conductivity even when the copper strips are worn or oxidized after long use.",
"One exemplary illustrative non-limiting pin assignment configuration may be as follows for a six-pin male connector: Pin 1: Vcc (3 volts) Pin 2: SCL (serial clock line) Pin 3: “Attach”",
"(connected to Vcc on the male plug 50 side, sensed on the female socket 100 side to determine whether a plug is connected or not) Pin 4: V-Batt (can be used for supplying external power through the connectors if desired;",
"this connection is optional in many games) Pin 5: SDA (serial data line) Pin 6: Ground In one implementation shown in FIG. 6B , Vcc and Ground (1 and 6) are in an exemplary illustrative non-limiting implementation made longer than the rest of the lines.",
"This means that power and ground will be connected first, before the other signal lines.",
"Furthermore, in the illustrative implementation, ground shield is connected first when the male and female connectors first come into contact (see for example FIG. 2I to 2 ).",
"One exemplary illustrative non-limiting connection sequence is thus: (1) shielding plates make contact (2) pins 1 and 6 (Vcc and ground) make contact simultaneously (3) pins 2-5 (all the rest) make contact.",
"Other variations are of course possible, e.g., pins 2-5 make contact first and then power and ground make contact.",
"Such earlier or staged connection helps to eliminate power surges etc.",
"FIGS. 3-5 show an exemplary illustrative non-limiting cable assembly including a multi-conductor cable with a male connector 50 at one end and an associated strain reliever 1500 at an opposite end.",
"The dimensions shown in these drawings (in millimeters) are exemplary (different dimensions could be used if desired).",
"Keyed Configuration FIG. 6B shows that the exemplary illustrative non-limiting implementation of the female connector 100 channeled projection 406 is symmetrical such that if taken by itself, it could be turned upside down and still connect equally well with the male connector plug rectangular opening conductors 306 .",
"However, FIG. 7A reveals that if the exemplary illustrative non-limiting implementation female connector channeled projection 406 were flipped in its connection orientation, then Vcc and Ground would be reversed, the clock line and the data line would be reversed, and the Attach and V-Batt lines would be reversed.",
"This would not provide a compatible or even working connection in the exemplary illustrative non-limiting implementation.",
"To avoid such inadvertent connection reversals, the outer profile of the male and female connector portions are keyed so they can made in only one orientation.",
"See the longitudinal key slot, trough or channel 320 in the male connector plug 50 of FIG. 2 and the corresponding mating and engaging longitudinal plateau 450 shown in the illustrative exemplary non-limiting female connector socket 100 shown in FIG. 12 .",
"Note also the curved corners in each connector.",
"While such conformal keying wherein plateau 450 slides into trough 320 provides good compatibility, it should be understood that other cross-sectional shapes and profiles could similarly provide partial compatibility and orientation control without being entirely conformal.",
"In particular, although the exemplary illustrative non-limiting implementations shown in FIGS. 1 and 12 provide substantially 100% complete conformality between the corresponding mating shapes, less than 100% conformality in shape and/or dimension might be attempted instead to nevertheless providing proper mating orientation, retention, etc.",
"Different Cross-Sectional Configurations FIGS. 17A-17L provide non-exhaustive examples of female socket insertion cavity cross-sectional shapes that may accept a FIG. 1 male connector plug 50 .",
"FIGS. 18A-18P provide non-exhaustive examples of male connector plug cross-sectional shapes that may be accepted by the FIG. 12 female connector socket 100 .",
"There are a very large number of potential variations and possibilities, so the examples shown in these drawings are only representative.",
"One can assume that an unauthorized or unlicensed hardware manufacturer would try to make his or her connector as different as possible from an authentic connector while still achieving electrical and mechanical compatibility.",
"Elements of electrical and mechanical compatibility include for example proper electrical connection of most of the six electrical connections in the exemplary implementation (at least data and clock line connections would presumably be wanted to provide electrical compatibility, although the pluggable device might be able to provide its own power it would presumably also tie to the common ground connection or to shield but perhaps not to both);",
"and prevention or correction in some way, shape or form from reversed orientation such that those lines are not reversed (although in some circumstances one could envision simply telling the user to try it one way or the other until it works since there are only two possibilities, so long as pin assignment is made carefully to avoid short-circuits).",
"Elements of mechanical compatibility depend to some extent on the particular application.",
"Rugged, locking, conformal compatibility is probably useful for many applications.",
"However, in applications where not much movement is involved, then perhaps the locking mechanism could be dispensed with or not used, and less conformality might be used.",
"Less conformal might weaken ruggedness, but other precautions (e.g., additional means of attachment or stabilization) might be used to compensate.",
"In some applications such as stationary docking port applications involving very little motion, the aspects of mechanical conformality used for compatibility might be reduced.",
"By setting for these illustrative non-limiting shapes and examples, applicants intend to capture any and all ways to compatibly connect to either the FIG. 1 (male) connector or to the FIG. 12 (female) connector.",
"All dimensions herein and in the drawings are in millimeters.",
"Tolerances are plus or minus 0.3 mm.",
"While the technology herein has been described in connection with exemplary illustrative non-limiting implementations, the invention is not to be limited by the disclosure.",
"For example, other connection means including sleeves, clip down, tie downs, plunger based retaining mechanisms, discrete fingers, capacitive or inductive proximity sensors, optical couplers and other variations could be used instead of what is described above.",
"Although the exemplary illustrative non-limiting implementation connects video game systems, other arrangements are also possible.",
"The invention is intended to be defined by the claims and to cover all corresponding and equivalent arrangements whether or not specifically disclosed herein."
] |
RELATED U.S. APPLICATIONS
This is a divisional application of Ser. No. 08/164,627, filed Dec. 9, 1993, issued as U.S. Pat. No. 5,338,748 on Aug. 16, 1994, which is a continuation of application Ser. No. 07/866,010, filed Apr. 9, 1992, now abandoned, which is a continuation of application Ser. No. 758,400, filed Aug. 27, 1991, which has matured into U.S. Pat. No. 5,124,359, granted Jun. 23, 1992 which is a continuation-in-part of Ser. No. 210,626 filed Jun. 23, 1988 which has matured into U.S. Pat. No. 4,923,899, granted May 8, 1990, which is a continuation-in-part of Ser. No. 139,166 filed Dec. 22, 1987 now abandoned which is a continuation of Ser. No. 906,557 filed Sep. 8, 1986 now abandoned which is a continuation of Ser. No. 776,479 filed Sep. 16, 1985 now abandoned which is a continuation-in-part of Ser. No. 692,776 filed Jan. 18, 1985 now abandoned.
FIELD OF THE INVENTION
This invention relates to a broad-spectrum biocidal composition effective for the rapid killing of a wide variety of bacteria, spores, fungi, and viruses on a wide variety of nonabsorbent surfaces such as metals, plastics, resins, woods, rubbers, ceramics, and glasses. The composition of the present invention kills so many organisms on such a wide variety of surfaces that it may be termed a sterilant.
Some of the articles which may be sterilized by the composition of the present invention are counters, floors, sheets, catheters, dialysis machine tubing, anesthetic breathing bags, surgical instruments, dental bite blocks, saliva-draining tubes, respirator equipment, and environmental surfaces in general.
BACKGROUND OF THE INVENTION
In the past in medical and dental circles, steam sterilization or treatment with ethylene oxide in a closed apparatus have been considered ideal ways of sterilizing equipment. But for many types or parts of apparatus, steam sterilization is impractical because of the size or number of items to be sterilized. For parts of equipment which actually come in contact with the patient, such as dental bite blocks, anesthetic breathing bags, respirators, etc. it is impermissible for ethylene oxide to be used because residual trace amounts might harm the patient.
Hence, a stable, benign, broad-spectrum sterilant effective at a wide range of pH's is greatly desired by the medical/dental profession for environmental use, especially on nonabsorbent surfaces.
A disinfectant is generally considered to be an agent which destroys bacterial organisms which are growing, but not bacterial spores. Germicide and bactericide are approximately synonymous with disinfectant. An antiseptic inhibits the growth of microorganisms. A sporicide kills spores of fungi molds, and bacteria. Since spores are more resistant than bacteria, sporicides are generally considered sterilizing agents. Biocides kill all living microorganisms, hence also are sterilizing agents. A virucide kills viruses; a fungicide kills fungi. The novel sterilant of this invention kills bacteria, spores, fungi and viruses. Hence, it may be termed a biocide or a sterilant.
The Hamilton U.S. Pat. No. 3,208,936, discloses combining a broad range of quaternary amines as germicides and foaming agents in recirculation type toilets.
The Halley U.S. Pat. No. 3,785,971, is directed to a waste treatment material for a storage holding tank in which paraformaldehyde and an alkali carbonate or hydroxide are combined.
U.S. Pat. No. 2,998,390, granted August 29, 1961 to Hamilton and U.S. Pat. No. 3,107,216, granted Oct. 15, 1963 to Hamilton, disclose a recirculating toilet fluid which contains a quaternary ammonium salt.
"Quaternary Ammonium Salts as Germicidals. Nonacylated Quaternary Ammonium Salts Derived from Aliphatic Amines," Shelton , R. S. et al., Journal of the American Chemical Society, vol. 68, pp. 753-55 (1946), reported that alkyl quaternary ammonium salts have germicidal powers and N-benzyl substitutes do not affect this germical activity.
It was reported in Gardner, J. Disinfection, Sterilization & Preservation, p. 900, S. S. Block, ed., Lea & Febiger, 2nd ed. (1977) to include chelating agents with phenols and certain quaternary ammonium salts for enhanced activity against Gram-negative bacteria.
The Schattner U.S. Pat. No. 4,103,001 discloses an aqueous mixture of phenol, sodium tetraborate, and sodium phenate solution to which is added aqueous glutaraldehyde in order to kill some bacteria and bacterial spores. This mixture cannot be used against fungi or viruses.
The Stonehill U.S. Pat. No. 3,282,775 discloses a mixture of dialdehydes and a cationic surface active agent, plus a lower alcohol, which kills four spore-forming bacteria, but not fungi or viruses.
The Pepper U.S. Pat. No. 3,016,328 discloses that simple dialdehydes plus a lower alkanol to the extent of about 60 to 70% and an alkalinizing agent to yield a pH range of about 8 to 9.5 kill four spore-forming bacteria, two of which are the same as in U.S. Pat. No. 3,282,775.
Borick, et al in the Journal of Pharmaceutical Sciences, Vol. 53, No. 10 at p. 1273 disclose that glutaraldehyde alkalinized with sodium bicarbonate kills eight nonspore-forming bacteria, four spore-forming bacteria, one fungus, and nine viruses, but that this alkaline solution was stable only for about two weeks.
French Patent 2,321,300 discloses that a mixture of aldehyde and quaternary ammonium compound has antiseptic properties by reducing the growth of five bacteria of interest to the food industry.
British Patent 1,443,786 discloses that a mixture of glutaraldehyde, a lower alcohol, and a highly ionizable salt at acidic pH ranges kills four sporulating bacteria by ion-exchange with the calcium in the walls of the bacterial spores.
The Wagner U.S. Pat. No. 4,107,312 discloses a disinfectant mixture of a strong formaldehyde solution, plus minor amounts of glyoxal and glutaraldehyde, plus a quaternary ammonium salt, methanol to stabilize the formaldehyde, a nonionic wetting agent, optionally some alcohol or glycol, and a scent, all at a neutral pH in order to avoid corrosion of aluminum toilets (or minimize corrosion of magnesium toilets) in aircraft.
The Mandt U.S. Pat. No. 4,444,785 discloses a disinfecting solution for soft contact lenses against two nonsporulating bacteria comprising a very low concentration of 1,5 pentanedial at neutral pH compatible with the human eye.
The Schaeufele U.S. Pat. No. 4,320,147 discloses a germicidal composition comprising quaternary ammonium chlorides, plus builder salts, which are useful for disinfection against bacteria.
Canadian Patent No. 1,154,555 discloses a bactericide composition containing formaldehyde, glutaraldehyde and a quaternary ammonium ingredient.
French Patent No. 2,145,444 discloses a bactericide composition containing formaldehyde and a quaternary ammonium compound.
The Lockwood U.S. Pat. No. 3,505,690 relates to a disinfectant dispersing system.
The Buchalter U.S. Pat. No. 3,983,252 discloses a chemical disinfecting composition comprising a dialdehyde and an alkali metal salt of a hydrocarbon carboxylic acid and optionally an alcohol.
The Goldhaft U.S. Pat. No. 4,022,911 discloses a disinfectant composition comprising three essential active ingredients, namely a dimethyl quaternary ammonium halide salt, a phenol or derivative thereof, and formaldehyde.
Oshchepkova and Kochkin in the Proceedings of the First All-Union Conference on Biocorrosion, Biodamage, and Marine Encrustation (1975), C.A.91:69799p report that a mixture of organotin fumarates or acryloyloxy stannate mixed with N-alkyl pyridinium salts or tetraalkylammonium salts protect wood samples in water from two common bacteria--A.niger and P. purpureum.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a stable, benign, nonodorous, solution which kills a broad-spectrum of bacteria, spores, fungi, and viruses rapidly at a wide range of pH.
It is a further object of this invention to provide a broad-spectrum sterilant which will remain an active solution for at least several weeks.
It is yet another object of this invention to provide a sterilant which is effective on hard, nonabsorbent, "environmental" surfaces such as anesthetic breathing bags, dialysis tubing, respirators, dental bite blocks, saliva-draining tubes, and the like for which sterilization by steam or ethylene oxide is either impractical or physiologically disfavored.
It is an object of the present invention to provide a sterilant composition effective for killing rapidly individual microorganisms or a combination of several different kinds of microorganisms, such as bacteria, spores, fungi and/or viruses.
Another object of the invention is to provide a sterilant for a wide variety of hard surfaces such as metals, plastics, resins, rubbers, ceramics, and glasses.
Yet another object of the present invention is to provide a sterilant which is effective in the presence of high concentrations of blood, sputum, feces, urine, vomitus, and other animal exudates.
Other objects of the present invention will be apparent to those skilled in the art.
SUMMARY OF THE INVENTION
Surprisingly, a broad-spectrum sterilant capable of rapidly killing bacteria, sporulating bacteria, spores, fungi, and viruses can be achieved by combining in an aqueous solution an effective amount of at least one quaternary ammonium compound, at least one aliphatic dialdehyde having from two to six carbon atoms, and at least one aliphatic hydroxyl compound having from one to eight carbon atoms.
Another aspect of the invention relates to the use of the novel sterilant on "hard" or "environmental" surfaces (nonabsorbing) such as medical or dental equipment for which previously steam sterilization or treatment with ethylene oxide were employed.
The sterilant of the present invention relates to a liquid composition which is effective for rapidly killing at least one microorganism or any combination of two or more different microorganisms such as bacteria, spores, fungi and viruses.
For still another aspect of the invention, the novel sterilant is employed over a wide range of pH and is stable for several weeks after having been compounded.
Yet another aspect of the present invention arises from its efficacy in the presence of high concentrations of blood, sputum, urine, feces, vomitus or other bodily liquids or suspensions.
A further aspect of the present invention is its efficacy in sterilizing hard surfaces of metals, plastics, rubbers, resins, wood, ceramics, or glasses.
A typical embodiment of the invention comprises:
______________________________________Component Weight %______________________________________Alkylbenzyldimethylammonium chloride 0.1Cetyldimethylethylammonium bromide 0.1Glutaraldehyde 2.6Isopropyl alcohol 0.2Propylene glycol 0.16Sodium nitrite 0.11Tetrasodium ethylenediamine tetraacetate 0.015Water balance______________________________________
Processes for employing these sterilant compositions are also disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
As discussed above, the prior art discloses individual compounds or mixtures of compounds which kill or inhibit the growth of a narrow range of organisms such as some bacteria, spores, fungi, or viruses. The synergistic combination of the seven components of the present invention unexpectedly kills all types of the names organisms, hence it is a sterilant. Among the classes of organisms killed by the composition of the present invention alone or admixed together are Gram-negative bacteria, Gram-positive bacteria, algae, protozoa, Gram-positive spore-forming bacteria, fungi, and many types of viruses.
Among the many typos of viruses killed by the composition of the present invention are:
orbiviruses, orthomyxoviruses, papovaviruses, paramyxoviruses, parvoviruses, picornaviruses, poxviruses, coronaviruses, flaviviruses, herpesviruses, adenoviruses, arenaviruses, bynyaviridae, caliciviruses, reoviruses, retioviruses, rhabdoviruses, rotaviruses, togaviruses, and various unclassified viruses, plus plant viruses.
In addition to the bacteria, spores, protozoa, algae, fungi, and viruses categorized above, the composition of the present invention can kill alone or in combination with the other organisms typified above various miscellaneous organisms from the Chlamydia Coxiella, Ehrlichia, Rickettsia, Rochalimaea, Wolbachia, and Thai tick typhus.
It is to be emphasized that the composition of the present invention is a sterilant which can kill any or all of the types of organisms described here alone or in any combination.
At the end of the Examples of this specification and before the claims, several hundred representative specific organisms are listed in Tables I to VII on which the synergistic composition of the present invention is effective.
The cationic, quaternary salts useful in the present invention may contain either or both of aliphatic and aromatic moieties. Although quaternary ammonium salts are preferred, cationic phosphonium, or sulfonium, or any other positive nonmetallic nuclei may be selected. Some of the aliphatic or alicyclic substituents for the quaternary ions are alkyl groups containing one to 30 carbon atoms both linear and branched, alkoxy groups also containing one to 30 carbon atoms both linear and branched, alicyclic groups such as cyclohexyl and its alkylated or alkyloxylated derivatives, and halogenated alkyl, halogenated alicyclic, or halogenated alkyloxy derivatives.
Aromatic moieties, which may themselves be substituted by aliphatic, alicyclic, alkyloxy groups, useful as substituents for the quaternary cationic salts of the present invention are benzyl, tolyl, xylyl, naphthyl, pyridyl, benzal, quinolyl and the like.
More specifically, some aliphatic quaternary ammonium salts which are useful in the present invention are:
tetramethyl ammonium halide, trimethylethyl ammonium halide, dimethyldiethyl ammonium halide, methyltriethyl ammonium halide, tetraethyl ammonium halide, cetyldimethylethyl ammonium halide, trimethyln-propyl ammonium halide, dimethyldin-propyl ammonium halide, methyltrin-propyl ammonium halide, tetran-propyl ammonium halide, methylethyln-propyln-butyl ammonium halide, ethyln-propyln-pentyl ammonium halide, trimethylallyl ammonium halide, dimethyldiallyl ammonium halide, methyltriallyl ammonium halide, tetraallyl ammonium halide, N,N,N,N',N',N'-hexaethyl-1,2-ethylene diammoniumhalide, N,N,N,N',N',N'-hexaethyl-1,4-butylene-diammonium halide, N,N,N'-dibenzyl-N,N,N',N', tetramethyl-1,2-ethylene diammonium halide, N,N'-di(4-chlorobenzyl)-N,N,N',N'-tetramethyl-1,2-ethylene diammonium halide, N,N,N'-tetraethyl-N,n"-dioctadecyl-1,2-ethylene diammonium halide, N,N,N',N'-tetraethyl-N,N'-dihexadecyl-1,4-butylene diammonium halide, octadecyltrimethyl ammonium halide, dioctadecyldimethyl ammonium halide, trioctadecylmethyl ammonium halide tetraoctadecyl ammonium halide, hexadecyltriethyl ammonium halide, hexadecyldimethylethyl ammonium halide, hexadecyldiethylmethyl ammonium halide, didecyldioctyl ammonium halide, didecyldihexyl ammonium halide, and hexyloctyldecyldodecyl ammonium halide.
Some representative useful quaternary ammonium salts containing an aromatic moiety include:
benzylodecyldimethyl ammonium halide, o-tolyldodecyldimethyl ammonium halide, m-tolyldodecyldimethyl ammonium halide, p-tolyldodecyldimethyl ammonium halide, 2,3-xylyldodecyldimethyl ammonium halide, 2,4-xylydodecyldimethyl ammonium halide, 2,5-xylyldodecyldimethyl ammonium halide, 3,4-xylyldodecyldimethyl ammonium halide, 3,5-xylyldodecyldimethyl ammoniuim halide, 2-chlorobenzyldodecyldimethyl ammonium halide, 3-chlorobenzyldodecyldimethyl ammonium halide, 4-chlorobenzyldodecyldimethyl ammonium halide, 2,3-dichlorobenzyldodecyldimethyl ammonium halide, 2,4-dichlorobenzyldodecyldimethyl ammonium halide, 2,5-dichlorobenzyldodecyldimethyl ammonium halide, 2,6-dichlorobenzyldodecyldimethyl ammonium halide, 3,4-dichlorobenzyldodecyldimethyl ammonium halide, 3,5-dichlorobenzyldodecyldimethyl ammonium halide, 2-nitrobenzyldodecyldimethyl ammonium halide, 3-nitrobenzyldodecyldimethyl ammonium halide, 4-nitrobenzyldodecyldimethyl ammonium halide, 2,4-dinitrobenzyldodecyldimethyl ammonium halide, 3,5-dinitrobenzyldodecyldimethyl ammonium halide, 2-sulfobenzyldodecyldimethyl ammonium halide, 3-sulfobenzyldodecyldimethyl ammonium halide, 4-sulfobenzyldodecyldimethyl ammonium halide, 2-carboxybenzyldodecyldimethyl ammonium halide, 3-carboxybenzyldodecyldimethyl ammonium halide, 4-carboxybenzyldodecyldimethYl ammonium halide, benzylhexyldimethyl ammonium halide, benzyloctyldimethyl ammonium halide, benzyldecyldimethyl ammonium halide, benzyldodecyldimethyl ammonium halide, benzyltetradecyldimethyl ammonium halide, benzylhexadecyldimethyl ammonium halide, benzyloctadecyldimethyl ammonium halide.
Some representative, useful quaternary ammonium salts containing heterocyclic, aromatic moieties include: n-hexylpyridinium halide, n-octylpyridinium halide, n-decylpyridinium halide, n-dodecylpyridinium halide, n-tetradecylpyridinium halide, n-hexadecylpyridinium halide, n-hexyllutidinium halide, n-octyllutidinium halide, n-decyllutidinium halide, n-dodecyllutidinium halide, n-tetradecyllutidinium halide, n-hexadecyllutidinium halide, n-hexylpicolinium halide, n-octylpicolinium halide, n-decylpicolinium halide, n-dodecylpicolinium halide, n-tetradecylpicolinium halide, n-hexadecylpicolinium halide, n-hexylquinolinium halide, n-octylquinolinium halide, n-decylquinolinium halide, n-dodecylquinolinium halide, n-tetradecylquinolinium halide, n-hexadecylquinolinium halide, n-hexylisoquinolinium halide, n-octylisoquinolinium halide, n-decylisoquinolinium halide, n-dodecylisoquinolinium halide, n-tetradecylisoquinolinium halide, n-hexadecylisoquinolinium halide, n-hexylquinazolinium halide, n-octylquinazolinium halide, n-decylquinazolinium halide, n-dodecylquinazolinium halide, n-tetradecylquinazolinium halide, n-hexadecylquinazolinium halide, n-hexylquinoxalinium halide, n-octylquinoxalinium halide, n-decylquinoxalinium halide, n-dodecylquinoxalinium halide, n-tetradecylquinoxalinium halide, n-hexadecylquinoxalinium halide, n-hexylpyridopyridinium halide, n-octylpyridopyridinium halide, n-decylpyridopyridinium halide, n-dodecylpyridopyridinium halide, n-tetradecylpyridopyridininum halide, and n-hexadecylpyridopyridinium halide.
The preferred counter ions for the quaternary cationic salts are halides, especially chloride and bromide. Particularly useful for practicing the present invention are alkylbenzyldimethyl ammonium chlorides, wherein the alkyl groups contain between 10 and 18 carbon atoms, and cetyldimethylethyl ammonium bromide. The useful range of quaternary cationic salts in an effective amount of sterilant is from about 0 05% to 3% in actual use by weight.
Other counter ions, anions, useful in the practice of the present invention to neutralize the positive charge of the ammonium, phosphonium, sulfonium, or other positive moieties can be found in the following list bicarbonate, bisulfite, fluoride, borate, carbonate, nitrite, nitrate, phosphite, phosphate, sulfite, sulfate, chloride, hypochlorite, chlorite, chlorate, perchlorate, hydroxide, fluoborate, iodide, iodate, periodate, and bromate.
The solubility of the various solutes in the novel sterilant of the instant invention is improved by using small amounts of alkanols having from one to six carbon atoms and/or glycols having from two to four carbon atoms. These alkanols and glycols also have concomitant and peripheral biocidal effect. Especially useful alkanols are methanol, ethanol, and isopropyl alcohol. Especially useful polyols are glycols such as ethylene glycol, propylene glycol, diethylene glycol, as well as glycerine. In the diluted solution for actual use, the effective amount for the alkanol is from about 0.1% to 3% by weight, and the effective amount for the polyol or glycol is from about 0.1% to 3% by weight.
Other alcohols having eight or less carbon atoms useful in the practice of the present invention are: 1-propanol, 1-butanol, 2-butanol, 2-methyl-1-propanol, 2-methyl-2-propanol, 1-pentanol, 2-pentanol, 3-pentanol, 2-methyl-2-butanol, 2-methyl-3-butanol, 2-methyl-4-butanol, 2,2-dimethyl-1-propanol, 1-hexanol, 2-hexanol, 3-hexanol, 2,2-dimethyl-3-butanol, 2,2-dimethyl-4-butanol, 2,3-dimethyl-2-butanol, 2-methyl-1-pentanol, 2-methyl-2-pentanol, 2-methyl-3-pentanol, 2-methyl-4-pentanol, 2-methyl-5-pentanol, 3-methyl-1-pentanol, 3-methyl-2-pentanol, 3-methyl-3-pentanol, 2,2-diethyl-1-ethanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, 2,2,3-trimethyl-3-butanol, 2,3-dimethyl-3-pentanol, 2,4-dimethyl-3-pentanol, 3-ethyl-1-pentanol, 3-ethyl-2-pentanol, 3-ethyl-3-pentanol, 4-ethyl-1-pentanol, 4-ethyl-2-pentanol, 4-ethyl-3-pentanol, 2-ethyl-1-pentanol, 2-methyl-1-hexanol, 2-methyl-2-hexanol, 2-methyl-3-hexanol, 2-methyl-4-hexanol, 3-methyl-1-hexanol, 4-methyl-1-hexanol, 5-methyl-1-hexanol, 3-methyl-2-hexanol, 4-methyl-2-hexanol, 3-methyl-3-hexanol, 3-methyl-4-hexanol, 1-octanol, 2-octanol, 3-octanol, 4-octanol, 2-methyl-1-heptanol, 3-methyl-1-heptanol, 4-methyl-1-heptanol, 5-methyl-1-heptanol, 5-methyl-1-heptanol, 6-methyl-1-heptanol, 2-methyl-2-heptanol, 3-methyl-2-heptanol, 4-methyl-2-heptanol, 5-methyl-2-heptanol, 6-methyl-2-heptanol, 2-methyl-3-heptanol, 3-methyl-3-heptanol, 4-methyl-3-heptanol, 5-methyl-3-heptanol, 6-methyl-3-heptanol, 2-methyl-4-heptanol, 3-methyl-4-heptanol, 4-methyl-4-heptanol, 5-methyl-4-heptanol, 6-methyl-4-heptanol, 2,2-dimethyl-1-hexanol, 3,3-dimethyl-1-hexanol, 4,4-dimethyl-1-hexanol, 5,5 -dimethyl-1-hexanol, 2,3-dimethyl-1-hexanol, 2,4-dimethyl-1-hexanol, 2,5-dimethyl-1-hexanol, 3,4-dimethyl-1-hexanol, 3,5-dimethyl-1-hexanol, 2-ethyl-1-hexanol, 3-ethyl-1-hexanol, 4-ethyl-1-hexanol, and 5-ethyl-1-hexanol.
Other glycols having eight or less carbon atoms useful in the practice of the present invention are:
1,2-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 2-methyl-1,2-propanediol, 2,methyl-1,3-propanediol, 1,2-pentanediol, 1,3-pentanediol, 1,4-pentanediol, 1,5-pentanediol, 2-methyl-1,2-butanediol, 2-methyl-1,3-butanediol, 2-methyl-1,4-butanediol, 2-methyl-2,3-butanediol, 2-methyl-3,4-butanediol, 1,2-hexanediol, 1,3-hexanediol, 1,4-hexanediol, 1,5-hexanediol, 1,6hexanediol, 2-methyl-1,2-pentanediol, 2-methyl-1,3-pentanediol, 2-methyl-1,4-pentanediol, 2-methyl-1,5-pentanediol, 2-methyl-2,3-pentanediol, 2-methyl-2,3-pentanediol, 2-methyl-2,4-pentanediol, 2-methyl-2,5-pentanediol, 2-methyl-3,4-pentanediol, 2-methyl-3,5-pentanediol, 2-methyl-4,5-pentanediol, 2,3-dimethyl-1,2-butanediol, 2,3-dimethyl-1,3-butanediol, 2,3-dimethyl-1,4-butanediol, 2,3-dimethyl-2,3-butanediol.
Certain salts with anions at less than full oxidation state, such as nitrite, bisulfite, or chlorite, may be optionally employed in the novel sterilant solution of the instant invention to prevent corrosion, as well as for their biocidal activity.
Also useful in the practice of the present invention are cations wherein the metal oxidation state is lower than its chemically possible maximum.
Some useful compounds with less than full oxidation states are found in the following salts first some with reduced anions and then some salts with less oxidized cations, as follows: sodium phosphite, sodium sulfite, sodium hypochlorite, sodium chlorite, sodium chlorate, sodium selenite, sodium arsenite, sodium hypobromite, sodium bromite, sodium bromate, sodium stannite, sodium antimonite, sodium tellurite, sodium ferrocyanide, sodium manganite, sodium manganate, potassium phosphite, potassium, sulfite, potassium hypochorite, potassium chlorite, potassium chlorate, potassium selenite, potassium arsenite, potassium hypobromite, potassium bromite, potassium bromate, potassium stannite, potassium antimonite, potassium tellurite, potassium ferrocyanide, potassium manganite, potassium manganate, lithium phosphite, lithium sulfite, lithium hypochlorite, lithium chlorite, lithium chlorate, lithium selenite, lithium arsenite, lithium hypobromite, lithium bromite, lithium bromate, lithium stannite, lithium antimonite, lithium antimonite, lithium tellurite, lithium ferrocyanide, lithium manganite, lithium manganate, rubidium nitrite, rubidium phosphate, rubidium sulfite, rubidium hypochlorite, rubidium chlorite, rubidium chlorate, rubidium selenite, rubidium arsenite, rubidium hypobromite, rubidium bromite, rubidium bromate, rubidium stannite, rubidium antimonite, rubidium tellurite, rubidium ferrocyanide, rubidium manganite, rubidium manganate, cesium nitrite, cesium phosphite, cesium sulfite, cesium hypochlorite, cesium chlorite, cesium chlorate, cesium selenite, cesium arsenite, cesium hypobromite, cesium bromite, cesium bromate, cesium stannite, cesium antimonite, cesium telurite, cessium ferrocyanide, cesium manganite, cesium manganate, ferrous ferrocyanide, ferrous ferricyanide, cuprous chloride, ferrous phosphate, stannous chloride, ferrous sulfate, manganous sulfate, plumbous sulfate, and chromous chloride.
Particularly useful are sodium, potassium, lithium, and ammonium salts of nitrite, bisulfite, and chlorite; especially useful is sodium nitrite. These optional salts may be employed in the range from 0.05% to about 2.0% by weight of the actual solution employed.
A chelating agent may be optionally employed in the broad-spectrum sterilant of the present invention from 0% to 0.025% by weight to aid in solubility of the other components, to counteract any deleterious effects from diluting concentrated commercial strengths with hard water for use, and to help break down the coatings of spores, which have a high concentration of multivalent ions. The preferred chelating agent to practice the current invention may range from 0% to 0.025% by weight and is ethylene diamine tetraacetic acid (EDTA). Partial esters or salts of EDTA may also be used. An example of a salt of EDTA is tetrasodium ethylenediamine tetraacetate.
Other useful chelating agents may be found in the following acids, full salts, or partial salts of: oxalic acid, malonic acid, oxaldihydrixamic acid, diaminoglyoxime, dithiomalonic acid, glyoxime, maleic acid, fumaric acid, oxalacetic acid, diglycolic acid, tartaric acid, oxalenediuramidoxime, thiodiglycolic acid, iminodiacetic acid, nitrilotriacetic acid, dimethylglyoxime, hydrazine-N,N'-diacetic acid, citraconic acid, itaconic acid, 2,4-pentanedione, glutaric acid, N-methyliminodi-acetic acid, glutamic acid, aconitric acid (trans), gluconic acid, 1,2-cyclohexanediamine-N,N,N'-tetraacetic acid (cis&trans), 1,2-ethylenediamine-N,N,N',N'-tetraacetic acid, N'-benzylethylene-diamine-N,N,N'-triacetic acid, diethylenetriamine-N,N,N',N",N"-pentaacetic acid, hexamethyldiamine-N,N,N',N'-tetraacetic acid, 2,2"-ethylenedioxybis(ethyliminodiacetic acid), 2,2'-oxybis (propyliminodiacetic acid), triethylenetetraminehexaacetic acid, 1,3,5-triaminocyclohexanehexaacetic acid, and ethyl acetoacetate.
A dialdehyde containing up to six carbon atoms is a component of the broad-spectrum sterilant of the present invention. Dialdehydes include malonaldehyde, succinaldehyde, oxaldehyde (glyoxal), adipaldehyde, and preferably glutaraldehyde. Alternatively, these compounds may be termed aliphatic dials, e.g. 1,5 pentanedial. By themselves, these compounds are effective germicides to some degree, at high pH, but they fail to have the wide breadth and speed of killing of the mixture of the current invention. This is especially true for the killing of the sporulent bacteria, where the dialdehydes alone can take up to ten hours to kill spores, and for many viruses, where dialdehydes are ineffective. In the final dilution as used, in the present invention, an effective amount of the dialdehyde is from about 0.5% to about 7% by weight. A concentration of dialdehyde of about 2.6 to 5 weight % is preferred and a concentration of dialdehyde of 3.2 weight % is especially preferred.
Some useful dialdehydes in the practice of the present invention are the following compounds and their mixtures: 1,2-ethanedial, 1,3-propanedial, 1,4-butanedial, 1,5-pentanedial, 2-methyl-1,4-butanedial, 2-methyl-1,3-propanedial, 2,2-dimethyl-1,3-propanedial, 2,3-dimethyl-1,4-butanedial, 2,2-dimethyl-1,4butanedial, 1,6 hexanedial, 2-methyl-1,5-pentanedial, 3-methyl-1,5-pentanedial, 2-ethyl-1,3-propanedial, and 2-n-propylpropanedial, some examples of heterocyclic dialdehydes are furan-2,5-dialdehyde, furan-3,4-dialdehyde, thiophene-2,5-dialdehyde, thiophene-3,4-dialdehyde, pyrrole-2,5-dialdehyde, pyrrole-3,4-dialdehyde, imidazole-4,5-dialdehyde, pyrazole-3,4-dialdehyde, 1,2,3-triazole-4,5-dialdehyde, pyrazine-2,3-dialdehyde, pyrimidine-4,5-dialdehyde, pyridazine-3,4-dialdehyde, pyridazine-4,5-dialdehyde. Aliphatic dialdehydes are preferred, but heterocyclic dialdehydes such as those named above may also be employed.
As a practical matter, it is preferred to produce the broad-spectrum sterilant of the present invention in the form of one or more concentrated solutions prior to transport and storage. The concentrations of these solutions would be 50 to 100-fold higher strength than the actual use-strengths given above. After transport and storage, the user, normally a medical or dental technician, will dilute the concentrate to produce an effective amount at the ultimate dilution and then add the dialdehyde.
In concentrated form, a preferred embodiment of the sterilant concentrate of the present invention would have the following approximate concentrations by weight:
______________________________________ Weight %______________________________________Alkyl*benzyldimethylammonium chloride 7*50% C-12, 30% C-14, 17% C-16, 3% C-18Cetyldimethylethylammonium bromide 7Isopropyl alcohol 14Propylene glycol 12Sodium nitrite 7EDTA 1.5Water, balance up to 100%______________________________________
In actual practice, the user will have prepared a desired quantity of the diluted sterilant concentrate by diluting the sterilant concentrate with distilled or tap water. This resulting solution will serve, further, as the diluent for the dialdehyde concentrate then to be added thereto.
The diluted sterilant solution after combination is an exceptionally broad-spectrum sterilant on a wide variety of metal, plastic, cross-linked resin, rubber, composite, coated, painted or natural wood, ceramic, or glass non-adsorbent surfaces, exemplified by but not limited to the following:
stainless steels (various), steels, not stainless (various), galvanized iron, copper, brass, aluminum, chromium plated metals, tinned plating metals, enameled metals, polyethylene, polypropylene, polystyrene, acrylics, polyacetals, nylons, "epoxy resin"-coated wood, polyurethane-coated wood, alkyd resin painted wood, alkyd resin-coated metal, oil-based painted wood, phenol-formaldehyde resin laminates ("Formica" type), polyvinyl chloride-based furniture surfaces ("Naugahyde" type), gum rubber surgical/dental adjuncts (dental dam, tubing, catheters, gloves), hard rubber devices (bite blocks), water-based, latex-painted wood, glazed porcelain and other ceramics and various types of glass such as lime, flint, and borosilicates.
The present invention will now be described by reference to the following examples, which are not to be deemed limitative of the present invention in any manner thereof.
EXAMPLE A
This example illustrates the preparation of an effective sterilizing amount of a final user solution of the sterilant composition of the invention.
A 15 ml ampule of the above sterilant concentrate was diluted with distiled water to a final volume of 1 liter. This was a dilution ratio of about 66.7:1. To this solution was added 50 ml of an aqueous 50% by weight solution of glutaraldehyde concentrate. On a weight basis, the concentration of glutaraldehyde will be about 2.6% in the final user solution.
Thus in the final user solution, the concentrations of the various components in the diluted sterilant will be as follows:
______________________________________ Wt. %______________________________________Alkylbenzyldimethylammonium chloride 0.1Cetyldimethylethylammonium bromide 0.1Isopropyl alcohol 0.2Propylene glycol 0.16Sodium nitrite 0.1EDTA 0.02Dialdehyde, esp. glutaraldehyde 2.6Water balance______________________________________
The diluted sterilant composition of the present invention may be employed over a wide, useful pH range from about pH 4 to about pH 9. The preferred range for use is from about pH 5 to about pH 8. This is in marked contrast to the use of alkalinized dialdehydes alone, which are effective only from about pH 7 to about pH 8.5. Although buffers may optionally be employed to keep the sterilant of the instant invention within a narrow pH range, no buffer is necessary to practice this invention.
EXAMPLE B
This example illustrates the preparation of an effective sterilizing amount of a final user solution of the sterilant composition of the invention.
A 15 ml ampule of the above sterilant concentrate was diluted with distilled water .to a final volume of 750 ml. This was a dilution ratio of about 50:1. To this solution was added 50 ml of an aqueous 50% by weight solution of glutaraldehyde concentrate. On a weight basis, the concentration of glutaraldehyde will be about 3.2% in the final user solution.
Thus, in the final user solution, the concentrations of the various components in the diluted sterilant will be as follows:
______________________________________ Wt. %______________________________________Alkylbenzyldimethylammonium chloride 0.15Cetyldimethylethylammonium bromide 0.15Isopropyl alcohol 0.25Propylene glycol 0.20Sodium nitrite 0.15EDTA 0.025Dialdehyde, esp. glutaraldehyde 3.2Water balance______________________________________
The diluted sterilant composition of the present invention may be employed over a wide, useful pH range from about pH 4 to about pH 9. The preferred range for use is from about pH 5 to about pH 8. This is in marked contrast to the use of alkalinized dialdehydes alone, which are effective only from about pH 7 to about pH 8.5. Although buffers may optionally be employed to keep the sterilant of the instant invention within a narrow pH range, no buffer is necessary to practice this invention.
EXAMPLE 1
This example illustrates the effectiveness of the sterilant composition of EXAMPLE A for nonsporulating bacteria.
The novel sterilant of the present invention was prepared with 400 ppm hard water as the diluent for test purposes:
______________________________________ Wt. %______________________________________Alkylbenzyldimethylammonium chloride 0.1Cetyldimethylethylammonium bromide 0.1Isopropyl alcohol 0.2Propylene glycol 0.16Sodium nitrite 0.11EDTA 0.02Glutaraldehyde 2.60Water balance______________________________________
Employing the Use-Dilution Method of the Association of Official Agricultural Chemists (AOAC) 60 ring carriers were tested on three batchs each for efficacy against the following organisms (US EPA Procedure DIS/TSS-1 and 2 of January 1982); Salmonella choleraesius ATCC 10708 (Gram-negative), Staphylococcus aureus ATCC 6538 (Gram-positive), and Pseudomonas aeruginosa ATCC 15442 (Gram-positive, nosocomial pathogen).
All these microorganisms were killed within 10 minutes at 20 degrees C.
EXAMPLE 2
This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing sporulating bacteria.
The novel sterilant solution was prepared as in EXAMPLE 1 for testing against Gram-positive, sporulating bacteria Bacillus subtilus ATCC 19659 and Clostridium sporogenes ATCC 3584 employing US EPA Procedure DIS/TSS-9 o f April 1981 (AOAC Sporicidal Test). Sixty carriers for each type of surface, porcelain penicylinders and silk suture loops, for each of three samples for each of three batches involved a total of 720 carriers.
As required, all microorganisms were killed on all carriers in about 5 hours, less than 6 hours at 20 degrees C.
In a similar test alkalinized glutaraldehyde can meet this standard only after 10 hours of contact.
EXAMPLE 3
This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing fungi and fungal spores.
The novel sterilant solution was prepared as in EXAMPLE 1 for testing against pathogenic fungus Trichophyton mentagrophytes ATCC 27289 according to the AOAC Fungicidal Test by EPA procedure DIS/TSS-6 of August 1981. For this fungus two batches were used for two samples each killing all organisms within 10 minutes at 20 degrees C.
EXAMPLE 4
This example illustrates the efficacy of the broad-spectrum sterilant of the present invention in killing viruses, some of which none of the components of the novel sterilant can kill individually under the same conditions.
The novel sterilant solution was prepared as in EXAMPLE 1 for testing against the following viruses: Herpes Simplex I and II, Coxsackie virus B1, Coxsackie virus A9, Vaccinia Virus, Influenza virus A, Adenos virus II, Poliovirus I, Rhino virus, Cytomegalo virus, and Corona virus, all according to EPA procedure DIS/TSSD-7. For two batches each, four replicates were carried by ten-fold dilution and measured to three-log diminution. After incubation, the samples were recovered after adsorption time on mammalian cell monolayers.
The novel sterilant inactivated all the viruses within 10 minutes at 20 degrees C. It is known that alkalinized glutaraldehyde fails to inactivate at least Coxsackie virus and Poliovirus I under these conditions.
EXAMPLE 5
This example illustrates the effectiveness of the sterilant composition of EXAMPLE B for nonsporulating bacteria.
The novel sterilant of the present invention was prepared with 400 ppm hard water as the diluent for test purposes:
______________________________________ Wt. %______________________________________Alkylbenzyldimethylammonium chloride 0.15Cetyldimethylethylammonium bromide 0.15Isopropyl alcohol 0.25Propylene glycol 0.20Sodium nitrite 0.15EDTA 0.025Glutaraldehyde 3.2Water balance______________________________________
Employing the Use-Dilution Method of the Association of Official Agricultural Chemists (AOAC) 60 ring carriers were tested on three batchs each for efficacy against the following organisms (US EPA Procedure DIS/TSS-1 and 2 of January 1982); Salmonella choleraesius ATCC 10708 (Gram-negative), Staphylococcus aureus ATCC 6538 (Gram-positive), and Pseudomonas aeruginosa ATCC 15442 (Gram-positive, nosocomial pathogen).
All these microorganisms were killed within 10 minutes at 20 degrees C.
EXAMPLE 6
This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing sporulating bacteria.
The novel sterilant solution was prepared as in EXAMPLE 5 for testing against Gram-positive, sporulating bacteria Bacillus subtilus ATCC 19659 and Clostridium sporogenes ATCC 3584 employing US EPA Procedure DIS/TSS-9 of April 1981 (AOAC Sporicidal Test) . Sixty carriers for each type of surface, porcelain penicylinders and silk suture loops, for each of three samples for each of three batches involved a total of 720 carriers.
As required, all microorganisms were killed on all carriers in about 5 hours, less than 6 hours at 20 degrees C.
In a similar test alkalinized glutaraldehyde can meet this standard only after 10 hours of contact.
EXAMPLE 7
This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing fungi and fungal spores.
The novel sterilant solution was prepared as in EXAMPLE 5 for testing against pathogenic fungus Trichophyton mentagrophytes ATCC 27289 according to the AOAC Fungicidal Test by EPA procedure DIS/TSS-6 of August 1981. For this fungus two batches were used for two samples each killing all organisms within 10 minutes at 20 degrees C.
EXAMPLE 8
This example illustrates the efficacy of the broad-spectrum sterilant of the present invention in killing viruses, some of which none of the components of the novel sterilant can kill individually under the same conditions.
The novel sterilant solution was prepared as in EXAMPLE 5 for testing against the following viruses: Herpes Simplex I and II, Coxsackie virus B1, Coxsackie virus A9, Vaccinia Virus, Influenza virus A, Adenos virus II , Poliovirus I, Rhino virus, Cytomegalo virus, and Corona virus, all according to EPA procedure DIS/TSSD-7. For two batches each, four replicates were carried by ten-fold dilution and measured to three-log diminution. After incubation, the samples were recovered after adsorption time on mammalian cell monolayers.
The novel sterilant inactivated all the viruses within 10 minutes at 20 degrees C. It is known that alkalinized glutaraldehyde fails to inactivate at least Coxsackie virus and Poliovirus I under these conditions.
The sterilant composition of the present invention has the advantages of being effective to kill a broad spectrum of microorganisms very rapidly with low concentrations of the active ingredients. The sterilant composition as a combination of ingredients is more effective against several microorganisms together at the same time than would be possible by using each active ingredient separately against the combination of microorganisms.
The sterilants of the disclosure above exemplified by the preferred embodiments of the various Examples are effective against a wide variety of microorganisms such as those of Tables I through VII.
TABLE I______________________________________VIRUSES______________________________________ ADENOVIRUSES Avian adenovirus Types 1-10 Marble spleen disease virus Bovine adenovirus Types 1-8 Canine adenovirus Infectious canine hepatitis Human adenovirus Types 1-41 Mouse adenovirus Swine adenovirus Baboon adenovirus Chimpanzee adenovirus Simian adenovirus Types 1-39 ARENAVIRUSES Amapari Junin Latino Lymphocytic choriomeningitis Bolivian Hemorrhagic Fever Parana Pichinde virus Tacaribe virus Tamiami virus BUNYAVIRIDAE Anopheles Group Bunyamwera Super Group Bwamba Group California Group Capim Group Gamboa Group Guama Group Koongol Group Patois Group Simbu Group Tete Group Turlock Group Phleboviruses Nairoviruses Hantaviruses CALICIVIRUSES Feline conjunctivitis Feline picornavirus Feline stomatitis CORONAVIRUSES Calf diarrheal coronavirus Canine coronavirus Feline infectious peritonitis Hemagglutinating encephalomyelitis Human coronavirus Infectious bronchitis Mouse hepatitis virus Rabbit coronavirus Rat coronavirus Sialodacryoadenitis virus Transmissible gastroenteritis Turkey enteritis coronavirus FLAVIVIRUSES Banzi Bukalasa Bussuquara Cowbone ridge Dakar bat Dengue Types 1-4 Edge Hill Entebbe bat Ilheus Japanese encephalitis Kokobera Kyasanur Louping III Modoc Montana myotis leukoencephalitis Murray Valley encephalitis Ntaya Powassan Rio Bravo Russian spring-summer encephalitis Sepik Simian hemorrhagic fever St. Louis encephalitis Stratford Tenbusu Uganda S West Nile Yellow fever Zika EERPESVIRUSES Avian laryngotracheitis Duck enteritis Falcon herpesvirus Lake Victoria cormorant Marek's disease Parrot herpesvirus Pigeon herpesvirus Turkey herpesvirus Bovine herpesvirus Infectious bovine rhinotracheitis Canine herpesvirus Equine cytomegalovirus Equine herpesvirus Feline herpesvirus Feline rhinotracheitis virus Channel catfish Herpesvirus salmonis Guinea pig herpes-like virus Guinea pig salivary gland virus Guinea pig X virus Burkitt's lymphoma Cytomegalovirus Herpes simplex Types 1 & 2 Varicella Varicella-Zoster B Virus Hepatitis A,B & C virus Herpesvirus aotus Herpesvirus ateles Herpesvirus saguinus Herpesvirus saimiri Monkey cytomegalovirus Simian herpesvirus 2 & 3 Squirrel monkey cytomegalovirus Pseudorabies Caprine herpesvirus Frog Virus 4 Mouse Salivary Gland Virus Rabbit herpesvirus ORBIVIRUSES Bluetongue all types Changuinola Colorado tick fever Corriparta Epizootic hemorrhagic disease of deer Ieri Irituia Lebomba Tribec Wad Medani ORTHOMYXOVIRUSES Avian Influenza Horse Influenza A Human Influenza A, B & C Swine Influenza Thogoto PAPOVAVIRUSES Human polyoma Bovine papilloma Human papilloma JC virus K-virus Lymphotropic Papovavirus Papilloma Polyoma Simian Papovavirus SV-40 PARAMYXOVIRUSES Bluegill Bovine morbillivirus-like Bovine respiratory syncytial virus Canine distemper Canine parainfluenza Fer de Lance virus Measles Mumps Nariva Newcastle disease Parainfluenza Pneumonia virus of mice Respiratory syncytial Simian paramyxovirus Subacute sclerosing panencephalitis Yucaipa PARVOVIRUSES Adeno-associated virus Aleutian disease Avian adeno-associated Bovine parvovirus Canine parvovirus Feline paneukopenia Hemorrhagic encephalopathy Porcine parvovirus PICORNAVIRUSES Poliovirus 1, 2 & 3 Coxsackievirus, all types Echovirus, all types Enterovirus, all types Human rhinovirus, all types Avian encephalomyelitis Baboon enterovirus Bovine enterovirus, all types Bovine rhinovirus, all types Encephalomyocarditis Mouse encephalomyelitis Porcine enterovirus, all types Rat encephalomyelitis Simian picornavirus, all types POXVIRUSES Alastrim (Variola minor) Bovine papular stomatitis Canary pox Cotia Cowpox Embu Fibroma Fowlpox Milker's nodule virus Monkeypox Myxoma Rabbit fibroma Rabbitpox Raccoonpox Smallpox Swine pox Tanapox Vaccinia Yabu tumor poxvirus REOVIRUSES Avian reovirus, all types Feline reovirus Reovirus, all types Turkey enteric reovirus RETROVIRUSES Avian leukosis-sarcoma complex Avian reticuloendotheliosis group Feline leukemia group Murine leukemia-sarcoma group Bovine syncytial virus Caprine arthritis- encephalitis virus Feline syncytia-forming Human T-cell lukemia virus Human immunodeficiency virus Mouse mammary tumor Simian foamyvirus Squirrel monkey retrovirus Syncytium-forming virus of Marmosets Visna virus RHABDOVIRUSES Aruac Bovine paralytic rabies Chaco Chandipura Cocal virus Hart virus Infectious hematopoietic necrosis Jurona Kern Canyon Klamath Kwatta Lagos bat March Mokola Mossuril Mount Elgon bat Navorro Piry virus Rabies Sawgrass Timbo Vesicular stomatitis ROTAVIRUSES Bovine rotavirus Calf rotavirus Human rotavirus Porcine pararotavirus Porcine rotavirus Rhesus rotavirus Simian rotavirus TOGAVIRUSES Alphavirus group Pestiviruses Rubeviruses UNCLASSIFIED VIRUSES Anaplasma marginale Creutzfeldt-Jakob Duck hepatitis Eretmapodites Equine infectious anemia virus Frog virus 3 Golden shine virus Grunt fin agent Hepatitis A virus Hepatitis B virus Ichampadi Infectious bursal disease of chickens Infectious pancreatic necrosis of trout Infectious pancreatic necrosis virus Kuru Lymphocystis Matucare Nodamura virus Quaranfil Tadpole edema virus Tembe Venkatapuram Wanowrie PLANT VIRUSES Agropyron Mosaic Alfalfa Mosaic Apple Chlorotic Apple Mosaic Artichoke Latent Barley Stripe Mosaic Barley Yellow Dwarf Bean Common Mosaic Bean Golden Mosaic Bean Pod Mottle Bearded Iris Mosaic Beet Curly Top Beet Mosaic Beet Western Yellows Belladonna Mottle Bidens Mottle Broad Bean Broccoli Necrotic Carnation Mottle Cherry Leaf Rool Chrysanthemum Aspermy Citrange Stunt Cowpea Chlorotic Mottle Desmodium Yellow Mottle Elm Mosaic Glycine Mottle Grapevine Fanleaf Henbane Mosaic Lettuce Mosaic Lychnis Ringspot Maize rough Dwarf Myrobalan Latent Ringspot Nasturtium Ringspot Oat Blue Dwarf Onion Yellow Dwarf Pangola Stunt Panicum Mosaic Passionfruit Woodiness Peanut Stunt Plantago Mottle Poa Semilatent Pokeweed Mosaic Prunus Necrotic Ringspot Raspberry Bushy Dwarf Scophularia Mottle Tobacco Mosaic Tomato Aspermy Tulip Breaking Watermelon Mosaic White Clover Mosaic Wound Tumor______________________________________
TABLE II______________________________________MISCELLANEOUS ORGANISMS______________________________________ Chlamydia psittaci Chlamydia trachomatis Coxiella burneti Ehrlichia risticii Rickettsia akari Rickettsia canada Rickettsia conori Rickettsia montana Rickettsia mooseri Rickettsia prowazeki Rickettsia rickettsii Rickettsia sennetsu Rickettsia tsutsugamushi Rochalimaea quintana Rochalimaea vinsonii Thai tick typhus Wolbachia persica______________________________________
TABLE III______________________________________GRAM NEGATIVE BACTERIA______________________________________Acetobacter acet FlavobacteriumAcholeplasma laidlawii meningosepticumAchromobacter viscosus Francisella tularensisAcidiphilium cryptum Fusobacterium necrophorumAcinetobacter calcoaceticus Gardnerella vaginalisAcinetobacter anatratus Haemophilus aegyptiusAcinetobacter lwoffii Hafnia alveiActinomyces bovis Klegsiella oxytocaActinomyces israelii Klebsiella pneumoniaeActinomyces pyogenes Legionella cherriiActinoplanes violaceus Legionella feeleiAeromonas hydrophila Legionella pneumophilaAeromonas salmonicida Leptospira biflexaAgrobacterium tumefaciens Moraxella phenylpyruvicaAlcaligenes denitrificans Morganella morganiiAlcaligenes faecalis Mycoplasma canisAnaerorhabdus furcosus Mycoplasma hyorhinisAquaspirillum anulus Mycoplasma pneumoniaeArachnia propionica Neisseria gonorrhoeaArthrobacter ilicis Neisseria meningitidisAzotobacter beijerinckii Oligella urethralisBacteroides bivius Pasteurella multocidaBacteroides fragilis Proteus mirabilisBacteroides levii Proteus vulgarisBdellovibrio solpii Providencia rettgeriBeggiatoa alba Providencia rustigianiiBeijerinckia indica Providencia stuartiiBifidobacterium boum Pseudomonas aeruginosaBordetella bronchiseptica Pseudomonas avenaeBordetella pertussis Pseudomonas cepaciaBorrelia burgdorferi Pseudomonas pseudomalleiBrucella abortus Pseudomonas putidaCampylobacter coli Salmonella choleraesuisCampylobacter jejuni Salmonella typhiCampylobacter pylori Salmonella typhimuriumChlamydia psittaci Serratia liquefaciensChlamydia trachomatis Serratia marcescensChromobacterium violaceum Shigella boydiCitrobacter freundii Shigella dysenteriaeComamonas terrigena Shigella flexneriDeleya aesta Shigella sonneiDeleya venusta Thiobacillus thiooxidansDermatophilus congolensis Treponema hyodysenteriaeEdwardsiella tarda Treponema pallidumEikenella corrodens Ureaplasma galloraleEnterobacter aerogenes Veillonella caviaeEnterococcus avium Vibrio choleraeEnterococcus faecalis Wolinella succinogenesEnterobacter cloacae Xanthobacter flavusErwinia citreus Xanthomonas campestrisEscherichia coli Yersinia pestisEwingella americana Zymomonas mobiles______________________________________
TABLE IV______________________________________GRAM POSITIVE BACTERIA______________________________________Deinococcus erythromyxa Mycobacterium bovisDeinococcus proteolyticus Mycobacterium fortuitumErysipelothrix insidiosa MycobacteriumErysipelothrix rhusiopathiae intracellulareEubacterium aerofaciens Mycobacterium lepraeEubacterium angustum Mycobacterium tuberculosisEubacterium combesii Norcardia asteroidesEubacterium eligens Norcardia brasiliensisEubacterium fossor Paracoccus denitrificansJonesia denitrificans Pediococcus dextrinicusKurthia gibsonii PeptostreptococcusLactobacillus agilis asaccharolyticusLactobacillus brevis Peptostreptococcus microsLactobacillus buchneri Phormidium spLactobacillus carnis Planococcus citreusLactobacillus casei Propionibacterium acnesLactobacillus divergens PropionibacteriumLactobacillus helveticus freudenreichiiLactobacillus jensenii Rhodococcus equiLactobacillus kefir Rhodococcus erythropolisLactobacillus xylosis Sarcina maximaLactococcus garviae Stalphylococcus aureusLactococcus lactis Staphylococcus epidermidisLactococcus plantarum Staphylococcus hominisLeptothrix buccalis Staphylococcus warneriLeuconostoc lactis StomatococcusLeuconostoc mesenteroides mucilaginosusLeuconostoc oenos StreptobacillusListeria grayi moniliformisListeria innocua Streptococcus dysgalactiaeListeria monocytogenes Streptococcus equiMicrococcus agilis Streptococcus equisimilusMicrococcus cryophilus Streptococcus faecalisMicrococcus halobius Streptococcus pyogenesMicrococcus luteus Streptomyces albulusMycobacerium aurum Streptomyces vulgarisMycobacterium avium______________________________________
TABLE V______________________________________GRAM POSITIVE SPORE FORMING BACTERIA______________________________________Bacillus Clostridiumacidocaldarius acetobutylicumalcalophilus acidiuricialvei aerotoleransaminoglucosidicus barkerianeurinolyticus beijerinickiianthracis bifermentansbadius botulinumbrevis cadaveriscapitovalis carniscereus cellulolyticumchitinosporus chauvoeicirculans clostridiiformecirroflagellosus coccoidescoagulans collagenovoransepiphytus cylindrosporumfastidiosus difficilefilicolonicus durumfirmus flavumfreudenreichii formicoaceticumfructosus haemolyticumglobigii hastiformeglobisporus histolyticumgordonae indolisimplexus kaneboiinsolitus kluyverilaevolacticus lentoputrescenslarvae limosumlaterosporus lortetiilentimorbus perfringenslentus putrificumlicheniformis septicummegaterium sordelliimycoides sporogenespumilus tetanischlegelii tetanomorphumstearothermophilus thermocellumsubtilis thermolacticumthuringiensis tyrobutyricumxerothermodurans villosum______________________________________
TABLE VI______________________________________FUNGI______________________________________Absidia blakesleeana Entonaema liquescensAchaetomium luteum Epidermophyton floccosumAchlya hypogyna Filobasidiella neoformansAciculoconidium aculeatum Fonsecaea pedrosoiAcladium castellanii Fusarium solaniAcemoniella lutzi Geotrichum candidumAcrodontium salmoneum Gibberella baccataActinodendron verticillatum Gymnosporangium globosumActinomucor elegans Histoplasma capsulatumAcytostelium elipticum Kluyveromyces wickerhamiiAgaricus abruptibulbus Madurella mycetomiAgaricus campestris Melampsora medusaeAkenomyces costatus Microsporum canisAlternaria alternata Mucor hiemalisAlternaria citri Nectriella pironiiArmillaria limonea Neurospora tetraspermaArthrobotrys oligospora Paecilomyces lilacinusArthroderma benhamiae Penicillium aurantiogriseumArthroderma gypseum Phialophora richardsiaeArthroderma incurvatum Phycomyces nitensArticulospora tetracladia Pichia membranaefaciensAspergillus carneus Pityrosporium ovaleAspergillus fischeri Pseudallescheria boydiiAspergillus fumigatus Puccinis graminisAspergillus niger Pyrenophora trichostomaAureobasidium mansonii Rhizoctonia repensBasidiobolus haptosporus Rhizomucor pusillusBlastobotrys aristata Rhizopus microsporusBlastomyces dermatitidis Rhodotorula rubraBlastoschizomyces capitatus Rhynchosporium secalisBotrytis squamosa Saccharomyces cerevisiaeByssochlamys fulva Sclerotium rolfsiiCandida albicans Sporothrix schenckiiCandida tropicalis Sporotrichum thermophileCephalosporium deformans Stemphylium botryosumCeratocytis ulmi Torula thermophilaChaetomium globosum Torulopsis pintolopesiiChrysosporium pannorum Trichoderma polysporumCladosporium carpophilum Trichophyton mentagrophytesCladosporium resinae Trichophyton rubrumCoccidioides immitis Ulocladium botrytisCronartium fusiforme Uromyces phaseoliCryptococcus neoformans Verticillium nigrescensCurvularia prasadii Xylohypha bantianaDictyostelium discoideum Yarrowia lipolytica Zygosaccharomyces bailii______________________________________
TABLE VII______________________________________PROTISTS - ALGAE/PROTOZOA______________________________________Acanthamoeba astronyxis Leishmania hertigiA. castellanii Leishmania mexicanaA. culbertsoni Leishmania tropicaA. hatchetti Leptomonas pyrrhocorisA. lenticulata Lingulamoeba leeiA. polyphaga Lohomonas piriformisA. royreba Monocercomonas colubrorumBabesia microti Muriella aurantiacaBotrydium cystosum Naegleria australiensisCephaleuros virescens Naegleria fowleriChlamydomonas dorsoventralis Naegleria gruberiChlorella protothecoides Naegleria jadiniChlorella saccharophilia Nosema necatrixChlorella sorokiniana Ochromonas malhamensisChlorella variegata Paramecium primaureliaChlorella xanthella ParameciumChlorella zopfingiensis multimicronucleatumChlorogonium elongatum Pentatrichoimonas hominisCrithidia fasciculata Plasmodium brasilianumDientamoeba fragilis Plasmodium coatneyiDunaliella tertiolecta Plasmodium cynomolgiEntamoeba coli Plasmodium falciparumEntamoeba gingivalis Plasmodium vivaxEntamoeba histolytica Prototheca wickerhamiiEuglena gracilis Tetracystis disociataGiardia intestinalis Tetrahymena borealisGiardia lamblia Tetrahymena thermophilaHaematococcus lacustris Trichomonas gallinaeHartmannella limax Trichomonas vaginalisHerpetomonas mariadeanei Tritrichomonas foetusLeishmania braziliensis Trypanosoma bruceiLeishmania donovani Trypanosoma cruzi______________________________________ | A biocidal, aqueous composition for killing bacteria, spores, fungi, and viruses on nonabsorbent surfaces comprises at least one quaternary ammonium compound, at least one aliphatic dialdehyde having from two to six carbon atoms, and at least one aliphatic hydroxyl compound having form one to eight carbon atoms.
This sterilant is stable for weeks, is especially useful between pH 4 to 9, and may additionally comprise a chelating agent. | Briefly describe the main invention outlined in the provided context. | [
"RELATED U.S. APPLICATIONS This is a divisional application of Ser.",
"No. 08/164,627, filed Dec. 9, 1993, issued as U.S. Pat. No. 5,338,748 on Aug. 16, 1994, which is a continuation of application Ser.",
"No. 07/866,010, filed Apr. 9, 1992, now abandoned, which is a continuation of application Ser.",
"No. 758,400, filed Aug. 27, 1991, which has matured into U.S. Pat. No. 5,124,359, granted Jun. 23, 1992 which is a continuation-in-part of Ser.",
"No. 210,626 filed Jun. 23, 1988 which has matured into U.S. Pat. No. 4,923,899, granted May 8, 1990, which is a continuation-in-part of Ser.",
"No. 139,166 filed Dec. 22, 1987 now abandoned which is a continuation of Ser.",
"No. 906,557 filed Sep. 8, 1986 now abandoned which is a continuation of Ser.",
"No. 776,479 filed Sep. 16, 1985 now abandoned which is a continuation-in-part of Ser.",
"No. 692,776 filed Jan. 18, 1985 now abandoned.",
"FIELD OF THE INVENTION This invention relates to a broad-spectrum biocidal composition effective for the rapid killing of a wide variety of bacteria, spores, fungi, and viruses on a wide variety of nonabsorbent surfaces such as metals, plastics, resins, woods, rubbers, ceramics, and glasses.",
"The composition of the present invention kills so many organisms on such a wide variety of surfaces that it may be termed a sterilant.",
"Some of the articles which may be sterilized by the composition of the present invention are counters, floors, sheets, catheters, dialysis machine tubing, anesthetic breathing bags, surgical instruments, dental bite blocks, saliva-draining tubes, respirator equipment, and environmental surfaces in general.",
"BACKGROUND OF THE INVENTION In the past in medical and dental circles, steam sterilization or treatment with ethylene oxide in a closed apparatus have been considered ideal ways of sterilizing equipment.",
"But for many types or parts of apparatus, steam sterilization is impractical because of the size or number of items to be sterilized.",
"For parts of equipment which actually come in contact with the patient, such as dental bite blocks, anesthetic breathing bags, respirators, etc.",
"it is impermissible for ethylene oxide to be used because residual trace amounts might harm the patient.",
"Hence, a stable, benign, broad-spectrum sterilant effective at a wide range of pH's is greatly desired by the medical/dental profession for environmental use, especially on nonabsorbent surfaces.",
"A disinfectant is generally considered to be an agent which destroys bacterial organisms which are growing, but not bacterial spores.",
"Germicide and bactericide are approximately synonymous with disinfectant.",
"An antiseptic inhibits the growth of microorganisms.",
"A sporicide kills spores of fungi molds, and bacteria.",
"Since spores are more resistant than bacteria, sporicides are generally considered sterilizing agents.",
"Biocides kill all living microorganisms, hence also are sterilizing agents.",
"A virucide kills viruses;",
"a fungicide kills fungi.",
"The novel sterilant of this invention kills bacteria, spores, fungi and viruses.",
"Hence, it may be termed a biocide or a sterilant.",
"The Hamilton U.S. Pat. No. 3,208,936, discloses combining a broad range of quaternary amines as germicides and foaming agents in recirculation type toilets.",
"The Halley U.S. Pat. No. 3,785,971, is directed to a waste treatment material for a storage holding tank in which paraformaldehyde and an alkali carbonate or hydroxide are combined.",
"U.S. Pat. No. 2,998,390, granted August 29, 1961 to Hamilton and U.S. Pat. No. 3,107,216, granted Oct. 15, 1963 to Hamilton, disclose a recirculating toilet fluid which contains a quaternary ammonium salt.",
""Quaternary Ammonium Salts as Germicidals.",
"Nonacylated Quaternary Ammonium Salts Derived from Aliphatic Amines,"",
"Shelton , R. S. et al.",
", Journal of the American Chemical Society, vol.",
"68, pp. 753-55 (1946), reported that alkyl quaternary ammonium salts have germicidal powers and N-benzyl substitutes do not affect this germical activity.",
"It was reported in Gardner, J. Disinfection, Sterilization &",
"Preservation, p. 900, S. S. Block, ed.",
", Lea &",
"Febiger, 2nd ed.",
"(1977) to include chelating agents with phenols and certain quaternary ammonium salts for enhanced activity against Gram-negative bacteria.",
"The Schattner U.S. Pat. No. 4,103,001 discloses an aqueous mixture of phenol, sodium tetraborate, and sodium phenate solution to which is added aqueous glutaraldehyde in order to kill some bacteria and bacterial spores.",
"This mixture cannot be used against fungi or viruses.",
"The Stonehill U.S. Pat. No. 3,282,775 discloses a mixture of dialdehydes and a cationic surface active agent, plus a lower alcohol, which kills four spore-forming bacteria, but not fungi or viruses.",
"The Pepper U.S. Pat. No. 3,016,328 discloses that simple dialdehydes plus a lower alkanol to the extent of about 60 to 70% and an alkalinizing agent to yield a pH range of about 8 to 9.5 kill four spore-forming bacteria, two of which are the same as in U.S. Pat. No. 3,282,775.",
"Borick, et al in the Journal of Pharmaceutical Sciences, Vol. 53, No. 10 at p. 1273 disclose that glutaraldehyde alkalinized with sodium bicarbonate kills eight nonspore-forming bacteria, four spore-forming bacteria, one fungus, and nine viruses, but that this alkaline solution was stable only for about two weeks.",
"French Patent 2,321,300 discloses that a mixture of aldehyde and quaternary ammonium compound has antiseptic properties by reducing the growth of five bacteria of interest to the food industry.",
"British Patent 1,443,786 discloses that a mixture of glutaraldehyde, a lower alcohol, and a highly ionizable salt at acidic pH ranges kills four sporulating bacteria by ion-exchange with the calcium in the walls of the bacterial spores.",
"The Wagner U.S. Pat. No. 4,107,312 discloses a disinfectant mixture of a strong formaldehyde solution, plus minor amounts of glyoxal and glutaraldehyde, plus a quaternary ammonium salt, methanol to stabilize the formaldehyde, a nonionic wetting agent, optionally some alcohol or glycol, and a scent, all at a neutral pH in order to avoid corrosion of aluminum toilets (or minimize corrosion of magnesium toilets) in aircraft.",
"The Mandt U.S. Pat. No. 4,444,785 discloses a disinfecting solution for soft contact lenses against two nonsporulating bacteria comprising a very low concentration of 1,5 pentanedial at neutral pH compatible with the human eye.",
"The Schaeufele U.S. Pat. No. 4,320,147 discloses a germicidal composition comprising quaternary ammonium chlorides, plus builder salts, which are useful for disinfection against bacteria.",
"Canadian Patent No. 1,154,555 discloses a bactericide composition containing formaldehyde, glutaraldehyde and a quaternary ammonium ingredient.",
"French Patent No. 2,145,444 discloses a bactericide composition containing formaldehyde and a quaternary ammonium compound.",
"The Lockwood U.S. Pat. No. 3,505,690 relates to a disinfectant dispersing system.",
"The Buchalter U.S. Pat. No. 3,983,252 discloses a chemical disinfecting composition comprising a dialdehyde and an alkali metal salt of a hydrocarbon carboxylic acid and optionally an alcohol.",
"The Goldhaft U.S. Pat. No. 4,022,911 discloses a disinfectant composition comprising three essential active ingredients, namely a dimethyl quaternary ammonium halide salt, a phenol or derivative thereof, and formaldehyde.",
"Oshchepkova and Kochkin in the Proceedings of the First All-Union Conference on Biocorrosion, Biodamage, and Marine Encrustation (1975), C.A[.",
"].91:69799p report that a mixture of organotin fumarates or acryloyloxy stannate mixed with N-alkyl pyridinium salts or tetraalkylammonium salts protect wood samples in water from two common bacteria--A.",
"niger and P. purpureum.",
"OBJECTS OF THE INVENTION It is an object of this invention to provide a stable, benign, nonodorous, solution which kills a broad-spectrum of bacteria, spores, fungi, and viruses rapidly at a wide range of pH.",
"It is a further object of this invention to provide a broad-spectrum sterilant which will remain an active solution for at least several weeks.",
"It is yet another object of this invention to provide a sterilant which is effective on hard, nonabsorbent, "environmental"",
"surfaces such as anesthetic breathing bags, dialysis tubing, respirators, dental bite blocks, saliva-draining tubes, and the like for which sterilization by steam or ethylene oxide is either impractical or physiologically disfavored.",
"It is an object of the present invention to provide a sterilant composition effective for killing rapidly individual microorganisms or a combination of several different kinds of microorganisms, such as bacteria, spores, fungi and/or viruses.",
"Another object of the invention is to provide a sterilant for a wide variety of hard surfaces such as metals, plastics, resins, rubbers, ceramics, and glasses.",
"Yet another object of the present invention is to provide a sterilant which is effective in the presence of high concentrations of blood, sputum, feces, urine, vomitus, and other animal exudates.",
"Other objects of the present invention will be apparent to those skilled in the art.",
"SUMMARY OF THE INVENTION Surprisingly, a broad-spectrum sterilant capable of rapidly killing bacteria, sporulating bacteria, spores, fungi, and viruses can be achieved by combining in an aqueous solution an effective amount of at least one quaternary ammonium compound, at least one aliphatic dialdehyde having from two to six carbon atoms, and at least one aliphatic hydroxyl compound having from one to eight carbon atoms.",
"Another aspect of the invention relates to the use of the novel sterilant on "hard"",
"or "environmental"",
"surfaces (nonabsorbing) such as medical or dental equipment for which previously steam sterilization or treatment with ethylene oxide were employed.",
"The sterilant of the present invention relates to a liquid composition which is effective for rapidly killing at least one microorganism or any combination of two or more different microorganisms such as bacteria, spores, fungi and viruses.",
"For still another aspect of the invention, the novel sterilant is employed over a wide range of pH and is stable for several weeks after having been compounded.",
"Yet another aspect of the present invention arises from its efficacy in the presence of high concentrations of blood, sputum, urine, feces, vomitus or other bodily liquids or suspensions.",
"A further aspect of the present invention is its efficacy in sterilizing hard surfaces of metals, plastics, rubbers, resins, wood, ceramics, or glasses.",
"A typical embodiment of the invention comprises: ______________________________________Component Weight %______________________________________Alkylbenzyldimethylammonium chloride 0.1Cetyldimethylethylammonium bromide 0.1Glutaraldehyde 2.6Isopropyl alcohol 0.2Propylene glycol 0.16Sodium nitrite 0.11Tetrasodium ethylenediamine tetraacetate 0.015Water balance______________________________________ Processes for employing these sterilant compositions are also disclosed herein.",
"DETAILED DESCRIPTION OF THE INVENTION As discussed above, the prior art discloses individual compounds or mixtures of compounds which kill or inhibit the growth of a narrow range of organisms such as some bacteria, spores, fungi, or viruses.",
"The synergistic combination of the seven components of the present invention unexpectedly kills all types of the names organisms, hence it is a sterilant.",
"Among the classes of organisms killed by the composition of the present invention alone or admixed together are Gram-negative bacteria, Gram-positive bacteria, algae, protozoa, Gram-positive spore-forming bacteria, fungi, and many types of viruses.",
"Among the many typos of viruses killed by the composition of the present invention are: orbiviruses, orthomyxoviruses, papovaviruses, paramyxoviruses, parvoviruses, picornaviruses, poxviruses, coronaviruses, flaviviruses, herpesviruses, adenoviruses, arenaviruses, bynyaviridae, caliciviruses, reoviruses, retioviruses, rhabdoviruses, rotaviruses, togaviruses, and various unclassified viruses, plus plant viruses.",
"In addition to the bacteria, spores, protozoa, algae, fungi, and viruses categorized above, the composition of the present invention can kill alone or in combination with the other organisms typified above various miscellaneous organisms from the Chlamydia Coxiella, Ehrlichia, Rickettsia, Rochalimaea, Wolbachia, and Thai tick typhus.",
"It is to be emphasized that the composition of the present invention is a sterilant which can kill any or all of the types of organisms described here alone or in any combination.",
"At the end of the Examples of this specification and before the claims, several hundred representative specific organisms are listed in Tables I to VII on which the synergistic composition of the present invention is effective.",
"The cationic, quaternary salts useful in the present invention may contain either or both of aliphatic and aromatic moieties.",
"Although quaternary ammonium salts are preferred, cationic phosphonium, or sulfonium, or any other positive nonmetallic nuclei may be selected.",
"Some of the aliphatic or alicyclic substituents for the quaternary ions are alkyl groups containing one to 30 carbon atoms both linear and branched, alkoxy groups also containing one to 30 carbon atoms both linear and branched, alicyclic groups such as cyclohexyl and its alkylated or alkyloxylated derivatives, and halogenated alkyl, halogenated alicyclic, or halogenated alkyloxy derivatives.",
"Aromatic moieties, which may themselves be substituted by aliphatic, alicyclic, alkyloxy groups, useful as substituents for the quaternary cationic salts of the present invention are benzyl, tolyl, xylyl, naphthyl, pyridyl, benzal, quinolyl and the like.",
"More specifically, some aliphatic quaternary ammonium salts which are useful in the present invention are: tetramethyl ammonium halide, trimethylethyl ammonium halide, dimethyldiethyl ammonium halide, methyltriethyl ammonium halide, tetraethyl ammonium halide, cetyldimethylethyl ammonium halide, trimethyln-propyl ammonium halide, dimethyldin-propyl ammonium halide, methyltrin-propyl ammonium halide, tetran-propyl ammonium halide, methylethyln-propyln-butyl ammonium halide, ethyln-propyln-pentyl ammonium halide, trimethylallyl ammonium halide, dimethyldiallyl ammonium halide, methyltriallyl ammonium halide, tetraallyl ammonium halide, N,N,N,N',N',N'-hexaethyl-1,2-ethylene diammoniumhalide, N,N,N,N',N',N'-hexaethyl-1,4-butylene-diammonium halide, N,N,N'-dibenzyl-N,N,N',N', tetramethyl-1,2-ethylene diammonium halide, N,N'-di(4-chlorobenzyl)-N,N,N',N'-tetramethyl-1,2-ethylene diammonium halide, N,N,N'-tetraethyl-N,n"-dioctadecyl-1,2-ethylene diammonium halide, N,N,N',N'-tetraethyl-N,N'-dihexadecyl-1,4-butylene diammonium halide, octadecyltrimethyl ammonium halide, dioctadecyldimethyl ammonium halide, trioctadecylmethyl ammonium halide tetraoctadecyl ammonium halide, hexadecyltriethyl ammonium halide, hexadecyldimethylethyl ammonium halide, hexadecyldiethylmethyl ammonium halide, didecyldioctyl ammonium halide, didecyldihexyl ammonium halide, and hexyloctyldecyldodecyl ammonium halide.",
"Some representative useful quaternary ammonium salts containing an aromatic moiety include: benzylodecyldimethyl ammonium halide, o-tolyldodecyldimethyl ammonium halide, m-tolyldodecyldimethyl ammonium halide, p-tolyldodecyldimethyl ammonium halide, 2,3-xylyldodecyldimethyl ammonium halide, 2,4-xylydodecyldimethyl ammonium halide, 2,5-xylyldodecyldimethyl ammonium halide, 3,4-xylyldodecyldimethyl ammonium halide, 3,5-xylyldodecyldimethyl ammoniuim halide, 2-chlorobenzyldodecyldimethyl ammonium halide, 3-chlorobenzyldodecyldimethyl ammonium halide, 4-chlorobenzyldodecyldimethyl ammonium halide, 2,3-dichlorobenzyldodecyldimethyl ammonium halide, 2,4-dichlorobenzyldodecyldimethyl ammonium halide, 2,5-dichlorobenzyldodecyldimethyl ammonium halide, 2,6-dichlorobenzyldodecyldimethyl ammonium halide, 3,4-dichlorobenzyldodecyldimethyl ammonium halide, 3,5-dichlorobenzyldodecyldimethyl ammonium halide, 2-nitrobenzyldodecyldimethyl ammonium halide, 3-nitrobenzyldodecyldimethyl ammonium halide, 4-nitrobenzyldodecyldimethyl ammonium halide, 2,4-dinitrobenzyldodecyldimethyl ammonium halide, 3,5-dinitrobenzyldodecyldimethyl ammonium halide, 2-sulfobenzyldodecyldimethyl ammonium halide, 3-sulfobenzyldodecyldimethyl ammonium halide, 4-sulfobenzyldodecyldimethyl ammonium halide, 2-carboxybenzyldodecyldimethyl ammonium halide, 3-carboxybenzyldodecyldimethyl ammonium halide, 4-carboxybenzyldodecyldimethYl ammonium halide, benzylhexyldimethyl ammonium halide, benzyloctyldimethyl ammonium halide, benzyldecyldimethyl ammonium halide, benzyldodecyldimethyl ammonium halide, benzyltetradecyldimethyl ammonium halide, benzylhexadecyldimethyl ammonium halide, benzyloctadecyldimethyl ammonium halide.",
"Some representative, useful quaternary ammonium salts containing heterocyclic, aromatic moieties include: n-hexylpyridinium halide, n-octylpyridinium halide, n-decylpyridinium halide, n-dodecylpyridinium halide, n-tetradecylpyridinium halide, n-hexadecylpyridinium halide, n-hexyllutidinium halide, n-octyllutidinium halide, n-decyllutidinium halide, n-dodecyllutidinium halide, n-tetradecyllutidinium halide, n-hexadecyllutidinium halide, n-hexylpicolinium halide, n-octylpicolinium halide, n-decylpicolinium halide, n-dodecylpicolinium halide, n-tetradecylpicolinium halide, n-hexadecylpicolinium halide, n-hexylquinolinium halide, n-octylquinolinium halide, n-decylquinolinium halide, n-dodecylquinolinium halide, n-tetradecylquinolinium halide, n-hexadecylquinolinium halide, n-hexylisoquinolinium halide, n-octylisoquinolinium halide, n-decylisoquinolinium halide, n-dodecylisoquinolinium halide, n-tetradecylisoquinolinium halide, n-hexadecylisoquinolinium halide, n-hexylquinazolinium halide, n-octylquinazolinium halide, n-decylquinazolinium halide, n-dodecylquinazolinium halide, n-tetradecylquinazolinium halide, n-hexadecylquinazolinium halide, n-hexylquinoxalinium halide, n-octylquinoxalinium halide, n-decylquinoxalinium halide, n-dodecylquinoxalinium halide, n-tetradecylquinoxalinium halide, n-hexadecylquinoxalinium halide, n-hexylpyridopyridinium halide, n-octylpyridopyridinium halide, n-decylpyridopyridinium halide, n-dodecylpyridopyridinium halide, n-tetradecylpyridopyridininum halide, and n-hexadecylpyridopyridinium halide.",
"The preferred counter ions for the quaternary cationic salts are halides, especially chloride and bromide.",
"Particularly useful for practicing the present invention are alkylbenzyldimethyl ammonium chlorides, wherein the alkyl groups contain between 10 and 18 carbon atoms, and cetyldimethylethyl ammonium bromide.",
"The useful range of quaternary cationic salts in an effective amount of sterilant is from about 0 05% to 3% in actual use by weight.",
"Other counter ions, anions, useful in the practice of the present invention to neutralize the positive charge of the ammonium, phosphonium, sulfonium, or other positive moieties can be found in the following list bicarbonate, bisulfite, fluoride, borate, carbonate, nitrite, nitrate, phosphite, phosphate, sulfite, sulfate, chloride, hypochlorite, chlorite, chlorate, perchlorate, hydroxide, fluoborate, iodide, iodate, periodate, and bromate.",
"The solubility of the various solutes in the novel sterilant of the instant invention is improved by using small amounts of alkanols having from one to six carbon atoms and/or glycols having from two to four carbon atoms.",
"These alkanols and glycols also have concomitant and peripheral biocidal effect.",
"Especially useful alkanols are methanol, ethanol, and isopropyl alcohol.",
"Especially useful polyols are glycols such as ethylene glycol, propylene glycol, diethylene glycol, as well as glycerine.",
"In the diluted solution for actual use, the effective amount for the alkanol is from about 0.1% to 3% by weight, and the effective amount for the polyol or glycol is from about 0.1% to 3% by weight.",
"Other alcohols having eight or less carbon atoms useful in the practice of the present invention are: 1-propanol, 1-butanol, 2-butanol, 2-methyl-1-propanol, 2-methyl-2-propanol, 1-pentanol, 2-pentanol, 3-pentanol, 2-methyl-2-butanol, 2-methyl-3-butanol, 2-methyl-4-butanol, 2,2-dimethyl-1-propanol, 1-hexanol, 2-hexanol, 3-hexanol, 2,2-dimethyl-3-butanol, 2,2-dimethyl-4-butanol, 2,3-dimethyl-2-butanol, 2-methyl-1-pentanol, 2-methyl-2-pentanol, 2-methyl-3-pentanol, 2-methyl-4-pentanol, 2-methyl-5-pentanol, 3-methyl-1-pentanol, 3-methyl-2-pentanol, 3-methyl-3-pentanol, 2,2-diethyl-1-ethanol, 1-heptanol, 2-heptanol, 3-heptanol, 4-heptanol, 2,2,3-trimethyl-3-butanol, 2,3-dimethyl-3-pentanol, 2,4-dimethyl-3-pentanol, 3-ethyl-1-pentanol, 3-ethyl-2-pentanol, 3-ethyl-3-pentanol, 4-ethyl-1-pentanol, 4-ethyl-2-pentanol, 4-ethyl-3-pentanol, 2-ethyl-1-pentanol, 2-methyl-1-hexanol, 2-methyl-2-hexanol, 2-methyl-3-hexanol, 2-methyl-4-hexanol, 3-methyl-1-hexanol, 4-methyl-1-hexanol, 5-methyl-1-hexanol, 3-methyl-2-hexanol, 4-methyl-2-hexanol, 3-methyl-3-hexanol, 3-methyl-4-hexanol, 1-octanol, 2-octanol, 3-octanol, 4-octanol, 2-methyl-1-heptanol, 3-methyl-1-heptanol, 4-methyl-1-heptanol, 5-methyl-1-heptanol, 5-methyl-1-heptanol, 6-methyl-1-heptanol, 2-methyl-2-heptanol, 3-methyl-2-heptanol, 4-methyl-2-heptanol, 5-methyl-2-heptanol, 6-methyl-2-heptanol, 2-methyl-3-heptanol, 3-methyl-3-heptanol, 4-methyl-3-heptanol, 5-methyl-3-heptanol, 6-methyl-3-heptanol, 2-methyl-4-heptanol, 3-methyl-4-heptanol, 4-methyl-4-heptanol, 5-methyl-4-heptanol, 6-methyl-4-heptanol, 2,2-dimethyl-1-hexanol, 3,3-dimethyl-1-hexanol, 4,4-dimethyl-1-hexanol, 5,5 -dimethyl-1-hexanol, 2,3-dimethyl-1-hexanol, 2,4-dimethyl-1-hexanol, 2,5-dimethyl-1-hexanol, 3,4-dimethyl-1-hexanol, 3,5-dimethyl-1-hexanol, 2-ethyl-1-hexanol, 3-ethyl-1-hexanol, 4-ethyl-1-hexanol, and 5-ethyl-1-hexanol.",
"Other glycols having eight or less carbon atoms useful in the practice of the present invention are: 1,2-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 2-methyl-1,2-propanediol, 2,methyl-1,3-propanediol, 1,2-pentanediol, 1,3-pentanediol, 1,4-pentanediol, 1,5-pentanediol, 2-methyl-1,2-butanediol, 2-methyl-1,3-butanediol, 2-methyl-1,4-butanediol, 2-methyl-2,3-butanediol, 2-methyl-3,4-butanediol, 1,2-hexanediol, 1,3-hexanediol, 1,4-hexanediol, 1,5-hexanediol, 1,6hexanediol, 2-methyl-1,2-pentanediol, 2-methyl-1,3-pentanediol, 2-methyl-1,4-pentanediol, 2-methyl-1,5-pentanediol, 2-methyl-2,3-pentanediol, 2-methyl-2,3-pentanediol, 2-methyl-2,4-pentanediol, 2-methyl-2,5-pentanediol, 2-methyl-3,4-pentanediol, 2-methyl-3,5-pentanediol, 2-methyl-4,5-pentanediol, 2,3-dimethyl-1,2-butanediol, 2,3-dimethyl-1,3-butanediol, 2,3-dimethyl-1,4-butanediol, 2,3-dimethyl-2,3-butanediol.",
"Certain salts with anions at less than full oxidation state, such as nitrite, bisulfite, or chlorite, may be optionally employed in the novel sterilant solution of the instant invention to prevent corrosion, as well as for their biocidal activity.",
"Also useful in the practice of the present invention are cations wherein the metal oxidation state is lower than its chemically possible maximum.",
"Some useful compounds with less than full oxidation states are found in the following salts first some with reduced anions and then some salts with less oxidized cations, as follows: sodium phosphite, sodium sulfite, sodium hypochlorite, sodium chlorite, sodium chlorate, sodium selenite, sodium arsenite, sodium hypobromite, sodium bromite, sodium bromate, sodium stannite, sodium antimonite, sodium tellurite, sodium ferrocyanide, sodium manganite, sodium manganate, potassium phosphite, potassium, sulfite, potassium hypochorite, potassium chlorite, potassium chlorate, potassium selenite, potassium arsenite, potassium hypobromite, potassium bromite, potassium bromate, potassium stannite, potassium antimonite, potassium tellurite, potassium ferrocyanide, potassium manganite, potassium manganate, lithium phosphite, lithium sulfite, lithium hypochlorite, lithium chlorite, lithium chlorate, lithium selenite, lithium arsenite, lithium hypobromite, lithium bromite, lithium bromate, lithium stannite, lithium antimonite, lithium antimonite, lithium tellurite, lithium ferrocyanide, lithium manganite, lithium manganate, rubidium nitrite, rubidium phosphate, rubidium sulfite, rubidium hypochlorite, rubidium chlorite, rubidium chlorate, rubidium selenite, rubidium arsenite, rubidium hypobromite, rubidium bromite, rubidium bromate, rubidium stannite, rubidium antimonite, rubidium tellurite, rubidium ferrocyanide, rubidium manganite, rubidium manganate, cesium nitrite, cesium phosphite, cesium sulfite, cesium hypochlorite, cesium chlorite, cesium chlorate, cesium selenite, cesium arsenite, cesium hypobromite, cesium bromite, cesium bromate, cesium stannite, cesium antimonite, cesium telurite, cessium ferrocyanide, cesium manganite, cesium manganate, ferrous ferrocyanide, ferrous ferricyanide, cuprous chloride, ferrous phosphate, stannous chloride, ferrous sulfate, manganous sulfate, plumbous sulfate, and chromous chloride.",
"Particularly useful are sodium, potassium, lithium, and ammonium salts of nitrite, bisulfite, and chlorite;",
"especially useful is sodium nitrite.",
"These optional salts may be employed in the range from 0.05% to about 2.0% by weight of the actual solution employed.",
"A chelating agent may be optionally employed in the broad-spectrum sterilant of the present invention from 0% to 0.025% by weight to aid in solubility of the other components, to counteract any deleterious effects from diluting concentrated commercial strengths with hard water for use, and to help break down the coatings of spores, which have a high concentration of multivalent ions.",
"The preferred chelating agent to practice the current invention may range from 0% to 0.025% by weight and is ethylene diamine tetraacetic acid (EDTA).",
"Partial esters or salts of EDTA may also be used.",
"An example of a salt of EDTA is tetrasodium ethylenediamine tetraacetate.",
"Other useful chelating agents may be found in the following acids, full salts, or partial salts of: oxalic acid, malonic acid, oxaldihydrixamic acid, diaminoglyoxime, dithiomalonic acid, glyoxime, maleic acid, fumaric acid, oxalacetic acid, diglycolic acid, tartaric acid, oxalenediuramidoxime, thiodiglycolic acid, iminodiacetic acid, nitrilotriacetic acid, dimethylglyoxime, hydrazine-N,N'-diacetic acid, citraconic acid, itaconic acid, 2,4-pentanedione, glutaric acid, N-methyliminodi-acetic acid, glutamic acid, aconitric acid (trans), gluconic acid, 1,2-cyclohexanediamine-N,N,N'-tetraacetic acid (cis&trans), 1,2-ethylenediamine-N,N,N',N'-tetraacetic acid, N'-benzylethylene-diamine-N,N,N'-triacetic acid, diethylenetriamine-N,N,N',N",N"-pentaacetic acid, hexamethyldiamine-N,N,N',N'-tetraacetic acid, 2,2"-ethylenedioxybis(ethyliminodiacetic acid), 2,2'-oxybis (propyliminodiacetic acid), triethylenetetraminehexaacetic acid, 1,3,5-triaminocyclohexanehexaacetic acid, and ethyl acetoacetate.",
"A dialdehyde containing up to six carbon atoms is a component of the broad-spectrum sterilant of the present invention.",
"Dialdehydes include malonaldehyde, succinaldehyde, oxaldehyde (glyoxal), adipaldehyde, and preferably glutaraldehyde.",
"Alternatively, these compounds may be termed aliphatic dials, e.g. 1,5 pentanedial.",
"By themselves, these compounds are effective germicides to some degree, at high pH, but they fail to have the wide breadth and speed of killing of the mixture of the current invention.",
"This is especially true for the killing of the sporulent bacteria, where the dialdehydes alone can take up to ten hours to kill spores, and for many viruses, where dialdehydes are ineffective.",
"In the final dilution as used, in the present invention, an effective amount of the dialdehyde is from about 0.5% to about 7% by weight.",
"A concentration of dialdehyde of about 2.6 to 5 weight % is preferred and a concentration of dialdehyde of 3.2 weight % is especially preferred.",
"Some useful dialdehydes in the practice of the present invention are the following compounds and their mixtures: 1,2-ethanedial, 1,3-propanedial, 1,4-butanedial, 1,5-pentanedial, 2-methyl-1,4-butanedial, 2-methyl-1,3-propanedial, 2,2-dimethyl-1,3-propanedial, 2,3-dimethyl-1,4-butanedial, 2,2-dimethyl-1,4butanedial, 1,6 hexanedial, 2-methyl-1,5-pentanedial, 3-methyl-1,5-pentanedial, 2-ethyl-1,3-propanedial, and 2-n-propylpropanedial, some examples of heterocyclic dialdehydes are furan-2,5-dialdehyde, furan-3,4-dialdehyde, thiophene-2,5-dialdehyde, thiophene-3,4-dialdehyde, pyrrole-2,5-dialdehyde, pyrrole-3,4-dialdehyde, imidazole-4,5-dialdehyde, pyrazole-3,4-dialdehyde, 1,2,3-triazole-4,5-dialdehyde, pyrazine-2,3-dialdehyde, pyrimidine-4,5-dialdehyde, pyridazine-3,4-dialdehyde, pyridazine-4,5-dialdehyde.",
"Aliphatic dialdehydes are preferred, but heterocyclic dialdehydes such as those named above may also be employed.",
"As a practical matter, it is preferred to produce the broad-spectrum sterilant of the present invention in the form of one or more concentrated solutions prior to transport and storage.",
"The concentrations of these solutions would be 50 to 100-fold higher strength than the actual use-strengths given above.",
"After transport and storage, the user, normally a medical or dental technician, will dilute the concentrate to produce an effective amount at the ultimate dilution and then add the dialdehyde.",
"In concentrated form, a preferred embodiment of the sterilant concentrate of the present invention would have the following approximate concentrations by weight: ______________________________________ Weight %______________________________________Alkyl*benzyldimethylammonium chloride 7*50% C-12, 30% C-14, 17% C-16, 3% C-18Cetyldimethylethylammonium bromide 7Isopropyl alcohol 14Propylene glycol 12Sodium nitrite 7EDTA 1.5Water, balance up to 100%______________________________________ In actual practice, the user will have prepared a desired quantity of the diluted sterilant concentrate by diluting the sterilant concentrate with distilled or tap water.",
"This resulting solution will serve, further, as the diluent for the dialdehyde concentrate then to be added thereto.",
"The diluted sterilant solution after combination is an exceptionally broad-spectrum sterilant on a wide variety of metal, plastic, cross-linked resin, rubber, composite, coated, painted or natural wood, ceramic, or glass non-adsorbent surfaces, exemplified by but not limited to the following: stainless steels (various), steels, not stainless (various), galvanized iron, copper, brass, aluminum, chromium plated metals, tinned plating metals, enameled metals, polyethylene, polypropylene, polystyrene, acrylics, polyacetals, nylons, "epoxy resin"-coated wood, polyurethane-coated wood, alkyd resin painted wood, alkyd resin-coated metal, oil-based painted wood, phenol-formaldehyde resin laminates ("Formica"",
"type), polyvinyl chloride-based furniture surfaces ("Naugahyde"",
"type), gum rubber surgical/dental adjuncts (dental dam, tubing, catheters, gloves), hard rubber devices (bite blocks), water-based, latex-painted wood, glazed porcelain and other ceramics and various types of glass such as lime, flint, and borosilicates.",
"The present invention will now be described by reference to the following examples, which are not to be deemed limitative of the present invention in any manner thereof.",
"EXAMPLE A This example illustrates the preparation of an effective sterilizing amount of a final user solution of the sterilant composition of the invention.",
"A 15 ml ampule of the above sterilant concentrate was diluted with distiled water to a final volume of 1 liter.",
"This was a dilution ratio of about 66.7:1.",
"To this solution was added 50 ml of an aqueous 50% by weight solution of glutaraldehyde concentrate.",
"On a weight basis, the concentration of glutaraldehyde will be about 2.6% in the final user solution.",
"Thus in the final user solution, the concentrations of the various components in the diluted sterilant will be as follows: ______________________________________ Wt.",
"%______________________________________Alkylbenzyldimethylammonium chloride 0.1Cetyldimethylethylammonium bromide 0.1Isopropyl alcohol 0.2Propylene glycol 0.16Sodium nitrite 0.1EDTA 0.02Dialdehyde, esp.",
"glutaraldehyde 2.6Water balance______________________________________ The diluted sterilant composition of the present invention may be employed over a wide, useful pH range from about pH 4 to about pH 9.",
"The preferred range for use is from about pH 5 to about pH 8.",
"This is in marked contrast to the use of alkalinized dialdehydes alone, which are effective only from about pH 7 to about pH 8.5.",
"Although buffers may optionally be employed to keep the sterilant of the instant invention within a narrow pH range, no buffer is necessary to practice this invention.",
"EXAMPLE B This example illustrates the preparation of an effective sterilizing amount of a final user solution of the sterilant composition of the invention.",
"A 15 ml ampule of the above sterilant concentrate was diluted with distilled water .",
"to a final volume of 750 ml.",
"This was a dilution ratio of about 50:1.",
"To this solution was added 50 ml of an aqueous 50% by weight solution of glutaraldehyde concentrate.",
"On a weight basis, the concentration of glutaraldehyde will be about 3.2% in the final user solution.",
"Thus, in the final user solution, the concentrations of the various components in the diluted sterilant will be as follows: ______________________________________ Wt.",
"%______________________________________Alkylbenzyldimethylammonium chloride 0.15Cetyldimethylethylammonium bromide 0.15Isopropyl alcohol 0.25Propylene glycol 0.20Sodium nitrite 0.15EDTA 0.025Dialdehyde, esp.",
"glutaraldehyde 3.2Water balance______________________________________ The diluted sterilant composition of the present invention may be employed over a wide, useful pH range from about pH 4 to about pH 9.",
"The preferred range for use is from about pH 5 to about pH 8.",
"This is in marked contrast to the use of alkalinized dialdehydes alone, which are effective only from about pH 7 to about pH 8.5.",
"Although buffers may optionally be employed to keep the sterilant of the instant invention within a narrow pH range, no buffer is necessary to practice this invention.",
"EXAMPLE 1 This example illustrates the effectiveness of the sterilant composition of EXAMPLE A for nonsporulating bacteria.",
"The novel sterilant of the present invention was prepared with 400 ppm hard water as the diluent for test purposes: ______________________________________ Wt.",
"%______________________________________Alkylbenzyldimethylammonium chloride 0.1Cetyldimethylethylammonium bromide 0.1Isopropyl alcohol 0.2Propylene glycol 0.16Sodium nitrite 0.11EDTA 0.02Glutaraldehyde 2.60Water balance______________________________________ Employing the Use-Dilution Method of the Association of Official Agricultural Chemists (AOAC) 60 ring carriers were tested on three batchs each for efficacy against the following organisms (US EPA Procedure DIS/TSS-1 and 2 of January 1982);",
"Salmonella choleraesius ATCC 10708 (Gram-negative), Staphylococcus aureus ATCC 6538 (Gram-positive), and Pseudomonas aeruginosa ATCC 15442 (Gram-positive, nosocomial pathogen).",
"All these microorganisms were killed within 10 minutes at 20 degrees C. EXAMPLE 2 This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing sporulating bacteria.",
"The novel sterilant solution was prepared as in EXAMPLE 1 for testing against Gram-positive, sporulating bacteria Bacillus subtilus ATCC 19659 and Clostridium sporogenes ATCC 3584 employing US EPA Procedure DIS/TSS-9 o f April 1981 (AOAC Sporicidal Test).",
"Sixty carriers for each type of surface, porcelain penicylinders and silk suture loops, for each of three samples for each of three batches involved a total of 720 carriers.",
"As required, all microorganisms were killed on all carriers in about 5 hours, less than 6 hours at 20 degrees C. In a similar test alkalinized glutaraldehyde can meet this standard only after 10 hours of contact.",
"EXAMPLE 3 This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing fungi and fungal spores.",
"The novel sterilant solution was prepared as in EXAMPLE 1 for testing against pathogenic fungus Trichophyton mentagrophytes ATCC 27289 according to the AOAC Fungicidal Test by EPA procedure DIS/TSS-6 of August 1981.",
"For this fungus two batches were used for two samples each killing all organisms within 10 minutes at 20 degrees C. EXAMPLE 4 This example illustrates the efficacy of the broad-spectrum sterilant of the present invention in killing viruses, some of which none of the components of the novel sterilant can kill individually under the same conditions.",
"The novel sterilant solution was prepared as in EXAMPLE 1 for testing against the following viruses: Herpes Simplex I and II, Coxsackie virus B1, Coxsackie virus A9, Vaccinia Virus, Influenza virus A, Adenos virus II, Poliovirus I, Rhino virus, Cytomegalo virus, and Corona virus, all according to EPA procedure DIS/TSSD-7.",
"For two batches each, four replicates were carried by ten-fold dilution and measured to three-log diminution.",
"After incubation, the samples were recovered after adsorption time on mammalian cell monolayers.",
"The novel sterilant inactivated all the viruses within 10 minutes at 20 degrees C. It is known that alkalinized glutaraldehyde fails to inactivate at least Coxsackie virus and Poliovirus I under these conditions.",
"EXAMPLE 5 This example illustrates the effectiveness of the sterilant composition of EXAMPLE B for nonsporulating bacteria.",
"The novel sterilant of the present invention was prepared with 400 ppm hard water as the diluent for test purposes: ______________________________________ Wt.",
"%______________________________________Alkylbenzyldimethylammonium chloride 0.15Cetyldimethylethylammonium bromide 0.15Isopropyl alcohol 0.25Propylene glycol 0.20Sodium nitrite 0.15EDTA 0.025Glutaraldehyde 3.2Water balance______________________________________ Employing the Use-Dilution Method of the Association of Official Agricultural Chemists (AOAC) 60 ring carriers were tested on three batchs each for efficacy against the following organisms (US EPA Procedure DIS/TSS-1 and 2 of January 1982);",
"Salmonella choleraesius ATCC 10708 (Gram-negative), Staphylococcus aureus ATCC 6538 (Gram-positive), and Pseudomonas aeruginosa ATCC 15442 (Gram-positive, nosocomial pathogen).",
"All these microorganisms were killed within 10 minutes at 20 degrees C. EXAMPLE 6 This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing sporulating bacteria.",
"The novel sterilant solution was prepared as in EXAMPLE 5 for testing against Gram-positive, sporulating bacteria Bacillus subtilus ATCC 19659 and Clostridium sporogenes ATCC 3584 employing US EPA Procedure DIS/TSS-9 of April 1981 (AOAC Sporicidal Test) .",
"Sixty carriers for each type of surface, porcelain penicylinders and silk suture loops, for each of three samples for each of three batches involved a total of 720 carriers.",
"As required, all microorganisms were killed on all carriers in about 5 hours, less than 6 hours at 20 degrees C. In a similar test alkalinized glutaraldehyde can meet this standard only after 10 hours of contact.",
"EXAMPLE 7 This example illustrates the efficacy of the broad-spectrum sterilant of the present invention for killing fungi and fungal spores.",
"The novel sterilant solution was prepared as in EXAMPLE 5 for testing against pathogenic fungus Trichophyton mentagrophytes ATCC 27289 according to the AOAC Fungicidal Test by EPA procedure DIS/TSS-6 of August 1981.",
"For this fungus two batches were used for two samples each killing all organisms within 10 minutes at 20 degrees C. EXAMPLE 8 This example illustrates the efficacy of the broad-spectrum sterilant of the present invention in killing viruses, some of which none of the components of the novel sterilant can kill individually under the same conditions.",
"The novel sterilant solution was prepared as in EXAMPLE 5 for testing against the following viruses: Herpes Simplex I and II, Coxsackie virus B1, Coxsackie virus A9, Vaccinia Virus, Influenza virus A, Adenos virus II , Poliovirus I, Rhino virus, Cytomegalo virus, and Corona virus, all according to EPA procedure DIS/TSSD-7.",
"For two batches each, four replicates were carried by ten-fold dilution and measured to three-log diminution.",
"After incubation, the samples were recovered after adsorption time on mammalian cell monolayers.",
"The novel sterilant inactivated all the viruses within 10 minutes at 20 degrees C. It is known that alkalinized glutaraldehyde fails to inactivate at least Coxsackie virus and Poliovirus I under these conditions.",
"The sterilant composition of the present invention has the advantages of being effective to kill a broad spectrum of microorganisms very rapidly with low concentrations of the active ingredients.",
"The sterilant composition as a combination of ingredients is more effective against several microorganisms together at the same time than would be possible by using each active ingredient separately against the combination of microorganisms.",
"The sterilants of the disclosure above exemplified by the preferred embodiments of the various Examples are effective against a wide variety of microorganisms such as those of Tables I through VII.",
"TABLE I______________________________________VIRUSES______________________________________ ADENOVIRUSES Avian adenovirus Types 1-10 Marble spleen disease virus Bovine adenovirus Types 1-8 Canine adenovirus Infectious canine hepatitis Human adenovirus Types 1-41 Mouse adenovirus Swine adenovirus Baboon adenovirus Chimpanzee adenovirus Simian adenovirus Types 1-39 ARENAVIRUSES Amapari Junin Latino Lymphocytic choriomeningitis Bolivian Hemorrhagic Fever Parana Pichinde virus Tacaribe virus Tamiami virus BUNYAVIRIDAE Anopheles Group Bunyamwera Super Group Bwamba Group California Group Capim Group Gamboa Group Guama Group Koongol Group Patois Group Simbu Group Tete Group Turlock Group Phleboviruses Nairoviruses Hantaviruses CALICIVIRUSES Feline conjunctivitis Feline picornavirus Feline stomatitis CORONAVIRUSES Calf diarrheal coronavirus Canine coronavirus Feline infectious peritonitis Hemagglutinating encephalomyelitis Human coronavirus Infectious bronchitis Mouse hepatitis virus Rabbit coronavirus Rat coronavirus Sialodacryoadenitis virus Transmissible gastroenteritis Turkey enteritis coronavirus FLAVIVIRUSES Banzi Bukalasa Bussuquara Cowbone ridge Dakar bat Dengue Types 1-4 Edge Hill Entebbe bat Ilheus Japanese encephalitis Kokobera Kyasanur Louping III Modoc Montana myotis leukoencephalitis Murray Valley encephalitis Ntaya Powassan Rio Bravo Russian spring-summer encephalitis Sepik Simian hemorrhagic fever St. Louis encephalitis Stratford Tenbusu Uganda S West Nile Yellow fever Zika EERPESVIRUSES Avian laryngotracheitis Duck enteritis Falcon herpesvirus Lake Victoria cormorant Marek's disease Parrot herpesvirus Pigeon herpesvirus Turkey herpesvirus Bovine herpesvirus Infectious bovine rhinotracheitis Canine herpesvirus Equine cytomegalovirus Equine herpesvirus Feline herpesvirus Feline rhinotracheitis virus Channel catfish Herpesvirus salmonis Guinea pig herpes-like virus Guinea pig salivary gland virus Guinea pig X virus Burkitt's lymphoma Cytomegalovirus Herpes simplex Types 1 &",
"2 Varicella Varicella-Zoster B Virus Hepatitis A,B &",
"C virus Herpesvirus aotus Herpesvirus ateles Herpesvirus saguinus Herpesvirus saimiri Monkey cytomegalovirus Simian herpesvirus 2 &",
"3 Squirrel monkey cytomegalovirus Pseudorabies Caprine herpesvirus Frog Virus 4 Mouse Salivary Gland Virus Rabbit herpesvirus ORBIVIRUSES Bluetongue all types Changuinola Colorado tick fever Corriparta Epizootic hemorrhagic disease of deer Ieri Irituia Lebomba Tribec Wad Medani ORTHOMYXOVIRUSES Avian Influenza Horse Influenza A Human Influenza A, B &",
"C Swine Influenza Thogoto PAPOVAVIRUSES Human polyoma Bovine papilloma Human papilloma JC virus K-virus Lymphotropic Papovavirus Papilloma Polyoma Simian Papovavirus SV-40 PARAMYXOVIRUSES Bluegill Bovine morbillivirus-like Bovine respiratory syncytial virus Canine distemper Canine parainfluenza Fer de Lance virus Measles Mumps Nariva Newcastle disease Parainfluenza Pneumonia virus of mice Respiratory syncytial Simian paramyxovirus Subacute sclerosing panencephalitis Yucaipa PARVOVIRUSES Adeno-associated virus Aleutian disease Avian adeno-associated Bovine parvovirus Canine parvovirus Feline paneukopenia Hemorrhagic encephalopathy Porcine parvovirus PICORNAVIRUSES Poliovirus 1, 2 &",
"3 Coxsackievirus, all types Echovirus, all types Enterovirus, all types Human rhinovirus, all types Avian encephalomyelitis Baboon enterovirus Bovine enterovirus, all types Bovine rhinovirus, all types Encephalomyocarditis Mouse encephalomyelitis Porcine enterovirus, all types Rat encephalomyelitis Simian picornavirus, all types POXVIRUSES Alastrim (Variola minor) Bovine papular stomatitis Canary pox Cotia Cowpox Embu Fibroma Fowlpox Milker's nodule virus Monkeypox Myxoma Rabbit fibroma Rabbitpox Raccoonpox Smallpox Swine pox Tanapox Vaccinia Yabu tumor poxvirus REOVIRUSES Avian reovirus, all types Feline reovirus Reovirus, all types Turkey enteric reovirus RETROVIRUSES Avian leukosis-sarcoma complex Avian reticuloendotheliosis group Feline leukemia group Murine leukemia-sarcoma group Bovine syncytial virus Caprine arthritis- encephalitis virus Feline syncytia-forming Human T-cell lukemia virus Human immunodeficiency virus Mouse mammary tumor Simian foamyvirus Squirrel monkey retrovirus Syncytium-forming virus of Marmosets Visna virus RHABDOVIRUSES Aruac Bovine paralytic rabies Chaco Chandipura Cocal virus Hart virus Infectious hematopoietic necrosis Jurona Kern Canyon Klamath Kwatta Lagos bat March Mokola Mossuril Mount Elgon bat Navorro Piry virus Rabies Sawgrass Timbo Vesicular stomatitis ROTAVIRUSES Bovine rotavirus Calf rotavirus Human rotavirus Porcine pararotavirus Porcine rotavirus Rhesus rotavirus Simian rotavirus TOGAVIRUSES Alphavirus group Pestiviruses Rubeviruses UNCLASSIFIED VIRUSES Anaplasma marginale Creutzfeldt-Jakob Duck hepatitis Eretmapodites Equine infectious anemia virus Frog virus 3 Golden shine virus Grunt fin agent Hepatitis A virus Hepatitis B virus Ichampadi Infectious bursal disease of chickens Infectious pancreatic necrosis of trout Infectious pancreatic necrosis virus Kuru Lymphocystis Matucare Nodamura virus Quaranfil Tadpole edema virus Tembe Venkatapuram Wanowrie PLANT VIRUSES Agropyron Mosaic Alfalfa Mosaic Apple Chlorotic Apple Mosaic Artichoke Latent Barley Stripe Mosaic Barley Yellow Dwarf Bean Common Mosaic Bean Golden Mosaic Bean Pod Mottle Bearded Iris Mosaic Beet Curly Top Beet Mosaic Beet Western Yellows Belladonna Mottle Bidens Mottle Broad Bean Broccoli Necrotic Carnation Mottle Cherry Leaf Rool Chrysanthemum Aspermy Citrange Stunt Cowpea Chlorotic Mottle Desmodium Yellow Mottle Elm Mosaic Glycine Mottle Grapevine Fanleaf Henbane Mosaic Lettuce Mosaic Lychnis Ringspot Maize rough Dwarf Myrobalan Latent Ringspot Nasturtium Ringspot Oat Blue Dwarf Onion Yellow Dwarf Pangola Stunt Panicum Mosaic Passionfruit Woodiness Peanut Stunt Plantago Mottle Poa Semilatent Pokeweed Mosaic Prunus Necrotic Ringspot Raspberry Bushy Dwarf Scophularia Mottle Tobacco Mosaic Tomato Aspermy Tulip Breaking Watermelon Mosaic White Clover Mosaic Wound Tumor______________________________________ TABLE II______________________________________MISCELLANEOUS ORGANISMS______________________________________ Chlamydia psittaci Chlamydia trachomatis Coxiella burneti Ehrlichia risticii Rickettsia akari Rickettsia canada Rickettsia conori Rickettsia montana Rickettsia mooseri Rickettsia prowazeki Rickettsia rickettsii Rickettsia sennetsu Rickettsia tsutsugamushi Rochalimaea quintana Rochalimaea vinsonii Thai tick typhus Wolbachia persica______________________________________ TABLE III______________________________________GRAM NEGATIVE BACTERIA______________________________________Acetobacter acet FlavobacteriumAcholeplasma laidlawii meningosepticumAchromobacter viscosus Francisella tularensisAcidiphilium cryptum Fusobacterium necrophorumAcinetobacter calcoaceticus Gardnerella vaginalisAcinetobacter anatratus Haemophilus aegyptiusAcinetobacter lwoffii Hafnia alveiActinomyces bovis Klegsiella oxytocaActinomyces israelii Klebsiella pneumoniaeActinomyces pyogenes Legionella cherriiActinoplanes violaceus Legionella feeleiAeromonas hydrophila Legionella pneumophilaAeromonas salmonicida Leptospira biflexaAgrobacterium tumefaciens Moraxella phenylpyruvicaAlcaligenes denitrificans Morganella morganiiAlcaligenes faecalis Mycoplasma canisAnaerorhabdus furcosus Mycoplasma hyorhinisAquaspirillum anulus Mycoplasma pneumoniaeArachnia propionica Neisseria gonorrhoeaArthrobacter ilicis Neisseria meningitidisAzotobacter beijerinckii Oligella urethralisBacteroides bivius Pasteurella multocidaBacteroides fragilis Proteus mirabilisBacteroides levii Proteus vulgarisBdellovibrio solpii Providencia rettgeriBeggiatoa alba Providencia rustigianiiBeijerinckia indica Providencia stuartiiBifidobacterium boum Pseudomonas aeruginosaBordetella bronchiseptica Pseudomonas avenaeBordetella pertussis Pseudomonas cepaciaBorrelia burgdorferi Pseudomonas pseudomalleiBrucella abortus Pseudomonas putidaCampylobacter coli Salmonella choleraesuisCampylobacter jejuni Salmonella typhiCampylobacter pylori Salmonella typhimuriumChlamydia psittaci Serratia liquefaciensChlamydia trachomatis Serratia marcescensChromobacterium violaceum Shigella boydiCitrobacter freundii Shigella dysenteriaeComamonas terrigena Shigella flexneriDeleya aesta Shigella sonneiDeleya venusta Thiobacillus thiooxidansDermatophilus congolensis Treponema hyodysenteriaeEdwardsiella tarda Treponema pallidumEikenella corrodens Ureaplasma galloraleEnterobacter aerogenes Veillonella caviaeEnterococcus avium Vibrio choleraeEnterococcus faecalis Wolinella succinogenesEnterobacter cloacae Xanthobacter flavusErwinia citreus Xanthomonas campestrisEscherichia coli Yersinia pestisEwingella americana Zymomonas mobiles______________________________________ TABLE IV______________________________________GRAM POSITIVE BACTERIA______________________________________Deinococcus erythromyxa Mycobacterium bovisDeinococcus proteolyticus Mycobacterium fortuitumErysipelothrix insidiosa MycobacteriumErysipelothrix rhusiopathiae intracellulareEubacterium aerofaciens Mycobacterium lepraeEubacterium angustum Mycobacterium tuberculosisEubacterium combesii Norcardia asteroidesEubacterium eligens Norcardia brasiliensisEubacterium fossor Paracoccus denitrificansJonesia denitrificans Pediococcus dextrinicusKurthia gibsonii PeptostreptococcusLactobacillus agilis asaccharolyticusLactobacillus brevis Peptostreptococcus microsLactobacillus buchneri Phormidium spLactobacillus carnis Planococcus citreusLactobacillus casei Propionibacterium acnesLactobacillus divergens PropionibacteriumLactobacillus helveticus freudenreichiiLactobacillus jensenii Rhodococcus equiLactobacillus kefir Rhodococcus erythropolisLactobacillus xylosis Sarcina maximaLactococcus garviae Stalphylococcus aureusLactococcus lactis Staphylococcus epidermidisLactococcus plantarum Staphylococcus hominisLeptothrix buccalis Staphylococcus warneriLeuconostoc lactis StomatococcusLeuconostoc mesenteroides mucilaginosusLeuconostoc oenos StreptobacillusListeria grayi moniliformisListeria innocua Streptococcus dysgalactiaeListeria monocytogenes Streptococcus equiMicrococcus agilis Streptococcus equisimilusMicrococcus cryophilus Streptococcus faecalisMicrococcus halobius Streptococcus pyogenesMicrococcus luteus Streptomyces albulusMycobacerium aurum Streptomyces vulgarisMycobacterium avium______________________________________ TABLE V______________________________________GRAM POSITIVE SPORE FORMING BACTERIA______________________________________Bacillus Clostridiumacidocaldarius acetobutylicumalcalophilus acidiuricialvei aerotoleransaminoglucosidicus barkerianeurinolyticus beijerinickiianthracis bifermentansbadius botulinumbrevis cadaveriscapitovalis carniscereus cellulolyticumchitinosporus chauvoeicirculans clostridiiformecirroflagellosus coccoidescoagulans collagenovoransepiphytus cylindrosporumfastidiosus difficilefilicolonicus durumfirmus flavumfreudenreichii formicoaceticumfructosus haemolyticumglobigii hastiformeglobisporus histolyticumgordonae indolisimplexus kaneboiinsolitus kluyverilaevolacticus lentoputrescenslarvae limosumlaterosporus lortetiilentimorbus perfringenslentus putrificumlicheniformis septicummegaterium sordelliimycoides sporogenespumilus tetanischlegelii tetanomorphumstearothermophilus thermocellumsubtilis thermolacticumthuringiensis tyrobutyricumxerothermodurans villosum______________________________________ TABLE VI______________________________________FUNGI______________________________________Absidia blakesleeana Entonaema liquescensAchaetomium luteum Epidermophyton floccosumAchlya hypogyna Filobasidiella neoformansAciculoconidium aculeatum Fonsecaea pedrosoiAcladium castellanii Fusarium solaniAcemoniella lutzi Geotrichum candidumAcrodontium salmoneum Gibberella baccataActinodendron verticillatum Gymnosporangium globosumActinomucor elegans Histoplasma capsulatumAcytostelium elipticum Kluyveromyces wickerhamiiAgaricus abruptibulbus Madurella mycetomiAgaricus campestris Melampsora medusaeAkenomyces costatus Microsporum canisAlternaria alternata Mucor hiemalisAlternaria citri Nectriella pironiiArmillaria limonea Neurospora tetraspermaArthrobotrys oligospora Paecilomyces lilacinusArthroderma benhamiae Penicillium aurantiogriseumArthroderma gypseum Phialophora richardsiaeArthroderma incurvatum Phycomyces nitensArticulospora tetracladia Pichia membranaefaciensAspergillus carneus Pityrosporium ovaleAspergillus fischeri Pseudallescheria boydiiAspergillus fumigatus Puccinis graminisAspergillus niger Pyrenophora trichostomaAureobasidium mansonii Rhizoctonia repensBasidiobolus haptosporus Rhizomucor pusillusBlastobotrys aristata Rhizopus microsporusBlastomyces dermatitidis Rhodotorula rubraBlastoschizomyces capitatus Rhynchosporium secalisBotrytis squamosa Saccharomyces cerevisiaeByssochlamys fulva Sclerotium rolfsiiCandida albicans Sporothrix schenckiiCandida tropicalis Sporotrichum thermophileCephalosporium deformans Stemphylium botryosumCeratocytis ulmi Torula thermophilaChaetomium globosum Torulopsis pintolopesiiChrysosporium pannorum Trichoderma polysporumCladosporium carpophilum Trichophyton mentagrophytesCladosporium resinae Trichophyton rubrumCoccidioides immitis Ulocladium botrytisCronartium fusiforme Uromyces phaseoliCryptococcus neoformans Verticillium nigrescensCurvularia prasadii Xylohypha bantianaDictyostelium discoideum Yarrowia lipolytica Zygosaccharomyces bailii______________________________________ TABLE VII______________________________________PROTISTS - ALGAE/PROTOZOA______________________________________Acanthamoeba astronyxis Leishmania hertigiA.",
"castellanii Leishmania mexicanaA.",
"culbertsoni Leishmania tropicaA.",
"hatchetti Leptomonas pyrrhocorisA.",
"lenticulata Lingulamoeba leeiA.",
"polyphaga Lohomonas piriformisA.",
"royreba Monocercomonas colubrorumBabesia microti Muriella aurantiacaBotrydium cystosum Naegleria australiensisCephaleuros virescens Naegleria fowleriChlamydomonas dorsoventralis Naegleria gruberiChlorella protothecoides Naegleria jadiniChlorella saccharophilia Nosema necatrixChlorella sorokiniana Ochromonas malhamensisChlorella variegata Paramecium primaureliaChlorella xanthella ParameciumChlorella zopfingiensis multimicronucleatumChlorogonium elongatum Pentatrichoimonas hominisCrithidia fasciculata Plasmodium brasilianumDientamoeba fragilis Plasmodium coatneyiDunaliella tertiolecta Plasmodium cynomolgiEntamoeba coli Plasmodium falciparumEntamoeba gingivalis Plasmodium vivaxEntamoeba histolytica Prototheca wickerhamiiEuglena gracilis Tetracystis disociataGiardia intestinalis Tetrahymena borealisGiardia lamblia Tetrahymena thermophilaHaematococcus lacustris Trichomonas gallinaeHartmannella limax Trichomonas vaginalisHerpetomonas mariadeanei Tritrichomonas foetusLeishmania braziliensis Trypanosoma bruceiLeishmania donovani Trypanosoma cruzi______________________________________"
] |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/883,103, now abandoned, filed May 14, 1992.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to a method and apparatus for reducing the strength of pulsating magnetic fields generated by various electronic devices.
Recently, it has been discovered that pulsating magnetic fields as well as varying electromagnetic fields affect biological matter and, consequently, cause health problems in human and animals, ranging from miscarriages to cancer. These discoveries have been made under laboratory conditions and through epidemiological studies.
Pulsating magnetic fields are very prevalent in modern society. Many of the electric devices man contacts in daily life emit pulsating magnetic fields. In television (TV) sets, video display terminals (VDT), personal computer monitors (PCM), etc., the pulsating magnetic field is produced by the deflecting magnetic coils which control the electron beam forming the display. The induced electric fields produced by the pulsating magnetic field associated with the deflecting magneticcoils in VDT, PCM, and TV sets expose human beings to prolonged action of extremely low frequency (ELF)and very low frequency (VLF) induced electric fields. Unreduced by shielding means these fields are generally greater than 1 milligauss.
In addition, biological effects may be induced by low frequency pulsating magnetic fields generated by high power lines and substation transformers. Electrical appliances, spark plugs in cars and trucks and electric devices used in home and offices also produce pulsating magnetic fields with strengths greater than 1 milligaus (mG). Among these are electric razors, fluorescent light transformers, electric clocks, hair dryers, electric heaters, microwave ovens, personal radio transmitters, and electric blankets. In fact, it has been published that there is a significant correlation between electric blankets and miscarriages. Even in hospitals operating rooms, due to the high-tech electronic instrumentation, hazardous electromagnetic fields have been detected.
Presently,there are no uniform standard for minimum magnetic field exposure. Epidemiological studies suggest that ELF values over 2-3 mG are hazardous for the health of humans under continuous exposure to these pulsating magnetic fields. At least one national authority in the biological effects of electromagnetic fields recommends a maximum exposure value of 0.3 mG. An advisory board to the Swedish government suggests a maximum VLF value of 0.25 mG for magnetic induction as measured at 20 inches from the screen of VDTs, PCMs, and TV sets.
There are several collections of experimental results and theoretical discussions of the effects of electromagnetic fields. Of interest is Handbook of Biological Effects of Electromagnetic Fields, Ed. C. Polk and E. Postow, CRC Press, Inc., Boca Raton Fla., 1988, Part II, Chapters 2, 3 and 5, in which biological effects are considered in relation to the action of ELF electromagnetic fields. In the group of epidemiological related to ELF fields, the paper by N. Wertheimer and E. Leeper, American Journal of Epidemiology, vol. 109, 273 (1979), is very illustrative about the relationship between exposure to 60 Hz magnetic fields from electric lines and childhood cancer. Another paper by J. Phillips et al., International Radiation Biology, 49, 463, (1986), shows that 60 Hz magnetic and electromagnetic fields increase the rate of growth of human cancer cells. Also, R. O. Becker, M.D., in Cross Currents: The Promise of Electromedicine--The Perils of Electropollution, Jeremy P. Tarcher, Inc., Los Angeles, Calif., 1990, p. 270, comments that studies "indicate that residential exposure to ambient fields greater than 3 milligauss are significantly related to increases in the incidence of childhood cancer. There is good evidence that such fields may also be associated with adult cancers. In risk protection, a factor of ten is generally applied. In this case, that would drop the theoretical safe level to 0.3 milligauss." Becker says: "Because of practical considerations, I advocate a maximum strength of 1 milligauss for continuous exposure to 60 Hz fields. Finally the paper by J. C. Cure', Cancer: An Electrical Phenomenon, Part 1 of 3, published in Health Consciousness, vol. XII, no. 5, p. 83, Oct. 1991, shows the electrophysical basis of the action of electromagnetic fields at a cellular level.
As it is well known the magnetic permeability of an immense variety of materials, including biological matter, is practically equal to the magnetic permeability of vacuum. This fact implies that permanent and pulsating magnetic fields penetrate and go through practically every kind of substances with the exception of ferromagnetic materials. Thus, to block magnetic fields with material shields is not practical unless one is willing to use enclosures made out of expensive ferromagnetic materials. Accordingly, magnetic field exposure represents a serious health problem that demands prompt solutions. U.S. Pat. No. 4,634,930 to Toshiyasu discloses a device which comprises a coil placed internal to a cathode ray tube display device for the purpose of cancelling electromagnetic field noise generated by the deflection yokes of the cathode ray tube.
U.S. Pat. No. 4,931,625 to Marlinski, discloses a device for shielding electromagnetic radiation. The device includes a cover arranged to enclose the heating means so as to block and contain the electromagnetic radiation emitted from heating pads and other similar devices. The cover has a layer of electrically conductive material and a ground connection for electrically grounding the conductive layer.
U.S. Pat. No. 4,891,468 to Andrae discloses a device to shield against electromagnetic fields. This invention relates to a device consisting of a shielding film of metal, in particular aluminum or metalized plastic, to shield against an electromagnetic field.
U.S. Pat. No. 4,992,624 to Benson et al., discloses a magnetic shield for visual display terminals. The invention is designed to shield the pulsating magnetic field created by the flyback transformer of a cathode ray tube display terminal. The magnetic shield consists of a layer of metal conductor, for example mu metal (magnalloy), and a layer of insulator (like polyester film), placed on top of the metal layer. The double layer is rolled to adopt the shape of a cylinder, which is installed around the flyback transformer.
U.S. Pat. No. 5,107,179 to Vidovich discloses a stray electromagnetic field reducing device comprising a pair of closed wire loops placed inside a cathode ray tube device and in physical contact with the cathode ray tube. One loop includes a capacitive element to cause the loop to form a resonant circuit. The resonant circuit allows greater induced current to flow in the loop with the consequence of improved cancellation of the stray cathode ray tube device generated fields.
Patents to Vidovich and to Toshiyasu, et. al. do not teach a device external to the cathode ray tube (CRT) enclosure, in fact, both patents disclose devices in physical contact with the CRT itself. Consequently, no disclosure to date has provided an external means of field cancellation for such devices as televisions and personal computers. Presently, there are approximately 100 million personal computers in the United States and many more world wide which were manufactured without benefit of the internal field cancellation devices disclosed by Vidovich and Toshiyasu et al. The present invention addresses a means for upgrade of these computers, and other devices using CRT's by simple placement of the present invention external to the computer or other CRT device.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method and apparatus for reducing the strength of pulsating magnetic fields, which overcome the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type.
With the foregoing and other objects in view there is provided, in accordance with the invention, an apparatus for reducing stray pulsating magnetic fields generated by a cathode ray tube device, said apparatus comprises a system of electrically insulated conducting loop circuits which are placed external, but in proximity to said cathode ray tube device.
The present invention is an apparatus for reducing the pulsating magnetic fields generated by a CRT. The apparatus which is placed external to the CRT device includes a set of closed loop circuits of sufficient number to reduce the stray pulsating magnetic field emanated by the CRT device into the volume external to the CRT device.
Several objects and advantages of the present invention are:
(a) to provide a device which does not require internal modification of the CRT device in the reduction of stray magnetic fields.
(b) To provide retrofit protection to users of CRT devices from the stray very low frequency (VLF) pulsating magnetic fields emanated by these devices.
(c) to provide users of CRT devices with a cost effective means of reducing the stray pulsating magnetic fields emanating from these devices.
(d) to provide a physically aesthetic field cancelling device for external attachment to a CRT device.
(e) to provide a field cancelling device which is easy to install.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method and apparatus for reducing the strength of pulsating magnetic fields, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of the specific embodiment when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot illustrating the effectiveness of the present invention in reducing the magnitude of the magnetic induction generated by a cathode ray tube device.
FIG. 2a is a pictorial diagram of the parallel loop geometry for a subassembly of the present invention.
FIG. 2b is a pictorial diagram of the concentric loop geometry for a subassembly of the present invention.
FIG. 2c is a pictorial diagram of the bundles geometry for a subassembly of the present invention.
FIG. 3 is a pictorial diagram of the coil geometry for a subassembly of the present invention.
FIG. 4 is a schematic diagram of a subassembly resonant loop circuit.
FIG. 5a is a pictorial diagram of a frame form subassembly.
FIG. 5b is a pictorial diagram of a plate form subassembly.
FIG. 6a is a pictorial diagram, of a preferred embodiment of the present invention installed on a CRT device.
FIG. 6b is a cross-sectional diagram of a means of attaching a subassembly to a CRT device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described with reference to specific embodiments and specific language will be used to describe the same. It is not intended that this description unduly limit the scope of the invention. Further embodiments are contemplated within the scope of the invention as will be understood by those ordinarily skill in the art.
It is not essential to the present invention to understand the theory behind its effectiveness. Yet, to aid understanding, the theoretical basis thereof will be discussed. This discussion is not intended to limit the invention in any way. The method is based on Faraday's law of electromagnetic induction. The electronic device generating the pulsating magnetic field is surrounded by an apparatus having the structure of a number of windings. To some extent, the counter magnetic field cancels the original magnetic field. In this way, the resultant pulsating magnetic field in the space beyond windings is reduced in strength and, in consequence, diminishes the intensity of the induced electric field acting in biological matter present in the volumetric region proximal to the electronic device.
The present invention consists of a system of electrically insulated conducting loop circuits which are placed external, but in proximity to a cathode ray tube device for the purpose of reducing the stray pulsating magnetic fields emanated by such a device. The system of conducting loop circuits reduces the strength of the magnetic field in the space outside the conducting loop circuits.
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen plots of the magnetic flux density associated with an example CRT device as a function of distance from the screen of such a device for the cases of a solitary CRT device and a CRT device using the present invention. The horizontal axis is in units of inches while the vertical axis is in units of milligauss. The effectiveness of the present invention is illustrated by comparison of curve 1 which represents the magnetic field of the solitary CRT device and curve 2 which represents the reduced magnetic field of the CRT device employing the present invention. It is to be noted that the present invention reduces the magnetic flux density to less than 0.25 milligauss at 20 inches from the screen of the CRT device.
The present invention comprises a system of insulated conducting loop circuits organized into a set of separate electrically insulated conducting loop subassemblies.
Alternative conductor topologies for such a subassembly include a multiple loop, coil and combination multiple loop-coil versions. FIGS. 2 depicts the multiple loop topology of a subassembly. In FIG. 2a, is shown a parallel loop geometry in which multiple closed loop conducting circuits 21 are placed in close proximity and largely parallel to one another. FIG. 2b shows a concentric loop geometry in which the conducting loop circuits 23 are placed in close proximity to one another and are largely concentric. The individual conducting loop circuits can be formed from wire or printed circuit board conductors. In the parallel loop geometry of FIG. 2a, multiple printed circuit boards can be stacked together to form the parallel loops. In yet another version shown in FIG. 2c, the individual circuits can be bundled together in a largely annular geometry. A cross-section 24 of the outer annular envelope 26 of this geometry depicts a random placement of the conducting loops within the annulus as represented by the cross-sections of the individual loop conductors 28. The individual circuits are electrically insulated by coating with any of a number of conventional insulating coatings such as plastic, enamel or lacquer. FIG. 3 depicts the coil topology of a subassembly. In this topology, the ends 25 and 27 of a multi-turn coil 29 are electrically connected as depicted by the dashed line 30 to form a closed circuit. The coil can be formed from wire or from multiple layers of circuit boards having the loop of each layer appropriately connected to loops of adjacent layers through edge connections. Conventional multilayer circuit boards can also be used to achieve an effective coil geometry. A degenerate subset of the subassembly geometries described above is that of a single closed loop.
The larger the magnitude of the currents induced in the closed loop circuits of the present invention, the greater will be the cancellation of stray magnetic field from the CRT device. The currents induced in the closed loop circuits of the present invention are limited by the circuit impedance. The impedance can be reduced by operating these circuits at resonance. Since the reactive component of the circuit impedance is dominated by inductance, resonance is achieved by including a series capacitor in the circuit. The value of the capacitor is chosen to provide a resonant frequency close to the main frequency of the CRT stray pulsating magnetic fields. FIG. 4 is a schematic diagram of a subassembly loop resonant circuit 31 comprising a loop conductor 32 which forms the inductive part of the circuit and a capacitor 33 in series with this inductor.
FIG. 5 depicts alternative enclosure forms for the individual subassemblies. In FIG. 5a is shown a frame form 34 which encloses the conducting loop circuits 35. The internally contained loop circuits 35 are depicted by emboldened lines. The frame form 34 is a largely rectangular loop with an arbitrary cross-section. This shape is a convenient one since it is compatible with the rectangular solid shape of most CRT devices. The shape of the frame form of this invention is not limited to the rectangular geometry. The frame form can constitute a hollow enclosure or a solid molding, preferably made of rigid plastic. FIG. 5b shows a plate form 36 which is a largely rectangular and is either a hollow enclosure or a solid molding containing conducting loop circuits 37.
FIG. 6a is a pictorial diagram of a preferred embodiment of the present invention comprising two conducting loop subassemblies. Shown is a CRT device 39 placed atop a plate form subassembly of conducting loop circuits 41. The subassembly 41 should extend about 3 to 4 inches from the screen 42 of the CRT device 39. The other edges of the subassembly should extend about 2 inches from the corresponding edges of the CRT device 39. In this manner, the closed loop circuits of subassembly 41 occupy an area in the proximal perimeter of the CRT device. An additional frame form subassembly of conducting loops circuits 43 is shown movably attached to CRT device 39 by two spring loaded contacting elements 44 positioned on opposite sides of the CRT device 39. In operational use, subassembly 43 is oriented with a first edge 45 positioned below and parallel to the lower leading edge 47 of the CRT device 39 and with a second edge 49, parallel to the first edge 45, positioned above and behind the upper leading edge 51 of CRT device 39. Inasmuch as contacting elements 44 act as pivot points for subassembly 43, the preferred position of subassembly 43 is maintained by providing additional weight to upper edge 49 in the design of subassembly 43. FIG. 6b provides a cross-sectional view of one of the contacting elements 44 affixed to subassembly 43. A plunger element 59 is captivated by a housing 55 and is in contact with spring 57. A foot 61 is formed on one end of the plunger element 59 for compressive contact with the housing of the CRT device 39. It is understood that the scope of the present invention includes other configurations of closed loop circuit subassemblies that are placed in proximity to a CRT device as well as many alternative means of attachment or placement of the subassemblies in proximity to the CRT. | An apparatus and a method for reducing VLF pulsating magnetic field generated by electronic devices to less than about 0.25 mG beyond about 20 inches from said device. The apparatus includes a closed inert circuit having a number of windings effective to accomplish the reduction. | Provide a concise summary of the essential information conveyed in the context. | [
"CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of application Ser.",
"No. 07/883,103, now abandoned, filed May 14, 1992.",
"BACKGROUND OF THE INVENTION Field of the Invention The present invention relates generally to a method and apparatus for reducing the strength of pulsating magnetic fields generated by various electronic devices.",
"Recently, it has been discovered that pulsating magnetic fields as well as varying electromagnetic fields affect biological matter and, consequently, cause health problems in human and animals, ranging from miscarriages to cancer.",
"These discoveries have been made under laboratory conditions and through epidemiological studies.",
"Pulsating magnetic fields are very prevalent in modern society.",
"Many of the electric devices man contacts in daily life emit pulsating magnetic fields.",
"In television (TV) sets, video display terminals (VDT), personal computer monitors (PCM), etc.",
", the pulsating magnetic field is produced by the deflecting magnetic coils which control the electron beam forming the display.",
"The induced electric fields produced by the pulsating magnetic field associated with the deflecting magneticcoils in VDT, PCM, and TV sets expose human beings to prolonged action of extremely low frequency (ELF)and very low frequency (VLF) induced electric fields.",
"Unreduced by shielding means these fields are generally greater than 1 milligauss.",
"In addition, biological effects may be induced by low frequency pulsating magnetic fields generated by high power lines and substation transformers.",
"Electrical appliances, spark plugs in cars and trucks and electric devices used in home and offices also produce pulsating magnetic fields with strengths greater than 1 milligaus (mG).",
"Among these are electric razors, fluorescent light transformers, electric clocks, hair dryers, electric heaters, microwave ovens, personal radio transmitters, and electric blankets.",
"In fact, it has been published that there is a significant correlation between electric blankets and miscarriages.",
"Even in hospitals operating rooms, due to the high-tech electronic instrumentation, hazardous electromagnetic fields have been detected.",
"Presently,there are no uniform standard for minimum magnetic field exposure.",
"Epidemiological studies suggest that ELF values over 2-3 mG are hazardous for the health of humans under continuous exposure to these pulsating magnetic fields.",
"At least one national authority in the biological effects of electromagnetic fields recommends a maximum exposure value of 0.3 mG.",
"An advisory board to the Swedish government suggests a maximum VLF value of 0.25 mG for magnetic induction as measured at 20 inches from the screen of VDTs, PCMs, and TV sets.",
"There are several collections of experimental results and theoretical discussions of the effects of electromagnetic fields.",
"Of interest is Handbook of Biological Effects of Electromagnetic Fields, Ed.",
"C. Polk and E. Postow, CRC Press, Inc., Boca Raton Fla.",
", 1988, Part II, Chapters 2, 3 and 5, in which biological effects are considered in relation to the action of ELF electromagnetic fields.",
"In the group of epidemiological related to ELF fields, the paper by N. Wertheimer and E. Leeper, American Journal of Epidemiology, vol.",
"109, 273 (1979), is very illustrative about the relationship between exposure to 60 Hz magnetic fields from electric lines and childhood cancer.",
"Another paper by J. Phillips et al.",
", International Radiation Biology, 49, 463, (1986), shows that 60 Hz magnetic and electromagnetic fields increase the rate of growth of human cancer cells.",
"Also, R. O. Becker, M.D., in Cross Currents: The Promise of Electromedicine--The Perils of Electropollution, Jeremy P. Tarcher, Inc., Los Angeles, Calif.",
", 1990, p. 270, comments that studies "indicate that residential exposure to ambient fields greater than 3 milligauss are significantly related to increases in the incidence of childhood cancer.",
"There is good evidence that such fields may also be associated with adult cancers.",
"In risk protection, a factor of ten is generally applied.",
"In this case, that would drop the theoretical safe level to 0.3 milligauss.",
""",
"Becker says: "Because of practical considerations, I advocate a maximum strength of 1 milligauss for continuous exposure to 60 Hz fields.",
"Finally the paper by J. C. Cure', Cancer: An Electrical Phenomenon, Part 1 of 3, published in Health Consciousness, vol.",
"XII, no. 5, p. 83, Oct. 1991, shows the electrophysical basis of the action of electromagnetic fields at a cellular level.",
"As it is well known the magnetic permeability of an immense variety of materials, including biological matter, is practically equal to the magnetic permeability of vacuum.",
"This fact implies that permanent and pulsating magnetic fields penetrate and go through practically every kind of substances with the exception of ferromagnetic materials.",
"Thus, to block magnetic fields with material shields is not practical unless one is willing to use enclosures made out of expensive ferromagnetic materials.",
"Accordingly, magnetic field exposure represents a serious health problem that demands prompt solutions.",
"U.S. Pat. No. 4,634,930 to Toshiyasu discloses a device which comprises a coil placed internal to a cathode ray tube display device for the purpose of cancelling electromagnetic field noise generated by the deflection yokes of the cathode ray tube.",
"U.S. Pat. No. 4,931,625 to Marlinski, discloses a device for shielding electromagnetic radiation.",
"The device includes a cover arranged to enclose the heating means so as to block and contain the electromagnetic radiation emitted from heating pads and other similar devices.",
"The cover has a layer of electrically conductive material and a ground connection for electrically grounding the conductive layer.",
"U.S. Pat. No. 4,891,468 to Andrae discloses a device to shield against electromagnetic fields.",
"This invention relates to a device consisting of a shielding film of metal, in particular aluminum or metalized plastic, to shield against an electromagnetic field.",
"U.S. Pat. No. 4,992,624 to Benson et al.",
", discloses a magnetic shield for visual display terminals.",
"The invention is designed to shield the pulsating magnetic field created by the flyback transformer of a cathode ray tube display terminal.",
"The magnetic shield consists of a layer of metal conductor, for example mu metal (magnalloy), and a layer of insulator (like polyester film), placed on top of the metal layer.",
"The double layer is rolled to adopt the shape of a cylinder, which is installed around the flyback transformer.",
"U.S. Pat. No. 5,107,179 to Vidovich discloses a stray electromagnetic field reducing device comprising a pair of closed wire loops placed inside a cathode ray tube device and in physical contact with the cathode ray tube.",
"One loop includes a capacitive element to cause the loop to form a resonant circuit.",
"The resonant circuit allows greater induced current to flow in the loop with the consequence of improved cancellation of the stray cathode ray tube device generated fields.",
"Patents to Vidovich and to Toshiyasu, et.",
"al.",
"do not teach a device external to the cathode ray tube (CRT) enclosure, in fact, both patents disclose devices in physical contact with the CRT itself.",
"Consequently, no disclosure to date has provided an external means of field cancellation for such devices as televisions and personal computers.",
"Presently, there are approximately 100 million personal computers in the United States and many more world wide which were manufactured without benefit of the internal field cancellation devices disclosed by Vidovich and Toshiyasu et al.",
"The present invention addresses a means for upgrade of these computers, and other devices using CRT's by simple placement of the present invention external to the computer or other CRT device.",
"SUMMARY OF THE INVENTION It is accordingly an object of the invention to provide a method and apparatus for reducing the strength of pulsating magnetic fields, which overcome the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type.",
"With the foregoing and other objects in view there is provided, in accordance with the invention, an apparatus for reducing stray pulsating magnetic fields generated by a cathode ray tube device, said apparatus comprises a system of electrically insulated conducting loop circuits which are placed external, but in proximity to said cathode ray tube device.",
"The present invention is an apparatus for reducing the pulsating magnetic fields generated by a CRT.",
"The apparatus which is placed external to the CRT device includes a set of closed loop circuits of sufficient number to reduce the stray pulsating magnetic field emanated by the CRT device into the volume external to the CRT device.",
"Several objects and advantages of the present invention are: (a) to provide a device which does not require internal modification of the CRT device in the reduction of stray magnetic fields.",
"(b) To provide retrofit protection to users of CRT devices from the stray very low frequency (VLF) pulsating magnetic fields emanated by these devices.",
"(c) to provide users of CRT devices with a cost effective means of reducing the stray pulsating magnetic fields emanating from these devices.",
"(d) to provide a physically aesthetic field cancelling device for external attachment to a CRT device.",
"(e) to provide a field cancelling device which is easy to install.",
"Other features which are considered as characteristic for the invention are set forth in the appended claims.",
"Although the invention is illustrated and described herein as embodied in a method and apparatus for reducing the strength of pulsating magnetic fields, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.",
"The construction of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of the specific embodiment when read in connection with the accompanying drawings.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plot illustrating the effectiveness of the present invention in reducing the magnitude of the magnetic induction generated by a cathode ray tube device.",
"FIG. 2a is a pictorial diagram of the parallel loop geometry for a subassembly of the present invention.",
"FIG. 2b is a pictorial diagram of the concentric loop geometry for a subassembly of the present invention.",
"FIG. 2c is a pictorial diagram of the bundles geometry for a subassembly of the present invention.",
"FIG. 3 is a pictorial diagram of the coil geometry for a subassembly of the present invention.",
"FIG. 4 is a schematic diagram of a subassembly resonant loop circuit.",
"FIG. 5a is a pictorial diagram of a frame form subassembly.",
"FIG. 5b is a pictorial diagram of a plate form subassembly.",
"FIG. 6a is a pictorial diagram, of a preferred embodiment of the present invention installed on a CRT device.",
"FIG. 6b is a cross-sectional diagram of a means of attaching a subassembly to a CRT device.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention will now be described with reference to specific embodiments and specific language will be used to describe the same.",
"It is not intended that this description unduly limit the scope of the invention.",
"Further embodiments are contemplated within the scope of the invention as will be understood by those ordinarily skill in the art.",
"It is not essential to the present invention to understand the theory behind its effectiveness.",
"Yet, to aid understanding, the theoretical basis thereof will be discussed.",
"This discussion is not intended to limit the invention in any way.",
"The method is based on Faraday's law of electromagnetic induction.",
"The electronic device generating the pulsating magnetic field is surrounded by an apparatus having the structure of a number of windings.",
"To some extent, the counter magnetic field cancels the original magnetic field.",
"In this way, the resultant pulsating magnetic field in the space beyond windings is reduced in strength and, in consequence, diminishes the intensity of the induced electric field acting in biological matter present in the volumetric region proximal to the electronic device.",
"The present invention consists of a system of electrically insulated conducting loop circuits which are placed external, but in proximity to a cathode ray tube device for the purpose of reducing the stray pulsating magnetic fields emanated by such a device.",
"The system of conducting loop circuits reduces the strength of the magnetic field in the space outside the conducting loop circuits.",
"Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen plots of the magnetic flux density associated with an example CRT device as a function of distance from the screen of such a device for the cases of a solitary CRT device and a CRT device using the present invention.",
"The horizontal axis is in units of inches while the vertical axis is in units of milligauss.",
"The effectiveness of the present invention is illustrated by comparison of curve 1 which represents the magnetic field of the solitary CRT device and curve 2 which represents the reduced magnetic field of the CRT device employing the present invention.",
"It is to be noted that the present invention reduces the magnetic flux density to less than 0.25 milligauss at 20 inches from the screen of the CRT device.",
"The present invention comprises a system of insulated conducting loop circuits organized into a set of separate electrically insulated conducting loop subassemblies.",
"Alternative conductor topologies for such a subassembly include a multiple loop, coil and combination multiple loop-coil versions.",
"FIGS. 2 depicts the multiple loop topology of a subassembly.",
"In FIG. 2a, is shown a parallel loop geometry in which multiple closed loop conducting circuits 21 are placed in close proximity and largely parallel to one another.",
"FIG. 2b shows a concentric loop geometry in which the conducting loop circuits 23 are placed in close proximity to one another and are largely concentric.",
"The individual conducting loop circuits can be formed from wire or printed circuit board conductors.",
"In the parallel loop geometry of FIG. 2a, multiple printed circuit boards can be stacked together to form the parallel loops.",
"In yet another version shown in FIG. 2c, the individual circuits can be bundled together in a largely annular geometry.",
"A cross-section 24 of the outer annular envelope 26 of this geometry depicts a random placement of the conducting loops within the annulus as represented by the cross-sections of the individual loop conductors 28.",
"The individual circuits are electrically insulated by coating with any of a number of conventional insulating coatings such as plastic, enamel or lacquer.",
"FIG. 3 depicts the coil topology of a subassembly.",
"In this topology, the ends 25 and 27 of a multi-turn coil 29 are electrically connected as depicted by the dashed line 30 to form a closed circuit.",
"The coil can be formed from wire or from multiple layers of circuit boards having the loop of each layer appropriately connected to loops of adjacent layers through edge connections.",
"Conventional multilayer circuit boards can also be used to achieve an effective coil geometry.",
"A degenerate subset of the subassembly geometries described above is that of a single closed loop.",
"The larger the magnitude of the currents induced in the closed loop circuits of the present invention, the greater will be the cancellation of stray magnetic field from the CRT device.",
"The currents induced in the closed loop circuits of the present invention are limited by the circuit impedance.",
"The impedance can be reduced by operating these circuits at resonance.",
"Since the reactive component of the circuit impedance is dominated by inductance, resonance is achieved by including a series capacitor in the circuit.",
"The value of the capacitor is chosen to provide a resonant frequency close to the main frequency of the CRT stray pulsating magnetic fields.",
"FIG. 4 is a schematic diagram of a subassembly loop resonant circuit 31 comprising a loop conductor 32 which forms the inductive part of the circuit and a capacitor 33 in series with this inductor.",
"FIG. 5 depicts alternative enclosure forms for the individual subassemblies.",
"In FIG. 5a is shown a frame form 34 which encloses the conducting loop circuits 35.",
"The internally contained loop circuits 35 are depicted by emboldened lines.",
"The frame form 34 is a largely rectangular loop with an arbitrary cross-section.",
"This shape is a convenient one since it is compatible with the rectangular solid shape of most CRT devices.",
"The shape of the frame form of this invention is not limited to the rectangular geometry.",
"The frame form can constitute a hollow enclosure or a solid molding, preferably made of rigid plastic.",
"FIG. 5b shows a plate form 36 which is a largely rectangular and is either a hollow enclosure or a solid molding containing conducting loop circuits 37.",
"FIG. 6a is a pictorial diagram of a preferred embodiment of the present invention comprising two conducting loop subassemblies.",
"Shown is a CRT device 39 placed atop a plate form subassembly of conducting loop circuits 41.",
"The subassembly 41 should extend about 3 to 4 inches from the screen 42 of the CRT device 39.",
"The other edges of the subassembly should extend about 2 inches from the corresponding edges of the CRT device 39.",
"In this manner, the closed loop circuits of subassembly 41 occupy an area in the proximal perimeter of the CRT device.",
"An additional frame form subassembly of conducting loops circuits 43 is shown movably attached to CRT device 39 by two spring loaded contacting elements 44 positioned on opposite sides of the CRT device 39.",
"In operational use, subassembly 43 is oriented with a first edge 45 positioned below and parallel to the lower leading edge 47 of the CRT device 39 and with a second edge 49, parallel to the first edge 45, positioned above and behind the upper leading edge 51 of CRT device 39.",
"Inasmuch as contacting elements 44 act as pivot points for subassembly 43, the preferred position of subassembly 43 is maintained by providing additional weight to upper edge 49 in the design of subassembly 43.",
"FIG. 6b provides a cross-sectional view of one of the contacting elements 44 affixed to subassembly 43.",
"A plunger element 59 is captivated by a housing 55 and is in contact with spring 57.",
"A foot 61 is formed on one end of the plunger element 59 for compressive contact with the housing of the CRT device 39.",
"It is understood that the scope of the present invention includes other configurations of closed loop circuit subassemblies that are placed in proximity to a CRT device as well as many alternative means of attachment or placement of the subassemblies in proximity to the CRT."
] |
BACKGROUND OF THE INVENTION
[0001] The present invention relates a solid oxide fuel cell, to a method for producing energy by means thereof, and to a process for preparing said solid oxide fuel cell.
PRIOR ART
[0002] As reported, for example, by S. Park et al., Applied Catalysis A: General 200 (2000), 55-61, fuel cells, e.g. solid oxide fuel cells (SOFCs), have received a great deal of attention as environmentally friendly and efficient means to generate energy, e.g. electrical power, for both stationary and mobile applications. The adoption of fuel cell, however, has been limited by a variety of technological hurdles including the fact that most conventional fuel cell designs require H 2 to be used as the fuel. This limitation is particularly significant for transportation applications where infrastructure and safety considerations favor the use of hydrocarbon fuel.
[0003] Reforming of hydrocarbons to produce H 2 is one approach that has been put forth to circumvent this problem. Unfortunately, reforming involves a complex set of catalytic reactions that must be carried out at temperatures higher than 850° C. to be effective. Such thermal requirements involve the use of special material for the construction of the fuel cell, with a consequent increasing of the cost.
[0004] Solid oxide fuel cells that could oxidize hydrocarbon fuels directly, without internally or externally reforming them to H 2 , would have significant advantages over traditional systems that require reforming, as reported, e.g., by Lu et al., J. Electrochem. Soc, 150 (10), A1357-A1359 (2003). An essential requirement for the direct oxidation of hydrocarbons in the absence of steam is that the materials used in anode fabrication do not catalyze carbon formation. Therefore, nickel (Ni), the most commonly used metal for SOFC anode, must be replaced with a different electronic conductor, since Ni catalyzes the formation of carbon filaments when exposed to hydrocarbons at SOFC operating temperatures. Replacement of Ni with copper (Cu), a poor catalyst for carbon formation was reported, for example, by S. Park et al., J. Electrochem. Soc., 146, 3603 ( 1999 ). Ceria (CeO 2 ) is included in the anode to enhance anode performance, in part because of catalytic activity of ceria for the oxidation of hydrocarbon fuels.
[0005] C. Lu et al., J. Electrochem. Soc, 150(3), A354-A358 (2003) disclose Cu-SDC (samaria-doped ceria) and Cu—CeO 2 —SDC anodes for SOFC, obtained by impregnating a porous layer of SDC (porosity of approximately 50%) with aqueous solutions of Cu(NO 3 ) 2 and Ce(NO 3 ) 3 to give a final weight percent with respect to the weight of the porous SDC matrix of 16% for Cu and 10% for CeO 2 . Said anodes are tested in a cell fed with butane (C 4 H 10 ) at 600-700° C. The maximum power density with C 4 H 10 fuel is 170 mW/cm 2 at 700° C. for the cell with the Cu—CeO 2 -SDC anode.
[0006] C. Lu et al., J. Electrochem. Soc, 150(10), A1357-A1359 (2003) show the comparison of Cu—CeO 2 —SDC and Au—CeO 2 —SDC composites for SOFC anodes, prepared in a manner similar to that of the just discussed paper, and describe as “relatively poor” the power density obtained in cells with said anodes performing in dry C 4 H 10 at 650° C.
[0007] It has to be considered that methane (CH 4 ) is much less reactive than butane in heterogeneous oxidation and exhibits the lowest reactivity for the anodes as well, as reported by R. J. Gorte, Electrochem. Soc. Proc., 2202-5, 60-71.
[0008] The need of a SOFC performing by directly oxidizing hydrocarbon fuels, and especially methane, and providing significant current and power densities with long lasting performances is still felt. Also, a sought characteristic for a SOFC is the possibility of operating at temperatures lower than 800° C.
SUMMARY OF THE INVENTION
[0009] The Applicant perceived that one of the key-points for affording such desired performance is the homogeneous distribution in the anode of the three functionalities for performing the cell, i.e. catalytic activity and ionical and electronical conductivity (three-phase boundary).
[0010] Applicant found that the problem could be solved by a SOFC with an anode comprising a cermet wherein the metallic and the electrolyte ceramic material portions are substantially uniformly interdispersed, the metallic portion being devoid of catalytic activity for hydrocarbon oxidation. Moreover, said cermet has a high porosity which allows the homogeneous distribution of a catalyst for hydrocarbon oxidation throughout the entire volume of the cermet. In view of such a homogeneous distribution, small amounts of catalyst are required for activating the cermet and making the anode to operate when fed with a hydrocarbon fuel.
[0011] Therefore, the present invention relates to a solid oxide fuel cell including a cathode, an anode and at least one electrolyte membrane disposed between said anode and said cathode, wherein said anode comprises
a cermet including a metallic portion and an electrolyte ceramic material portion, said portions being substantially uniformly interdispersed, said metallic portion having a melting point equal to or lower than 1200° C. and being substantially inert as catalyst for hydrocarbon oxidation; said cermet having a porosity equal to or higher than 40%, and being activated by a catalyst for hydrocarbon oxidation in an amount equal to or lower than 20 wt %.
[0013] In the present description and claims as “substantially uniformly interdispersed” is meant that the portions of the cermet are intimately admixed in the entire volume of the cermet, and not merely overlaid one another.
[0014] The metallic portion of the cermet can be selected from a metal such as copper, aluminum, gold, praseodymium, ytterbium, cerium, and alloys thereof. Preferably, said metallic portion is copper.
[0015] Preferably the metallic portion has a melting point higher than 500° C. Preferably the electrolyte ceramic material portion has a specific conductivity equal to or higher than 0.01 S/cm at 650° C. For example, it is doped ceria or La 1-x Sr x Ga 1-y Mg y O 3-δ wherein x and y are comprised between 0 and 0.7 and δ is from stoichiometry. Preferably, the ceria is doped with gadolinia (gadolinium oxide) or samaria (samarium oxide).
[0016] Alternatively, the ceramic material of the SOFC of the invention is yttria-stabilized zirconia (YSZ).
[0017] In the cermet of the invention the weight ratio metallic portion/ceramic portion preferably ranges between 9:1 and 3:7, preferably between 8:2 and 5:5.
[0018] The cermet of the present invention advantageously has a specific surface area equal to or lower than about 5 m 2 /g, more preferably equal to or lower than about 2 m 2 /g.
[0019] The catalyst activating the cermet suitable for the invention can be selected from nickel, iron, cobalt, molybdenum, platinum, iridium, rhutenium, rhodium, silver, palladium, cerium oxide, manganese oxide, molybdenum oxide, titania, samaria-doped ceria, gadolinia-doped ceria, niobia-doped ceria and mixtures comprising them. Preferably it is selected from nickel, cerium oxide and mixtures comprising them.
[0020] The amount of said catalyst can advantageously range between about 0.5 wt % and about 15 wt %. The percentages disclosed for the amount of the catalyst are expressed with respect to the total weight of the anode.
[0021] Advantageously the catalyst suitable for the invention has a specific surface area higher than 20 m 2 /g, more preferably higher than 30 m 2 /g.
[0022] According to an embodiment of the invention, a first type of cathode for the solid oxide fuel cell of the invention comprises a metal such as platinum, silver or gold or mixtures thereof, and an oxide of a rare earth element, such as praseodymium oxide.
[0023] According to another embodiment of the invention, a second type of cathode comprises a ceramic selected from
La 1-x Sr x MnO 3-δ , wherein x and y are independently equal to a value comprised between 0 and 1, extremes included and δ is from stoichiometry; and
[0025] La 1-x Sr x Co 1-y Fe y O 3-δ , wherein x and y are independently equal to a value comprised between 0 and 1, extremes included and δ is from stoichiometry.
[0026] Said second type of cathode can further comprise doped ceria.
[0027] According to a further embodiment of the invention, a third type of cathode comprises a combination of the materials above mentioned for the cathodes of the first and second type.
[0028] Preferably, the electrolyte membrane of the SOFC of the invention is selected from the materials listed above in connection with the electrolyte ceramic material portion of the cermet. More preferably, the electrolyte membrane comprises the same material of the electrolyte ceramic portion of the cermet suitable for the invention.
[0029] In another aspect, the present invention relates to a method for producing energy comprising the steps of:
[0000] a) feeding at least one hydrocarbon fuel into an anode side of a solid oxide fuel cell comprising
an anode including a cermet including a metallic portion and an electrolyte ceramic material portion, said portions being substantially uniformly interdispersed, said metallic portion having a melting point equal to or lower than 1200° C. and being substantially inert as catalyst for hydrocarbon oxidation; said cermet having a porosity equal to or higher than 40%, and being activated by a catalyst for hydrocarbon oxidation in an amount equal to or lower than 20 wt %; a cathode, and at least one electrolyte membrane disposed between said anode and said cathode;
b) feeding an oxidant into a cathode side of said solid oxide fuel cell; and
c) oxidizing said at least one fuel in said solid oxide fuel cell, resulting in production of energy.
[0033] The hydrocarbon fuel suitable for the method of the invention can be in gaseous form, e.g. methane, ethane, propane, butane, natural gas, reformed gas, biogas, syngas and mixture thereof, either in the presence of water or substantially dry; or a hydrocarbon in liquid form, e.g. diesel, toluene, kerosene, jet fuels (JP-4, JP-5, JP-8, etc).
[0034] Advantageously, the hydrocarbon fuel is substantially dry. As “substantially dry” it is intended that the water content can be lower than 10 vol %. Preferred for the present invention is substantially dry methane.
[0035] In the method according to the invention the hydrocarbon fuel can be directly oxidized at the anode side. For instance, in the case of methane, the reaction at the anode is the following
[0000] CH 4 +4O 2− →CO 2 +2H 2 O+8 e −
[0036] As already said above, the direct oxidation of a dry fuel such as a dry hydrocarbon yields coking phenomena (deposition of graphite fibers) at the catalyst of the anode thus exhausting its catalytic activity. The phenomenon is particularly reported when nickel is used as catalyst. The structure of the anode of the invention allows the activating catalyst to effectively perform without being affected by such deposition phenomenon. Thus the solid oxide fuel cell of the present invention can perform by direct oxidation of a dry fuel.
[0037] Advantageously, the solid oxide fuel cell of the invention operates at a temperature ranging between about 400° C. and about 800° C., more preferably between about 500° C. and about 700° C.
[0038] Besides the possibility of skipping the necessity of using special thermo-resistant material for manufacturing the solid oxide fuel cell, an advantage provided by low operating temperatures, such those preferred by the present invention, is the reduction of NO x formation at the cathode. The formation of such undesired by-products is due to the reaction of the nitrogen present in the air fed at the cathode side, such reaction being related to temperature increase.
[0039] The solid oxide fuel cell according to the invention substantially displays a great flexibility in the choose of the fuel to be fed with. Besides hydrocarbons, it can performs by feeding the anode also with hydrogen, or with an wet hydrocarbon fuel (in the case of methane, generally 1:3 methane/water) to provide reformed fuel.
[0040] In case of operating with reformed fuel, the fuel can be internally reformed at the anode side.
[0041] The solid oxide fuel cell can be prepared with methods known in the art. Advantageously it is prepared by the following process.
[0042] In a further aspect, the present invention relates to a process for preparing a solid oxide fuel cell including a cathode, an anode and at least one electrolyte membrane disposed between said anode and said cathode wherein said anode comprises a cermet including a metallic portion and an electrolyte ceramic material portion; said process comprising the steps of:
providing the cathode; providing the at least one electrolyte membrane; and providing the anode
wherein the step of providing the anode includes the steps of:
a) providing a precursor of the metallic portion, said precursor having a particle size ranging between 0.2 μm and 5 μm; b) providing the electrolyte ceramic material having a particle size ranging between 1 μm and 10 μm; c) mixing said precursor and said ceramic material to provide a starting mixture; d) heating and grinding said starting mixture in the presence of at least one first dispersant; e) adding at least one binder and at least one second dispersant to the starting mixture from step d) to give a slurry; f) thermally treating the slurry to provide a pre-cermet; g) reducing the pre-cermet to provide a cermet h) distributing at least one catalyst for hydrocarbon oxidation into the cermet.
[0054] Unless otherwise indicated, in the present description and claims as “particle size” is intended the average particle size determined by physical separation methods, for example by sedimentography, as shown hereinbelow.
[0055] According to an embodiment of the invention, the slurry resulting from step e) is applied on the electrolyte membrane.
[0056] According to an embodiment of the invention, step h) comprises impregnating the pre-cermet with a precursor of the catalyst which is subsequently reduced during the reducing step g).
[0057] According to another embodiment of the invention, step h) comprises impregnating the cermet with a precursor of the catalyst which is subsequently reduced during an additional reducing step i).
[0058] Preferably the precursor of the metallic portion is an oxide of the metals already listed above. For example, in the case of copper the oxide is Cu 2 O or CuO, the latter being preferred.
[0059] Preferably said precursor has a particle size ranging between 1 and 3 μm.
[0060] Preferably the ceramic material has a particle size ranging between 2 and 5 μm.
[0061] Advantageously, step d) is effected more than one time.
[0062] The first dispersant is a solvent or a solvent mixture. Preferably it is selected from polar organic solvents, such as alcohols, polyols, esters, ketones, ethers, amides, optionally halogenated aromatic solvents such as benzene, chlorobenzene, dichlorobenzene, xylene and toluene, halogenated solvents such as chloroform and dichloroethane, or mixtures thereof. It ensures homogeneity to the starting mixture. Examples are provided in Table 1.
[0063] The second dispersant can be the same or different from the first dispersant.
[0064] Advantageously, the binder is soluble in the second dispersant. Preferably it is selected from polymeric compounds containing polar groups such as polyvinylbutyral, nitrocellulose, polybutyl methacrylate, colophony, ethyl cellulose. Examples of mixtures binder/second dispersant are provided in Table 1.
[0000]
TABLE 1
Binder
Dispersant
Polyvinylbutyral
ethanol
ethanol + benzene
ethanol + acetone + butyl alcohol
ethanol + isopropanol + monomethyl ether
ethylene glycol
isopropanol
isopropanol + ethyl acetate + sebacic acid
dibutyl ether
Nitrocellulose
isoamylacetate + tetrahydrofurane
Polybutyl methacrylate
ethyl acetate
butyl acetate
acetone + butanol
isopropanol + isoamylacetate + ethyl acetate
Colophony
ethanol + dichlorobenzene
Ethyl cellulose
ethyleneglycol monoethyl ether + p-xylene
[0065] Preferred binder is polyvinylbutyral. Preferred first and second dispersants are ethanol and isopropanol.
[0066] Advantageously, step f) is carried out at a temperature ranging between about 700° C. and about 1100° C., more preferably between about 900° C. and about 1000° C.
[0067] The reduction step g) is preferably carried out at a temperature ranging between about 300° C. and about 800° C., more preferably between about 400° C. and about 600° C.
[0068] Hydrogen is a preferred reducing agent. Advantageously, it is introduced in the reduction environment, for example an oven, which has been previously conditioned with an inert gas, such as argon. Advantageously, hydrogen contains from 1 vol. % to 10 vol. % of water, preferably from 2 vol. % to 5 vol. %.
[0069] Advantageously, the precursor of the catalyst is a salt thereof.
[0070] In another further aspect the present invention relates to a cermet including a metallic portion and an electrolyte ceramic material portion, said portions being substantially uniformly interdispersed, said metallic portion having a melting point equal to or lower than, 1200° C. and being substantially inert as catalyst for hydrocarbon oxidation; said cermet having a porosity equal to or higher than 40%, and being activated by a catalyst for hydrocarbon oxidation in an amount equal to or lower than 20 wt %.
BRIEF DESCRIPTION OF THE DRAWINGS
[0071] The invention will be further illustrated hereinafter with reference to the following examples and figures, wherein
[0072] FIG. 1 schematically illustrates a fuel cell power system;
[0073] FIG. 2 shows the variation of the electric resistance upon temperature of a Cu-SDC cermet suitable for the invention;
[0074] FIGS. 3 a and 3 b are micrographs of a Cu-SDC cermet in (a) secondary electron emission and (b) backscattering modes;
[0075] FIG. 4 shows the experimental set-up for testing the solid oxide fuel cells of the invention;
[0076] FIG. 5 shows anodic polarization curves of a Cu-SDC anode activated with CeO 2 +Ni fed with CH 4 at 547, 595 and 646° C.;
[0077] FIG. 6 shows cell potential and power density as function of the current density in a fuel cell fed with CH 4 at 596, 645 and 696° C.;
[0078] FIG. 7 shows anodic polarization curves of a Cu-SDC anode activated with CeO 2 +Ni+MoO x fed with CH 4 at 599, 648 and 698° C.;
[0079] FIG. 8 shows the performance of a SOFC MoO x +Ni+CeO 2 —(Cu-SDC)/SDC/Pt+PrO 2-x , fed with CH 4 at 600, 645 and 700° C.;
[0080] FIG. 9 shows anodic polarization curves of Cu-SDC cermet activated with MoOx+Ni+CeO 2 in CH 4 /air fuel cell after (□) 25 h and (◯) 46 h in CH 4 +3% H 2 O mixtures, and further (Δ) 7 h in CH 4 +3% H 2 O atmosphere.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0081] FIG. 1 schematically illustrates a solid oxide fuel cell power system. The solid oxide fuel cell ( 1 ) comprises an anode ( 2 ), a cathode ( 4 ) and an electrolyte membrane ( 3 ) disposed between them.
[0082] According to a preferred embodiment of the invention, a substantially dry fuel is fed to the anode ( 2 ) where direct oxidation is effected. The heat can be used in a bottoming cycle, while the electric power in form of direct current (DC) can be exploited as such, for example in telecommunication systems, or converted into alternate current (AC) via a power conditioner (not illustrated).
[0083] From anode ( 2 ) an effluent flows which can be composed by unreacted fuel and/or reaction product/s, for example water and/or carbon dioxide.
Example 1
Preparation of a Cu-SDC (54 wt %-46 wt %) cermet with Cu 2 O+Ce 0.8 Sm 0.2 O 1.9 as starting materials
A. Starting Mixture
[0084] Cu 2 O powder (“analytically pure” grade, >99.5%) was ground in the drum of a “sand” planetary mill with jasper balls using isopropanol as dispersant. The drum was charged with 50 g of the powder oxide, 150 g of balls, and 45 ml of isopropanol. The procedure was carried out for 30 minutes at a drum speed of 110 rpm.
[0085] After the dispersant was removed in oven at 100° C., the specific surface area (S) of the ground powder (determined by low-temperature adsorption of nitrogen in a Sorpty-1750 device, Carlo Erba, Italy) and the average particle size (d) (determined by CP-2 centrifugal sedimentographer, Shimadzu, Japan) were measured and found to be S Cu 2 O =1.7 m 2 /g and d Cu 2 O =1.8 μm, with a normal particle size distribution from 0 to 2.1 μm.
[0086] The ground Cu 2 O and Ce 0.8 Sm 0.2 O 1.9 (SDC) powder (S SDC 1.9 m 2 /g and d SDC =3.3 μm) were mixed together in a planetary mill with jasper balls in the presence of isopropanol. The charge of the drum included 25 g of the powder mixture 72.4 wt % Cu 2 O+27.6 wt % SDC (18.1 g Cu 2 O and 6.9 g SDC), 50 g of balls and 25 ml of isopropanol. The procedure was carried out for 50 minutes at a speed of 80 rpm and for 10 minutes at 110 rpm. The dispersant was removed in oven at 100° C., and the Cu 2 O-SDC mixture was added with a 5 wt % aqueous solution of polyvinyl alcohol (PVA) as binder (10 wt % of the powder mass). Pellets 20 mm in diameter were prepared by semi-dry compaction method at a specific pressure of about 30 MPa.
[0087] A heat treatment was performed at 800° C. with a 1.5 hour isothermal holding time and air blasting. The pellets were heated and cooled at a rate of 250° C./hour. After the heat treatment, the pellets changed color from brown to black. The diameter shrinkage and the geometrical density of the sintered pellets were 1.7% and 4.05 g/cm 3 respectively.
[0088] The pellets were broken in a jasper mortar to obtain grains ≦1.25 mm in size. The coarse-grain powder was ground in a “sand” planetary mill with jasper balls in the presence of isopropyl alcohol. The charge of the mill drum did not exceed ⅔ of their volume. The powder/dispersant ratio was maintained at ˜1:0.95. The grinding conditions were: powder/balls ratio of 1:3, n (grinding speed)=110 rpm, grinding time=45 min. An average surface area S=2.9 m 2 /g and average particle size d)=2.7 μm were measured for the resulting powder. The powder was used to prepare a slurry.
B. Slurry
[0089] The powder mixture of A. was ground in the drum of a “sand” planetary mill with jasper balls. Polyvinyl butyral (PVB) was used as binder and ethanol as dispersant. The charge included 20 g of the powder mixture, 8 ml of 5 wt % solution of PVB in ethanol, and 15 ml of ethyl alcohol. Four jasper balls, 14 mm in diameter, were put per 20 g of the powder. The charge was mixed for 30 min at a speed of 80 rpm. The resulting slurry was poured into a vessel outfitted with a tight cover to prevent evaporation of the dispersant.
C. Pre-Cermet.
[0090] The slurry of B. was brushed onto an SDC electrolyte membrane (1.82 mm-hick) while stirring. An amount of 16±4 mg/cm 2 (corresponding to a thickness of 65±5 μm) was applied by three brushings with intermediate drying in a warm air jet.
[0091] The slurry/electrolyte membrane assembly was then heated in air at 1050° C. under the following conditions: heating at a rate of 200° C./hour in the interval from 20 to 500° C. and at a rate of 250° C./hour in the interval from 500° C. to the experimental temperature. The assembly was kept under isothermal conditions for 2 hours at the final temperature, then cooled at a rate 200° C./hour to provide a pre-cermet/electrolyte membrane assembly.
[0092] The final thickness of the pre-cermet in the pre-cermet/electrolyte membrane assembly was 42 μm and the thickness shrinkage was 38.7% pointing for a good sintering of pre-cermet layer.
[0093] The density of the applied slurry and the pre-cermet was calculated from mass and geometrical dimensions, and accounted for 45% and 64% of the design density, respectively. Thus, the porosity of the pre-cermet was of about 36%.
[0094] The porosity value was also evaluated by mercury porosimetry. The pre-cermet material was deposited on ten plates of SDC electrolyte to a total mass of 0.448 g. The experiments were carried out on PA-3M mercury porosimetric installation, and the volume normalized for 1 g of pre-cermet material was 0.0776 cm 3 . The volume porosity was then calculated from the following equation:
[0000]
p
=
0.0776
(
1
/
(
m
(
CuO
x
)
×
d
(
CuO
x
)
+
m
(
SDC
)
×
d
(
SDC
)
)
+
0.0776
(
1
)
[0000] where m CuOx and in m SDC indicate the relative weight amount of the phases in the pre-cermet, and d CuOx and d SDC the specific densities of Cu 2 O (6 g/cm 3 ) and SDC (7.13 g/cm 3 ) phases.
[0095] The measured volume porosity was 34±3%, which is in agreement with the porosity estimated from mass and geometric values. The average size of the pores was seen to be 1 μm.
D. Reduction of the Pre-Cermet to Cermet.
[0096] After cooling to room temperature, the pre-cermet of the pre-cermet/electrolyte membrane assembly of C. was reduced at a temperature of 500° C. (at a rate of 200° C./hour). The oven was conditioned with argon (3 vol. % H 2 O), then hydrogen (3 vol. % H 2 O) was introduced to replace argon and kept for 40 min.
E. Morphological Characterization of the Cu-SDC Cermet.
[0097] Morphological characterization of the Cu-SDC cermet was effected using a scanning electron microscope (JSM-5900LV). FIGS. 3 a and 3 b represent two micrographs of the outer surface of the anode, respectively in the secondary electron emission mode ( FIG. 3 a ) and in the backscattering mode ( FIG. 3 b ). From these two pictures it can be seen that the cermet has a porous structure where both phases (Cu and SDC) are intimately mixed and homogeneously distributed.
[0098] As metallic copper forms an amalgam with mercury, the above described method cannot be used to determine the cermet porosity. The porosity of the cermet was calculated considering the following:
a) the volume of the cermet does not change with the reduction process (V pre-cermet(ox) =V cermet(red) ) b) the volume of the SDC electrolyte phase does not change with the reduction process (V SDC(ox) =V SDC(red) ) c) the variation in cermet porosity upon reduction is due to the variation of volume of copper containing phases, and the following relation (2) can be applied:
[0000]
V
CuO
x
-
V
Cu
=
V
CuO
x
(
1
-
(
d
CuO
x
d
Cu
)
+
(
Δ
m
d
Cu
)
)
(
2
)
[0000] where Δm is the mass difference between the copper and copper oxide, and d CuOx and d Cu are, respectively the density of copper oxide CuO (6 g/cm 3 ) and metallic copper (8.9 g/cm 3 ).
[0102] Considering 1 g of oxidized cermet (the cermet pre-reduction), its volume V pre-cermet(ox) is given by:
[0000]
V
pre
-
cermet
(
ox
)
=
V
SDC
(
ox
)
+
V
CuOx
(
ox
)
+
V
pore
(
ox
)
or
(
3
)
V
pre
-
cermet
(
ox
)
=
m
SDC
(
ox
)
d
SDC
(
ox
)
+
m
CuOx
(
ox
)
d
CuOx
(
ox
)
+
V
pore
(
ox
)
(
4
)
[0000] where m SDC and m CuOx are the mass of both phases in the cermet. Being V pore (ox)=0.36V pre-cermet (ox) (from porosimetry measurements), equation ( 4 ) can be rewritten as:
[0000]
(
1
-
0.36
)
V
pre
-
cermet
(
ox
)
=
m
SDC
(
ox
)
d
SDC
(
ox
)
+
m
CuOx
(
ox
)
d
CuOx
(
ox
)
+
V
pore
(
ox
)
(
5
)
[0000] and the calculated value for V pre-cermet (ox) is 0.249 cm 3 .
[0103] As the porosity volume of the reduced cermet, V pore (red) is given by:
[0000] V pore (red)= V pore (ox)+Δ V (6)
[0000] and equal to 0.143 cm 3 , the final porosity of the cermet V pore (red)/V cermet (red) was of 55%.
[0104] The specific surface area was determined by the nitrogen BET method (Sorpty 1750, Carlo Erba Strumentazione, Italy) and resulted to be 1.6 m 2 /g.
F. Measurement of the Electrical Resistance of the Cu-SDC Cermet.
[0105] The layer resistance (measured along the major layer axis) of the cermet was measured by the dc four-probe method using an EC-1286 device (Solartron Schlumberger). The cermet had a surface of 1×1 cm 2 and was 42 μm-thick. Current and potential probes were made of platinum wire.
[0106] The following procedure was used. After reduction of the pre-cermet layer to cermet, the sample was further heated in hydrogen (3 vol. % H 2 O) up to 700° C. at a rate of 200° C./hour. The temperature was maintained for 2 hours, then sequential measurements of resistance were done and the stability of the cermet anode was ascertained. The sample was cooled to 500° C. by steps of 50° C. at a rate of 100° C./hour and step time of 10 min, and its resistance was measured at each grade. Finally, the sample was cooled at a rate of 200° C./hour to room temperature and its resistance was measured again.
[0107] The results are shown in FIG. 2 . The cermet has a metallic behavior with a resistance increasing with temperature. This reads for a uniform distribution of the metallic phase through the cermet.
[0108] The electric resistance longitudinally along the anode, 1×1 cm 2 in size and 0.004 cm thick, changes between 6.3 mΩ and 21.0 mΩ at a temperature from 20 to 700° C. The results are set forth in Table 2 below.
Example 2
Preparation and Characterization of a Cu-SDC (70 Wt %-30 Wt %) Cermet Using CuO and SDC Starting Materials
[0109] The same preparation procedure described in example 1 was used with CuO (15 g) and SDC (6.37 g) as starting material. The ground CuO had a total specific surface area (S) of 0.9 m 2 /g and a mean particle size (d) of 3.4 μm at a normal particle size distribution from 0 to 20 μm.
[0110] The same amount of slurry (16±4 mg/cm 2 ) was deposited on a SDC electrolyte, and after the heat treatment at 1050° C. the final thickness of the pre-cermet was 39 μm; the thickness shrinkage was 33.7% indicating a good sintering of electrode structure.
[0111] The final thickness of the pre-cermet was 43.6 μm and the thickness shrinkage was 32.5% indicating a good sintering of the structure.
[0112] The porosity of the pre-cermet before reduction was 36%, and after reduction was 54.4%.
[0113] The electrical resistance along the cermet was measured according to example 1. The measured values (5.8 mΩ at 20° C. and 23.0 mΩ at 700° C.) are according to the requirements for an anodes used in fuel cells, as set forth in Table 2.
[0000]
TABLE 2
Electrical resistance and specific conductivity
alone the Cu-SDC anodes
Example
Resistance at 20° C. (mΩ)
Resistance at 700° C. (mΩ)
1
6.3
21.0
2
5.8
23.0
Example 3
Activation of Cu-SDC Cermet with SDC
[0114] A Cu-SDC cermet prepared according to example 1 was activated by impregnation with SDC oxide material. The Cu-SDC cermet in the reduced state was impregnated with a solution of Ce(OCOC(CH 3 ) 2 C 4 H 9 ) 3 and Sm(OCOC(CH 3 ) 2 C 4 H 9 ) 3 (cerium and samarium 2,2-dimethyl-hexanoate) in benzene (4 g/100 ml). Filtering paper was used to remove the excess solution from the cermet surface. The cermet was impregnated dried and heat treated (400° C.) three times. The activated cermet was then heated at a rate of 200° C./h up to 650° C. in H 2 (3 vol. % water) and the total amount of deposited SDC was 0.27 mg (6 wt %). The specific surface area of the SDC phase was 56.2 m 2 /g.
Example 4
Activation of Cu-SDC Cermet with CeO 2
[0115] A Cu-SDC cermet prepared according to example 2 was activated by impregnation with CeO 2 . The Cu-SDC cermet in the reduced state was impregnated with a solution of Ce(NO 3 ) 2 in water (140 g/100 ml). Filtering paper was used to remove the excess solution from the cermet surface. The cermet was impregnated dried and heat treated (400° C.) twice. The activated cermet which was then heated at a rate of 100° C./h up to 650° C. in H 2 (3 vol. % water), and total amount of deposited CeO 2 was 8.42 mg (15.4 wt %). The specific surface area was determined by the nitrogen BET method (Sorpty 1750, Carlo Erba Strumentazione, Italy), and resulted to be for CeO 2 of 39.4 m 2 /g.
Example 5
Activation of a Cu-SDC Cermet with Ni+CGO
[0116] A Cu-SDC cermet prepared according to example 2 was activated with a mixture of Ni (70 wt %) and CGO (Ce 0.8 Gd 0.2 O 1.9 ; 30 wt %). The Cu-SDC cermet in reduced state was impregnated with a solution of 4 g/100 ml of M(OCOC(CH 3 ) 2 C 4 H 9 ) x wherein M-=e, Gd and Ni, x is from stoichiometry (3.29 g of Ni precursor, 0.67 g of Ce precursor and 0.04 g of Gd precursor) in C 6 H 6 . Filtering paper was used to remove the excess of solution from the cermitic surface. The cermet was impregnated, dried and heat treated (400° C.) thrice. The activated cermet was and heated at a rate of 200° C./h up to 650° C. in H 2 (3 vol. % water). The total amount of deposited activator was 0.1 mg (2 wt %). The specific surface area of the activator was of 135 m 2 /g.
Example 6
Activation of a Cu-SDC Cermet with CeO 2 +Ni
[0117] A Cu-SDC cermet prepared according to example 2 was activated with CeO 2 and Ni. First the Cu-SDC cermet in reduced state was impregnated with a solution of Ce(NO 3 ) 3 in water (140 g/100 ml H 2 O). Filtering paper was used to remove the excess of solution from the cermitic surface. The cermet was impregnated, dried and heat treated (500° C.). Then the activated cermet was impregnated with a solution of Ni(NO 3 ) 2 in water (167.5 g/100 ml H 2 O). Filtering paper was used to remove the excess of solution from the cermitic surface. The cermet was impregnated, dried and heat treated (500° C.). The resulting activated cermet was dried and heated up to 500° C. with the rate 100° C./h in H 2 (3 vol. % water). The total amount of deposited activator was 0.45 mg CeO 2 and 0.1 mg Ni (9 wt % and 2 wt %, respectively).
[0118] The specific surface areas were determined by the nitrogen BET method (Sorpty 1750, Carlo Erba Strumentazione, Italy), first for CeO 2 and subsequently for Ni. CeO 2 showed a specific surface area of 39.4 m 2 /g, and Ni showed a specific surface area of 84.6 m 2 /g.
Example 7
Evaluation of a Solid Oxide Fuel Cell with Anode Comprising a Cu-SDC Cermet Activated with Ni—CeO 2
[0119] The electrochemical measurements under conditions of a CH 4 /air were effected as follows.
[0120] A three-electrode cell ( 5 ) as from FIG. 4 was used. The cell comprised an anode ( 6 ), an electrolyte membrane ( 7 ) and a cathode ( 4 ). Anode ( 6 ) and electrolyte membrane ( 7 ) were a disk-shaped anode/electrolyte membrane assembly (Ø=12 mm) wherein the anode layer was as from the title and the electrolyte membrane was SDC. A fine Pt+PrO x paste was painted as cathode ( 8 ) on the surface of the electrolyte membrane ( 7 ) opposite to that in contact with the anode ( 6 ) (SU invention certificate No. 1.786.965). Each of anode ( 6 ) and cathode ( 8 ) had an area of about 0.3 cm 2 . A reference electrode ( 9 ) was made of a platinum coil on the circumference of the electrolyte membrane ( 7 ). The three-electrode cell was pressed by a spring load against the rim of a zirconium dioxide tube ( 10 ).
[0121] Methane fuel gas (3 vol. % H 2 O, V CH 4 ˜2-5 l/hour) was fed to the anode side through an alumina tube ( 11 ) positioned inside the zirconium dioxide tube ( 10 ). The cathode side was blown with air (v=6 l/hour). The composition of the combusted anode cermet was determined by means of a solid electrolyte oxygen sensor ( 12 ). The cell temperature was measured by a chromel-alumel thermocouple ( 13 ).
[0122] The overvoltage of the electrodes and the ohmic voltage drop in the electrolyte were determined under stationary conditions (galvanostatic mode) by the current interruption method. The length of the current interruption edge did not exceed 0.3 μs. The off-current state time of the cell was ˜0.3 ms (millisecond). The relative duration of the cut-off pulses (off/on) was ≦1/1540.
[0123] The measuring set-up included the following instruments:
universal digital voltmeter type B7-39 (0.02% accuracy class); universal digital oscillograph type C 9-8 (1.5% accuracy class); dc power source type VIP-009; relay switch unit type RSD-725; programmed temperature controller type TP-403; IBM PC 286 AT personal computer, gas flow-rate regulator type SRG-23.
[0131] The instruments and the computer communicated via a COP interface bus (IEEE-488).
[0132] The following measurement procedure of was used. Methane (3 vol. % H 2 O) was flown at 2 l/hour and the cell heated to a temperature of 700° C. at a rate of 200° C./hour. The cell ( 5 ) was allowed to stand for 0.5 hour before its polarization characteristics were measured. The measurements were made between 700° C. and 500° C., decreasing temperature. To check the time stability of the characteristics, the measurements were repeated at 700° C. The stability of the cell was ascertained.
[0133] The Cu-SDC cermet activated with Ni—CeO 2 (example 6) was tested as anode for polarization measurement. FIG. 4 illustrates polarization curves recorded under methane (3% H 2 O, V CH 4 =2.7 l/h) at three different temperatures, 547° C., 595° C. and 646° C. The cermet Ni+CeO 2 provides an anode having remarkable activity in methane oxidation. For example, at 646° C. to a polarization of 50 mV corresponds to the current density of 0.38 A/cm 2 .
[0134] FIG. 5 shows the characteristic performance of potential and power density as function of the current density of the single fuel cell with an anode as said above, a SDC 0.0250 cm thick electrolyte membrane and a Pt+PrO 2-x , cathode, fed with CH 4 /air at 596, 645 and 696° C. The measured OCV voltages (U oc ) are near 0.9 V. Taking into account the value predicted by the Nernst equation (about 1.0 V at 800° C.), the obtained OCV voltages indicate that methane is efficiently oxidized. At 696° C. a maximum power density of 0.24 W/cm 2 was measured at 0.45 A/cm 2 .
Example 8
Solid Oxide Fuel Cell with a Cu-SDC Cermet Activated with [Ni+CeO 2 ]+MoOx
[0135] The Cu-SDC cermet activated with Ni—CeO 2 (example 6) was further impregnated with a (NH 4 ) 6 Mo 7 O 24 .4H 2 O aqueous solution at (4.14 g/100 ml, pH=7-8), following the procedure of example 6. The amount of MoOx (a mixture of MoO 2 and MoO 3 ) was 0.07 mg corresponding to 11 wt % of the total mass of the activating materials (about 1 wt % of the total anode mass).
[0136] FIG. 7 shows the polarization curves of anodes based on said Cu-SDC cermet activated with MoOx+Ni+CeO 2 at three different temperatures, 599, 648 and 698° C. From this figure it is seen that the anode is active towards methane oxidation, and at 698° C. an anodic polarization of 50 mV corresponds to the current density of 0.37 A/cm 2 .
[0137] FIG. 8 shows the characteristic performance of a fuel cell MoO+Ni+CeO 2 —(Cu-SDC)/SDC/Pt+PrO 2-x , fed with CH 4 at 600, 645 and 700° C. The electrolyte was 0.0560 cm thick. The measured OCV voltages (U oc ) are near 0.9 V, and a maximum power density of 0.120 W/cm 2 was measured at 0.21/Acm 2 at 700° C.
[0138] The stability of the activated anode was tested in CH 4 atmosphere. FIG. 9 illustrates anodic polarization curves recorded in CH 4 /air fuel cell after 25 (□) and 46 h (∘) in CH 4 +3% 1120 mixtures, and further 7 h (Δ) in CH 4 +3% H 2 O atmosphere. It can be seen that after an initial deactivation the anode response is stable in time.
[0139] The following Table 3 provides a comparison between the electrochemical performance of solid oxide fuel cells according to the invention, fed with CH 4 , and those of the prior art fed with C 4 H 10 .
[0000]
TABLE 3
Current density
Power density
SOFC
(A/cm 2 at 50 mV)
(W/cm 2 )
Example 7
0.38 at 646° C.
0.24 at 0.45 A/cm 2 and 696° C.
Example 8
0.37 at 698° C.
0.12 at 0.21 A/cm 2 and 700° C.
CeO 2 —Cu-SDC*
0.06 at 650° C.
0.05 at 0.17 A/cm 2 and 650° C.
CeO 2 —Au-SDC*
0.10 at 650° C.
0.05 at 0.13 A/cm 2 and 650° C.
*C. Lu et al., J. Electrochem. Soc, 150(10), A1357-A1359 (2003)
[0140] In spite of the fact that the SOFC of the prior art were tested under C 4 H 10 which, as already mentioned above, is known to be more reactive to oxidation than CH 4 , their electrochemical performances is dramatically lower than those of the SOFC according to the present invention. The different temperatures in some instances applied cannot be seen as a key-factor in evaluating this disparity of performance, because the ΔT is of just 50° C. or less. | Solid oxide fuel cell including an anode which has a cermet activated by a catalyst for hydrocarbon oxidation, process for the preparation thereof, and method for the production of energy exploiting it. | Concisely explain the essential features and purpose of the concept presented in the passage. | [
"BACKGROUND OF THE INVENTION [0001] The present invention relates a solid oxide fuel cell, to a method for producing energy by means thereof, and to a process for preparing said solid oxide fuel cell.",
"PRIOR ART [0002] As reported, for example, by S. Park et al.",
", Applied Catalysis A: General 200 (2000), 55-61, fuel cells, e.g. solid oxide fuel cells (SOFCs), have received a great deal of attention as environmentally friendly and efficient means to generate energy, e.g. electrical power, for both stationary and mobile applications.",
"The adoption of fuel cell, however, has been limited by a variety of technological hurdles including the fact that most conventional fuel cell designs require H 2 to be used as the fuel.",
"This limitation is particularly significant for transportation applications where infrastructure and safety considerations favor the use of hydrocarbon fuel.",
"[0003] Reforming of hydrocarbons to produce H 2 is one approach that has been put forth to circumvent this problem.",
"Unfortunately, reforming involves a complex set of catalytic reactions that must be carried out at temperatures higher than 850° C. to be effective.",
"Such thermal requirements involve the use of special material for the construction of the fuel cell, with a consequent increasing of the cost.",
"[0004] Solid oxide fuel cells that could oxidize hydrocarbon fuels directly, without internally or externally reforming them to H 2 , would have significant advantages over traditional systems that require reforming, as reported, e.g., by Lu et al.",
", J. Electrochem.",
"Soc, 150 (10), A1357-A1359 (2003).",
"An essential requirement for the direct oxidation of hydrocarbons in the absence of steam is that the materials used in anode fabrication do not catalyze carbon formation.",
"Therefore, nickel (Ni), the most commonly used metal for SOFC anode, must be replaced with a different electronic conductor, since Ni catalyzes the formation of carbon filaments when exposed to hydrocarbons at SOFC operating temperatures.",
"Replacement of Ni with copper (Cu), a poor catalyst for carbon formation was reported, for example, by S. Park et al.",
", J. Electrochem.",
"Soc.",
", 146, 3603 ( 1999 ).",
"Ceria (CeO 2 ) is included in the anode to enhance anode performance, in part because of catalytic activity of ceria for the oxidation of hydrocarbon fuels.",
"[0005] C. Lu et al.",
", J. Electrochem.",
"Soc, 150(3), A354-A358 (2003) disclose Cu-SDC (samaria-doped ceria) and Cu—CeO 2 —SDC anodes for SOFC, obtained by impregnating a porous layer of SDC (porosity of approximately 50%) with aqueous solutions of Cu(NO 3 ) 2 and Ce(NO 3 ) 3 to give a final weight percent with respect to the weight of the porous SDC matrix of 16% for Cu and 10% for CeO 2 .",
"Said anodes are tested in a cell fed with butane (C 4 H 10 ) at 600-700° C. The maximum power density with C 4 H 10 fuel is 170 mW/cm 2 at 700° C. for the cell with the Cu—CeO 2 -SDC anode.",
"[0006] C. Lu et al.",
", J. Electrochem.",
"Soc, 150(10), A1357-A1359 (2003) show the comparison of Cu—CeO 2 —SDC and Au—CeO 2 —SDC composites for SOFC anodes, prepared in a manner similar to that of the just discussed paper, and describe as “relatively poor”",
"the power density obtained in cells with said anodes performing in dry C 4 H 10 at 650° C. [0007] It has to be considered that methane (CH 4 ) is much less reactive than butane in heterogeneous oxidation and exhibits the lowest reactivity for the anodes as well, as reported by R. J. Gorte, Electrochem.",
"Soc.",
"Proc.",
", 2202-5, 60-71.",
"[0008] The need of a SOFC performing by directly oxidizing hydrocarbon fuels, and especially methane, and providing significant current and power densities with long lasting performances is still felt.",
"Also, a sought characteristic for a SOFC is the possibility of operating at temperatures lower than 800° C. SUMMARY OF THE INVENTION [0009] The Applicant perceived that one of the key-points for affording such desired performance is the homogeneous distribution in the anode of the three functionalities for performing the cell, i.e. catalytic activity and ionical and electronical conductivity (three-phase boundary).",
"[0010] Applicant found that the problem could be solved by a SOFC with an anode comprising a cermet wherein the metallic and the electrolyte ceramic material portions are substantially uniformly interdispersed, the metallic portion being devoid of catalytic activity for hydrocarbon oxidation.",
"Moreover, said cermet has a high porosity which allows the homogeneous distribution of a catalyst for hydrocarbon oxidation throughout the entire volume of the cermet.",
"In view of such a homogeneous distribution, small amounts of catalyst are required for activating the cermet and making the anode to operate when fed with a hydrocarbon fuel.",
"[0011] Therefore, the present invention relates to a solid oxide fuel cell including a cathode, an anode and at least one electrolyte membrane disposed between said anode and said cathode, wherein said anode comprises a cermet including a metallic portion and an electrolyte ceramic material portion, said portions being substantially uniformly interdispersed, said metallic portion having a melting point equal to or lower than 1200° C. and being substantially inert as catalyst for hydrocarbon oxidation;",
"said cermet having a porosity equal to or higher than 40%, and being activated by a catalyst for hydrocarbon oxidation in an amount equal to or lower than 20 wt %.",
"[0013] In the present description and claims as “substantially uniformly interdispersed”",
"is meant that the portions of the cermet are intimately admixed in the entire volume of the cermet, and not merely overlaid one another.",
"[0014] The metallic portion of the cermet can be selected from a metal such as copper, aluminum, gold, praseodymium, ytterbium, cerium, and alloys thereof.",
"Preferably, said metallic portion is copper.",
"[0015] Preferably the metallic portion has a melting point higher than 500° C. Preferably the electrolyte ceramic material portion has a specific conductivity equal to or higher than 0.01 S/cm at 650° C. For example, it is doped ceria or La 1-x Sr x Ga 1-y Mg y O 3-δ wherein x and y are comprised between 0 and 0.7 and δ is from stoichiometry.",
"Preferably, the ceria is doped with gadolinia (gadolinium oxide) or samaria (samarium oxide).",
"[0016] Alternatively, the ceramic material of the SOFC of the invention is yttria-stabilized zirconia (YSZ).",
"[0017] In the cermet of the invention the weight ratio metallic portion/ceramic portion preferably ranges between 9:1 and 3:7, preferably between 8:2 and 5:5.",
"[0018] The cermet of the present invention advantageously has a specific surface area equal to or lower than about 5 m 2 /g, more preferably equal to or lower than about 2 m 2 /g.",
"[0019] The catalyst activating the cermet suitable for the invention can be selected from nickel, iron, cobalt, molybdenum, platinum, iridium, rhutenium, rhodium, silver, palladium, cerium oxide, manganese oxide, molybdenum oxide, titania, samaria-doped ceria, gadolinia-doped ceria, niobia-doped ceria and mixtures comprising them.",
"Preferably it is selected from nickel, cerium oxide and mixtures comprising them.",
"[0020] The amount of said catalyst can advantageously range between about 0.5 wt % and about 15 wt %.",
"The percentages disclosed for the amount of the catalyst are expressed with respect to the total weight of the anode.",
"[0021] Advantageously the catalyst suitable for the invention has a specific surface area higher than 20 m 2 /g, more preferably higher than 30 m 2 /g.",
"[0022] According to an embodiment of the invention, a first type of cathode for the solid oxide fuel cell of the invention comprises a metal such as platinum, silver or gold or mixtures thereof, and an oxide of a rare earth element, such as praseodymium oxide.",
"[0023] According to another embodiment of the invention, a second type of cathode comprises a ceramic selected from La 1-x Sr x MnO 3-δ , wherein x and y are independently equal to a value comprised between 0 and 1, extremes included and δ is from stoichiometry;",
"and [0025] La 1-x Sr x Co 1-y Fe y O 3-δ , wherein x and y are independently equal to a value comprised between 0 and 1, extremes included and δ is from stoichiometry.",
"[0026] Said second type of cathode can further comprise doped ceria.",
"[0027] According to a further embodiment of the invention, a third type of cathode comprises a combination of the materials above mentioned for the cathodes of the first and second type.",
"[0028] Preferably, the electrolyte membrane of the SOFC of the invention is selected from the materials listed above in connection with the electrolyte ceramic material portion of the cermet.",
"More preferably, the electrolyte membrane comprises the same material of the electrolyte ceramic portion of the cermet suitable for the invention.",
"[0029] In another aspect, the present invention relates to a method for producing energy comprising the steps of: [0000] a) feeding at least one hydrocarbon fuel into an anode side of a solid oxide fuel cell comprising an anode including a cermet including a metallic portion and an electrolyte ceramic material portion, said portions being substantially uniformly interdispersed, said metallic portion having a melting point equal to or lower than 1200° C. and being substantially inert as catalyst for hydrocarbon oxidation;",
"said cermet having a porosity equal to or higher than 40%, and being activated by a catalyst for hydrocarbon oxidation in an amount equal to or lower than 20 wt %;",
"a cathode, and at least one electrolyte membrane disposed between said anode and said cathode;",
"b) feeding an oxidant into a cathode side of said solid oxide fuel cell;",
"and c) oxidizing said at least one fuel in said solid oxide fuel cell, resulting in production of energy.",
"[0033] The hydrocarbon fuel suitable for the method of the invention can be in gaseous form, e.g. methane, ethane, propane, butane, natural gas, reformed gas, biogas, syngas and mixture thereof, either in the presence of water or substantially dry;",
"or a hydrocarbon in liquid form, e.g. diesel, toluene, kerosene, jet fuels (JP-4, JP-5, JP-8, etc).",
"[0034] Advantageously, the hydrocarbon fuel is substantially dry.",
"As “substantially dry”",
"it is intended that the water content can be lower than 10 vol %.",
"Preferred for the present invention is substantially dry methane.",
"[0035] In the method according to the invention the hydrocarbon fuel can be directly oxidized at the anode side.",
"For instance, in the case of methane, the reaction at the anode is the following [0000] CH 4 +4O 2− →CO 2 +2H 2 O+8 e − [0036] As already said above, the direct oxidation of a dry fuel such as a dry hydrocarbon yields coking phenomena (deposition of graphite fibers) at the catalyst of the anode thus exhausting its catalytic activity.",
"The phenomenon is particularly reported when nickel is used as catalyst.",
"The structure of the anode of the invention allows the activating catalyst to effectively perform without being affected by such deposition phenomenon.",
"Thus the solid oxide fuel cell of the present invention can perform by direct oxidation of a dry fuel.",
"[0037] Advantageously, the solid oxide fuel cell of the invention operates at a temperature ranging between about 400° C. and about 800° C., more preferably between about 500° C. and about 700° C. [0038] Besides the possibility of skipping the necessity of using special thermo-resistant material for manufacturing the solid oxide fuel cell, an advantage provided by low operating temperatures, such those preferred by the present invention, is the reduction of NO x formation at the cathode.",
"The formation of such undesired by-products is due to the reaction of the nitrogen present in the air fed at the cathode side, such reaction being related to temperature increase.",
"[0039] The solid oxide fuel cell according to the invention substantially displays a great flexibility in the choose of the fuel to be fed with.",
"Besides hydrocarbons, it can performs by feeding the anode also with hydrogen, or with an wet hydrocarbon fuel (in the case of methane, generally 1:3 methane/water) to provide reformed fuel.",
"[0040] In case of operating with reformed fuel, the fuel can be internally reformed at the anode side.",
"[0041] The solid oxide fuel cell can be prepared with methods known in the art.",
"Advantageously it is prepared by the following process.",
"[0042] In a further aspect, the present invention relates to a process for preparing a solid oxide fuel cell including a cathode, an anode and at least one electrolyte membrane disposed between said anode and said cathode wherein said anode comprises a cermet including a metallic portion and an electrolyte ceramic material portion;",
"said process comprising the steps of: providing the cathode;",
"providing the at least one electrolyte membrane;",
"and providing the anode wherein the step of providing the anode includes the steps of: a) providing a precursor of the metallic portion, said precursor having a particle size ranging between 0.2 μm and 5 μm;",
"b) providing the electrolyte ceramic material having a particle size ranging between 1 μm and 10 μm;",
"c) mixing said precursor and said ceramic material to provide a starting mixture;",
"d) heating and grinding said starting mixture in the presence of at least one first dispersant;",
"e) adding at least one binder and at least one second dispersant to the starting mixture from step d) to give a slurry;",
"f) thermally treating the slurry to provide a pre-cermet;",
"g) reducing the pre-cermet to provide a cermet h) distributing at least one catalyst for hydrocarbon oxidation into the cermet.",
"[0054] Unless otherwise indicated, in the present description and claims as “particle size”",
"is intended the average particle size determined by physical separation methods, for example by sedimentography, as shown hereinbelow.",
"[0055] According to an embodiment of the invention, the slurry resulting from step e) is applied on the electrolyte membrane.",
"[0056] According to an embodiment of the invention, step h) comprises impregnating the pre-cermet with a precursor of the catalyst which is subsequently reduced during the reducing step g).",
"[0057] According to another embodiment of the invention, step h) comprises impregnating the cermet with a precursor of the catalyst which is subsequently reduced during an additional reducing step i).",
"[0058] Preferably the precursor of the metallic portion is an oxide of the metals already listed above.",
"For example, in the case of copper the oxide is Cu 2 O or CuO, the latter being preferred.",
"[0059] Preferably said precursor has a particle size ranging between 1 and 3 μm.",
"[0060] Preferably the ceramic material has a particle size ranging between 2 and 5 μm.",
"[0061] Advantageously, step d) is effected more than one time.",
"[0062] The first dispersant is a solvent or a solvent mixture.",
"Preferably it is selected from polar organic solvents, such as alcohols, polyols, esters, ketones, ethers, amides, optionally halogenated aromatic solvents such as benzene, chlorobenzene, dichlorobenzene, xylene and toluene, halogenated solvents such as chloroform and dichloroethane, or mixtures thereof.",
"It ensures homogeneity to the starting mixture.",
"Examples are provided in Table 1.",
"[0063] The second dispersant can be the same or different from the first dispersant.",
"[0064] Advantageously, the binder is soluble in the second dispersant.",
"Preferably it is selected from polymeric compounds containing polar groups such as polyvinylbutyral, nitrocellulose, polybutyl methacrylate, colophony, ethyl cellulose.",
"Examples of mixtures binder/second dispersant are provided in Table 1.",
"[0000] TABLE 1 Binder Dispersant Polyvinylbutyral ethanol ethanol + benzene ethanol + acetone + butyl alcohol ethanol + isopropanol + monomethyl ether ethylene glycol isopropanol isopropanol + ethyl acetate + sebacic acid dibutyl ether Nitrocellulose isoamylacetate + tetrahydrofurane Polybutyl methacrylate ethyl acetate butyl acetate acetone + butanol isopropanol + isoamylacetate + ethyl acetate Colophony ethanol + dichlorobenzene Ethyl cellulose ethyleneglycol monoethyl ether + p-xylene [0065] Preferred binder is polyvinylbutyral.",
"Preferred first and second dispersants are ethanol and isopropanol.",
"[0066] Advantageously, step f) is carried out at a temperature ranging between about 700° C. and about 1100° C., more preferably between about 900° C. and about 1000° C. [0067] The reduction step g) is preferably carried out at a temperature ranging between about 300° C. and about 800° C., more preferably between about 400° C. and about 600° C. [0068] Hydrogen is a preferred reducing agent.",
"Advantageously, it is introduced in the reduction environment, for example an oven, which has been previously conditioned with an inert gas, such as argon.",
"Advantageously, hydrogen contains from 1 vol.",
"% to 10 vol.",
"% of water, preferably from 2 vol.",
"% to 5 vol.",
"[0069] Advantageously, the precursor of the catalyst is a salt thereof.",
"[0070] In another further aspect the present invention relates to a cermet including a metallic portion and an electrolyte ceramic material portion, said portions being substantially uniformly interdispersed, said metallic portion having a melting point equal to or lower than, 1200° C. and being substantially inert as catalyst for hydrocarbon oxidation;",
"said cermet having a porosity equal to or higher than 40%, and being activated by a catalyst for hydrocarbon oxidation in an amount equal to or lower than 20 wt %.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0071] The invention will be further illustrated hereinafter with reference to the following examples and figures, wherein [0072] FIG. 1 schematically illustrates a fuel cell power system;",
"[0073] FIG. 2 shows the variation of the electric resistance upon temperature of a Cu-SDC cermet suitable for the invention;",
"[0074] FIGS. 3 a and 3 b are micrographs of a Cu-SDC cermet in (a) secondary electron emission and (b) backscattering modes;",
"[0075] FIG. 4 shows the experimental set-up for testing the solid oxide fuel cells of the invention;",
"[0076] FIG. 5 shows anodic polarization curves of a Cu-SDC anode activated with CeO 2 +Ni fed with CH 4 at 547, 595 and 646° C.;",
"[0077] FIG. 6 shows cell potential and power density as function of the current density in a fuel cell fed with CH 4 at 596, 645 and 696° C.;",
"[0078] FIG. 7 shows anodic polarization curves of a Cu-SDC anode activated with CeO 2 +Ni+MoO x fed with CH 4 at 599, 648 and 698° C.;",
"[0079] FIG. 8 shows the performance of a SOFC MoO x +Ni+CeO 2 —(Cu-SDC)/SDC/Pt+PrO 2-x , fed with CH 4 at 600, 645 and 700° C.;",
"[0080] FIG. 9 shows anodic polarization curves of Cu-SDC cermet activated with MoOx+Ni+CeO 2 in CH 4 /air fuel cell after (□) 25 h and (◯) 46 h in CH 4 +3% H 2 O mixtures, and further (Δ) 7 h in CH 4 +3% H 2 O atmosphere.",
"DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0081] FIG. 1 schematically illustrates a solid oxide fuel cell power system.",
"The solid oxide fuel cell ( 1 ) comprises an anode ( 2 ), a cathode ( 4 ) and an electrolyte membrane ( 3 ) disposed between them.",
"[0082] According to a preferred embodiment of the invention, a substantially dry fuel is fed to the anode ( 2 ) where direct oxidation is effected.",
"The heat can be used in a bottoming cycle, while the electric power in form of direct current (DC) can be exploited as such, for example in telecommunication systems, or converted into alternate current (AC) via a power conditioner (not illustrated).",
"[0083] From anode ( 2 ) an effluent flows which can be composed by unreacted fuel and/or reaction product/s, for example water and/or carbon dioxide.",
"Example 1 Preparation of a Cu-SDC (54 wt %-46 wt %) cermet with Cu 2 O+Ce 0.8 Sm 0.2 O 1.9 as starting materials A. Starting Mixture [0084] Cu 2 O powder (“analytically pure”",
"grade, >99.5%) was ground in the drum of a “sand”",
"planetary mill with jasper balls using isopropanol as dispersant.",
"The drum was charged with 50 g of the powder oxide, 150 g of balls, and 45 ml of isopropanol.",
"The procedure was carried out for 30 minutes at a drum speed of 110 rpm.",
"[0085] After the dispersant was removed in oven at 100° C., the specific surface area (S) of the ground powder (determined by low-temperature adsorption of nitrogen in a Sorpty-1750 device, Carlo Erba, Italy) and the average particle size (d) (determined by CP-2 centrifugal sedimentographer, Shimadzu, Japan) were measured and found to be S Cu 2 O =1.7 m 2 /g and d Cu 2 O =1.8 μm, with a normal particle size distribution from 0 to 2.1 μm.",
"[0086] The ground Cu 2 O and Ce 0.8 Sm 0.2 O 1.9 (SDC) powder (S SDC 1.9 m 2 /g and d SDC =3.3 μm) were mixed together in a planetary mill with jasper balls in the presence of isopropanol.",
"The charge of the drum included 25 g of the powder mixture 72.4 wt % Cu 2 O+27.6 wt % SDC (18.1 g Cu 2 O and 6.9 g SDC), 50 g of balls and 25 ml of isopropanol.",
"The procedure was carried out for 50 minutes at a speed of 80 rpm and for 10 minutes at 110 rpm.",
"The dispersant was removed in oven at 100° C., and the Cu 2 O-SDC mixture was added with a 5 wt % aqueous solution of polyvinyl alcohol (PVA) as binder (10 wt % of the powder mass).",
"Pellets 20 mm in diameter were prepared by semi-dry compaction method at a specific pressure of about 30 MPa.",
"[0087] A heat treatment was performed at 800° C. with a 1.5 hour isothermal holding time and air blasting.",
"The pellets were heated and cooled at a rate of 250° C./hour.",
"After the heat treatment, the pellets changed color from brown to black.",
"The diameter shrinkage and the geometrical density of the sintered pellets were 1.7% and 4.05 g/cm 3 respectively.",
"[0088] The pellets were broken in a jasper mortar to obtain grains ≦1.25 mm in size.",
"The coarse-grain powder was ground in a “sand”",
"planetary mill with jasper balls in the presence of isopropyl alcohol.",
"The charge of the mill drum did not exceed ⅔ of their volume.",
"The powder/dispersant ratio was maintained at ˜1:0.95.",
"The grinding conditions were: powder/balls ratio of 1:3, n (grinding speed)=110 rpm, grinding time=45 min.",
"An average surface area S=2.9 m 2 /g and average particle size d)=2.7 μm were measured for the resulting powder.",
"The powder was used to prepare a slurry.",
"B. Slurry [0089] The powder mixture of A. was ground in the drum of a “sand”",
"planetary mill with jasper balls.",
"Polyvinyl butyral (PVB) was used as binder and ethanol as dispersant.",
"The charge included 20 g of the powder mixture, 8 ml of 5 wt % solution of PVB in ethanol, and 15 ml of ethyl alcohol.",
"Four jasper balls, 14 mm in diameter, were put per 20 g of the powder.",
"The charge was mixed for 30 min at a speed of 80 rpm.",
"The resulting slurry was poured into a vessel outfitted with a tight cover to prevent evaporation of the dispersant.",
"C. Pre-Cermet.",
"[0090] The slurry of B. was brushed onto an SDC electrolyte membrane (1.82 mm-hick) while stirring.",
"An amount of 16±4 mg/cm 2 (corresponding to a thickness of 65±5 μm) was applied by three brushings with intermediate drying in a warm air jet.",
"[0091] The slurry/electrolyte membrane assembly was then heated in air at 1050° C. under the following conditions: heating at a rate of 200° C./hour in the interval from 20 to 500° C. and at a rate of 250° C./hour in the interval from 500° C. to the experimental temperature.",
"The assembly was kept under isothermal conditions for 2 hours at the final temperature, then cooled at a rate 200° C./hour to provide a pre-cermet/electrolyte membrane assembly.",
"[0092] The final thickness of the pre-cermet in the pre-cermet/electrolyte membrane assembly was 42 μm and the thickness shrinkage was 38.7% pointing for a good sintering of pre-cermet layer.",
"[0093] The density of the applied slurry and the pre-cermet was calculated from mass and geometrical dimensions, and accounted for 45% and 64% of the design density, respectively.",
"Thus, the porosity of the pre-cermet was of about 36%.",
"[0094] The porosity value was also evaluated by mercury porosimetry.",
"The pre-cermet material was deposited on ten plates of SDC electrolyte to a total mass of 0.448 g. The experiments were carried out on PA-3M mercury porosimetric installation, and the volume normalized for 1 g of pre-cermet material was 0.0776 cm 3 .",
"The volume porosity was then calculated from the following equation: [0000] p = 0.0776 ( 1 / ( m ( CuO x ) × d ( CuO x ) + m ( SDC ) × d ( SDC ) ) + 0.0776 ( 1 ) [0000] where m CuOx and in m SDC indicate the relative weight amount of the phases in the pre-cermet, and d CuOx and d SDC the specific densities of Cu 2 O (6 g/cm 3 ) and SDC (7.13 g/cm 3 ) phases.",
"[0095] The measured volume porosity was 34±3%, which is in agreement with the porosity estimated from mass and geometric values.",
"The average size of the pores was seen to be 1 μm.",
"D. Reduction of the Pre-Cermet to Cermet.",
"[0096] After cooling to room temperature, the pre-cermet of the pre-cermet/electrolyte membrane assembly of C. was reduced at a temperature of 500° C. (at a rate of 200° C./hour).",
"The oven was conditioned with argon (3 vol.",
"% H 2 O), then hydrogen (3 vol.",
"% H 2 O) was introduced to replace argon and kept for 40 min.",
"E. Morphological Characterization of the Cu-SDC Cermet.",
"[0097] Morphological characterization of the Cu-SDC cermet was effected using a scanning electron microscope (JSM-5900LV).",
"FIGS. 3 a and 3 b represent two micrographs of the outer surface of the anode, respectively in the secondary electron emission mode ( FIG. 3 a ) and in the backscattering mode ( FIG. 3 b ).",
"From these two pictures it can be seen that the cermet has a porous structure where both phases (Cu and SDC) are intimately mixed and homogeneously distributed.",
"[0098] As metallic copper forms an amalgam with mercury, the above described method cannot be used to determine the cermet porosity.",
"The porosity of the cermet was calculated considering the following: a) the volume of the cermet does not change with the reduction process (V pre-cermet(ox) =V cermet(red) ) b) the volume of the SDC electrolyte phase does not change with the reduction process (V SDC(ox) =V SDC(red) ) c) the variation in cermet porosity upon reduction is due to the variation of volume of copper containing phases, and the following relation (2) can be applied: [0000] V CuO x - V Cu = V CuO x ( 1 - ( d CuO x d Cu ) + ( Δ m d Cu ) ) ( 2 ) [0000] where Δm is the mass difference between the copper and copper oxide, and d CuOx and d Cu are, respectively the density of copper oxide CuO (6 g/cm 3 ) and metallic copper (8.9 g/cm 3 ).",
"[0102] Considering 1 g of oxidized cermet (the cermet pre-reduction), its volume V pre-cermet(ox) is given by: [0000] V pre - cermet ( ox ) = V SDC ( ox ) + V CuOx ( ox ) + V pore ( ox ) or ( 3 ) V pre - cermet ( ox ) = m SDC ( ox ) d SDC ( ox ) + m CuOx ( ox ) d CuOx ( ox ) + V pore ( ox ) ( 4 ) [0000] where m SDC and m CuOx are the mass of both phases in the cermet.",
"Being V pore (ox)=0.36V pre-cermet (ox) (from porosimetry measurements), equation ( 4 ) can be rewritten as: [0000] ( 1 - 0.36 ) V pre - cermet ( ox ) = m SDC ( ox ) d SDC ( ox ) + m CuOx ( ox ) d CuOx ( ox ) + V pore ( ox ) ( 5 ) [0000] and the calculated value for V pre-cermet (ox) is 0.249 cm 3 .",
"[0103] As the porosity volume of the reduced cermet, V pore (red) is given by: [0000] V pore (red)= V pore (ox)+Δ V (6) [0000] and equal to 0.143 cm 3 , the final porosity of the cermet V pore (red)/V cermet (red) was of 55%.",
"[0104] The specific surface area was determined by the nitrogen BET method (Sorpty 1750, Carlo Erba Strumentazione, Italy) and resulted to be 1.6 m 2 /g.",
"F. Measurement of the Electrical Resistance of the Cu-SDC Cermet.",
"[0105] The layer resistance (measured along the major layer axis) of the cermet was measured by the dc four-probe method using an EC-1286 device (Solartron Schlumberger).",
"The cermet had a surface of 1×1 cm 2 and was 42 μm-thick.",
"Current and potential probes were made of platinum wire.",
"[0106] The following procedure was used.",
"After reduction of the pre-cermet layer to cermet, the sample was further heated in hydrogen (3 vol.",
"% H 2 O) up to 700° C. at a rate of 200° C./hour.",
"The temperature was maintained for 2 hours, then sequential measurements of resistance were done and the stability of the cermet anode was ascertained.",
"The sample was cooled to 500° C. by steps of 50° C. at a rate of 100° C./hour and step time of 10 min, and its resistance was measured at each grade.",
"Finally, the sample was cooled at a rate of 200° C./hour to room temperature and its resistance was measured again.",
"[0107] The results are shown in FIG. 2 .",
"The cermet has a metallic behavior with a resistance increasing with temperature.",
"This reads for a uniform distribution of the metallic phase through the cermet.",
"[0108] The electric resistance longitudinally along the anode, 1×1 cm 2 in size and 0.004 cm thick, changes between 6.3 mΩ and 21.0 mΩ at a temperature from 20 to 700° C. The results are set forth in Table 2 below.",
"Example 2 Preparation and Characterization of a Cu-SDC (70 Wt %-30 Wt %) Cermet Using CuO and SDC Starting Materials [0109] The same preparation procedure described in example 1 was used with CuO (15 g) and SDC (6.37 g) as starting material.",
"The ground CuO had a total specific surface area (S) of 0.9 m 2 /g and a mean particle size (d) of 3.4 μm at a normal particle size distribution from 0 to 20 μm.",
"[0110] The same amount of slurry (16±4 mg/cm 2 ) was deposited on a SDC electrolyte, and after the heat treatment at 1050° C. the final thickness of the pre-cermet was 39 μm;",
"the thickness shrinkage was 33.7% indicating a good sintering of electrode structure.",
"[0111] The final thickness of the pre-cermet was 43.6 μm and the thickness shrinkage was 32.5% indicating a good sintering of the structure.",
"[0112] The porosity of the pre-cermet before reduction was 36%, and after reduction was 54.4%.",
"[0113] The electrical resistance along the cermet was measured according to example 1.",
"The measured values (5.8 mΩ at 20° C. and 23.0 mΩ at 700° C.) are according to the requirements for an anodes used in fuel cells, as set forth in Table 2.",
"[0000] TABLE 2 Electrical resistance and specific conductivity alone the Cu-SDC anodes Example Resistance at 20° C. (mΩ) Resistance at 700° C. (mΩ) 1 6.3 21.0 2 5.8 23.0 Example 3 Activation of Cu-SDC Cermet with SDC [0114] A Cu-SDC cermet prepared according to example 1 was activated by impregnation with SDC oxide material.",
"The Cu-SDC cermet in the reduced state was impregnated with a solution of Ce(OCOC(CH 3 ) 2 C 4 H 9 ) 3 and Sm(OCOC(CH 3 ) 2 C 4 H 9 ) 3 (cerium and samarium 2,2-dimethyl-hexanoate) in benzene (4 g/100 ml).",
"Filtering paper was used to remove the excess solution from the cermet surface.",
"The cermet was impregnated dried and heat treated (400° C.) three times.",
"The activated cermet was then heated at a rate of 200° C./h up to 650° C. in H 2 (3 vol.",
"% water) and the total amount of deposited SDC was 0.27 mg (6 wt %).",
"The specific surface area of the SDC phase was 56.2 m 2 /g.",
"Example 4 Activation of Cu-SDC Cermet with CeO 2 [0115] A Cu-SDC cermet prepared according to example 2 was activated by impregnation with CeO 2 .",
"The Cu-SDC cermet in the reduced state was impregnated with a solution of Ce(NO 3 ) 2 in water (140 g/100 ml).",
"Filtering paper was used to remove the excess solution from the cermet surface.",
"The cermet was impregnated dried and heat treated (400° C.) twice.",
"The activated cermet which was then heated at a rate of 100° C./h up to 650° C. in H 2 (3 vol.",
"% water), and total amount of deposited CeO 2 was 8.42 mg (15.4 wt %).",
"The specific surface area was determined by the nitrogen BET method (Sorpty 1750, Carlo Erba Strumentazione, Italy), and resulted to be for CeO 2 of 39.4 m 2 /g.",
"Example 5 Activation of a Cu-SDC Cermet with Ni+CGO [0116] A Cu-SDC cermet prepared according to example 2 was activated with a mixture of Ni (70 wt %) and CGO (Ce 0.8 Gd 0.2 O 1.9 ;",
"30 wt %).",
"The Cu-SDC cermet in reduced state was impregnated with a solution of 4 g/100 ml of M(OCOC(CH 3 ) 2 C 4 H 9 ) x wherein M-=e, Gd and Ni, x is from stoichiometry (3.29 g of Ni precursor, 0.67 g of Ce precursor and 0.04 g of Gd precursor) in C 6 H 6 .",
"Filtering paper was used to remove the excess of solution from the cermitic surface.",
"The cermet was impregnated, dried and heat treated (400° C.) thrice.",
"The activated cermet was and heated at a rate of 200° C./h up to 650° C. in H 2 (3 vol.",
"% water).",
"The total amount of deposited activator was 0.1 mg (2 wt %).",
"The specific surface area of the activator was of 135 m 2 /g.",
"Example 6 Activation of a Cu-SDC Cermet with CeO 2 +Ni [0117] A Cu-SDC cermet prepared according to example 2 was activated with CeO 2 and Ni.",
"First the Cu-SDC cermet in reduced state was impregnated with a solution of Ce(NO 3 ) 3 in water (140 g/100 ml H 2 O).",
"Filtering paper was used to remove the excess of solution from the cermitic surface.",
"The cermet was impregnated, dried and heat treated (500° C.).",
"Then the activated cermet was impregnated with a solution of Ni(NO 3 ) 2 in water (167.5 g/100 ml H 2 O).",
"Filtering paper was used to remove the excess of solution from the cermitic surface.",
"The cermet was impregnated, dried and heat treated (500° C.).",
"The resulting activated cermet was dried and heated up to 500° C. with the rate 100° C./h in H 2 (3 vol.",
"% water).",
"The total amount of deposited activator was 0.45 mg CeO 2 and 0.1 mg Ni (9 wt % and 2 wt %, respectively).",
"[0118] The specific surface areas were determined by the nitrogen BET method (Sorpty 1750, Carlo Erba Strumentazione, Italy), first for CeO 2 and subsequently for Ni.",
"CeO 2 showed a specific surface area of 39.4 m 2 /g, and Ni showed a specific surface area of 84.6 m 2 /g.",
"Example 7 Evaluation of a Solid Oxide Fuel Cell with Anode Comprising a Cu-SDC Cermet Activated with Ni—CeO 2 [0119] The electrochemical measurements under conditions of a CH 4 /air were effected as follows.",
"[0120] A three-electrode cell ( 5 ) as from FIG. 4 was used.",
"The cell comprised an anode ( 6 ), an electrolyte membrane ( 7 ) and a cathode ( 4 ).",
"Anode ( 6 ) and electrolyte membrane ( 7 ) were a disk-shaped anode/electrolyte membrane assembly (Ø=12 mm) wherein the anode layer was as from the title and the electrolyte membrane was SDC.",
"A fine Pt+PrO x paste was painted as cathode ( 8 ) on the surface of the electrolyte membrane ( 7 ) opposite to that in contact with the anode ( 6 ) (SU invention certificate No. 1.786.965).",
"Each of anode ( 6 ) and cathode ( 8 ) had an area of about 0.3 cm 2 .",
"A reference electrode ( 9 ) was made of a platinum coil on the circumference of the electrolyte membrane ( 7 ).",
"The three-electrode cell was pressed by a spring load against the rim of a zirconium dioxide tube ( 10 ).",
"[0121] Methane fuel gas (3 vol.",
"% H 2 O, V CH 4 ˜2-5 l/hour) was fed to the anode side through an alumina tube ( 11 ) positioned inside the zirconium dioxide tube ( 10 ).",
"The cathode side was blown with air (v=6 l/hour).",
"The composition of the combusted anode cermet was determined by means of a solid electrolyte oxygen sensor ( 12 ).",
"The cell temperature was measured by a chromel-alumel thermocouple ( 13 ).",
"[0122] The overvoltage of the electrodes and the ohmic voltage drop in the electrolyte were determined under stationary conditions (galvanostatic mode) by the current interruption method.",
"The length of the current interruption edge did not exceed 0.3 μs.",
"The off-current state time of the cell was ˜0.3 ms (millisecond).",
"The relative duration of the cut-off pulses (off/on) was ≦1/1540.",
"[0123] The measuring set-up included the following instruments: universal digital voltmeter type B7-39 (0.02% accuracy class);",
"universal digital oscillograph type C 9-8 (1.5% accuracy class);",
"dc power source type VIP-009;",
"relay switch unit type RSD-725;",
"programmed temperature controller type TP-403;",
"IBM PC 286 AT personal computer, gas flow-rate regulator type SRG-23.",
"[0131] The instruments and the computer communicated via a COP interface bus (IEEE-488).",
"[0132] The following measurement procedure of was used.",
"Methane (3 vol.",
"% H 2 O) was flown at 2 l/hour and the cell heated to a temperature of 700° C. at a rate of 200° C./hour.",
"The cell ( 5 ) was allowed to stand for 0.5 hour before its polarization characteristics were measured.",
"The measurements were made between 700° C. and 500° C., decreasing temperature.",
"To check the time stability of the characteristics, the measurements were repeated at 700° C. The stability of the cell was ascertained.",
"[0133] The Cu-SDC cermet activated with Ni—CeO 2 (example 6) was tested as anode for polarization measurement.",
"FIG. 4 illustrates polarization curves recorded under methane (3% H 2 O, V CH 4 =2.7 l/h) at three different temperatures, 547° C., 595° C. and 646° C. The cermet Ni+CeO 2 provides an anode having remarkable activity in methane oxidation.",
"For example, at 646° C. to a polarization of 50 mV corresponds to the current density of 0.38 A/cm 2 .",
"[0134] FIG. 5 shows the characteristic performance of potential and power density as function of the current density of the single fuel cell with an anode as said above, a SDC 0.0250 cm thick electrolyte membrane and a Pt+PrO 2-x , cathode, fed with CH 4 /air at 596, 645 and 696° C. The measured OCV voltages (U oc ) are near 0.9 V. Taking into account the value predicted by the Nernst equation (about 1.0 V at 800° C.), the obtained OCV voltages indicate that methane is efficiently oxidized.",
"At 696° C. a maximum power density of 0.24 W/cm 2 was measured at 0.45 A/cm 2 .",
"Example 8 Solid Oxide Fuel Cell with a Cu-SDC Cermet Activated with [Ni+CeO 2 ]+MoOx [0135] The Cu-SDC cermet activated with Ni—CeO 2 (example 6) was further impregnated with a (NH 4 ) 6 Mo 7 O 24 [.",
"].4H 2 O aqueous solution at (4.14 g/100 ml, pH=7-8), following the procedure of example 6.",
"The amount of MoOx (a mixture of MoO 2 and MoO 3 ) was 0.07 mg corresponding to 11 wt % of the total mass of the activating materials (about 1 wt % of the total anode mass).",
"[0136] FIG. 7 shows the polarization curves of anodes based on said Cu-SDC cermet activated with MoOx+Ni+CeO 2 at three different temperatures, 599, 648 and 698° C. From this figure it is seen that the anode is active towards methane oxidation, and at 698° C. an anodic polarization of 50 mV corresponds to the current density of 0.37 A/cm 2 .",
"[0137] FIG. 8 shows the characteristic performance of a fuel cell MoO+Ni+CeO 2 —(Cu-SDC)/SDC/Pt+PrO 2-x , fed with CH 4 at 600, 645 and 700° C. The electrolyte was 0.0560 cm thick.",
"The measured OCV voltages (U oc ) are near 0.9 V, and a maximum power density of 0.120 W/cm 2 was measured at 0.21/Acm 2 at 700° C. [0138] The stability of the activated anode was tested in CH 4 atmosphere.",
"FIG. 9 illustrates anodic polarization curves recorded in CH 4 /air fuel cell after 25 (□) and 46 h (∘) in CH 4 +3% 1120 mixtures, and further 7 h (Δ) in CH 4 +3% H 2 O atmosphere.",
"It can be seen that after an initial deactivation the anode response is stable in time.",
"[0139] The following Table 3 provides a comparison between the electrochemical performance of solid oxide fuel cells according to the invention, fed with CH 4 , and those of the prior art fed with C 4 H 10 .",
"[0000] TABLE 3 Current density Power density SOFC (A/cm 2 at 50 mV) (W/cm 2 ) Example 7 0.38 at 646° C. 0.24 at 0.45 A/cm 2 and 696° C. Example 8 0.37 at 698° C. 0.12 at 0.21 A/cm 2 and 700° C. CeO 2 —Cu-SDC* 0.06 at 650° C. 0.05 at 0.17 A/cm 2 and 650° C. CeO 2 —Au-SDC* 0.10 at 650° C. 0.05 at 0.13 A/cm 2 and 650° C. *C.",
"Lu et al.",
", J. Electrochem.",
"Soc, 150(10), A1357-A1359 (2003) [0140] In spite of the fact that the SOFC of the prior art were tested under C 4 H 10 which, as already mentioned above, is known to be more reactive to oxidation than CH 4 , their electrochemical performances is dramatically lower than those of the SOFC according to the present invention.",
"The different temperatures in some instances applied cannot be seen as a key-factor in evaluating this disparity of performance, because the ΔT is of just 50° C. or less."
] |
This invention was developed under a contract with the United States Government and is subject to the rights of the Government.
This is a division of application Ser. No. 846,411 filed Mar. 31, 1986, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and device for growing multi-layer crystals and, in particular, to a device used to mask off portions of a substrate on which such a crystal is growing so that the various multi-layers have edge portions exposed that may be connected to electrical leads.
2. Description of Related Art
Solid-state electronic devices employ crystalline materials. These crystalline materials are very fragile and some devices require multi-layers of thin crystal material to be formed on a suitable crystalline substrate. When such multi-layered crystals are made, it is important that the successive layers of crystals have portions exposed so that these portions can be connected to electrical leads. The present techniques for accomplishing this are very cumbersome and frequently lead to the breakage of the crystalline material. Some crystalline materials are particularly fragile, and there are suitable ways to accomplishy this task without breakage.
SUMMARY OF THE INVENTION
The present invention provides both a simplified method and device for forming multi-layered crystals with edge portions exposed. Typically, a rectangular multi-layered crystal is formed by growing successive layers of crystalline material on a rectangular, preferably square shaped, crystalline substrate. It is not critical for the purposes of this invention what crystalline material is employed for the layers other than it is of the type that, upon melting and then cooling, will form the crystalline layer. A suitable crystalline material substrate is, for example, silver gallium sulfide (AgGaS 2 ). The same or different crystalline materials are then grown on this substrate. For example, these successive multi-layers of crystal may be gallium arsenide, but the layers will alternate between low resistivity and high resistivity. If the layers are essentially of the same material, the resistivity will be controlled by appropriate doping, as known in the art.
In accordance with this invention, the rectangular substrate is placed in a holder. The holder is made from a material which can withstand the high temperatures of the liquid crystal melt, in which the substrate and holder will be dipped. For example, the holder may be of graphite.
The holder has a window or opening in it, in which the substrate sits. The masking element leaves most of the substrate exposed except that a cover piece, usually a corner, rests over a holder over the substrate. A masking element is placed on the portion on the surface of the substrate. The substrate and masking element are detachably secured together to the holder. This assembly is dipped into a molten liquid crystal of low resistivity. The molten material is allowed to cool slowly while a thin layer of crystalline material is formed on the substrate. By proper control of residence time and temperature of the molten material, a thin, smooth layer can be produced; this will also depend on the nature of the molten material. This crystalline material, however, does not form on the surface of the substrate where the cover piece of the masking element rests on it.
When the thin layer of crystalline material is formed on the substrate, the assembly is removed from the bath, cleaned, the masking element is removed and a second masking element is placed in the holder over the substrate. The main difference between the two masking elements is that the second masking element includes two cover pieces, one of which corresponds in size, shape and location as the cover piece on the first masking element. The thickness of this cover piece is greater than the thickness of the second cover piece so that it sets in the recess or uncoated area created by the cover piece in the first masking element.
This assembly of holder, substrate, and the second masking element is then reinserted into a melt of high resistivity, which is again allowed to cool to form a second crystalline layer that overlies the first crystalline layer except where the cover pieces are located.
Upon removal of the holder from the liquid melt, the substrate has two layers on it. The substrate has one uncoated corner; the first layer has a void corresponding to that uncoated corner and a second corner that is uncoated. By progressively using additional masking elements which have additional cover pieces, additional crystalline layers of alternating resistivity may be added to the substrate and each layer will have a uniquely positioned exposed portion for electrical contact.
If the holder is open on both sides of the substrate, masking elements on each side of the substrate can be used to form crystalline layers on each side. For convenience, it is preferred that the successive pairs of masking elements have matching cover pieces.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the holder of this invention and a set of the masking elements shown in exploded positions.
FIG. 1a is an exploded perspective of the multi-layered crystal made using the device of this invention, with the multi-layers being in the same relative positions as masking elements of FIG. 1 used to form them.
FIG. 2 is a perspective view of the holder, with the substrate and one masking element in place.
FIG. 3 is an exaggerated perspective view of an eight-layered crystal formed using the device of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, there is shown the holder 14 of this invention used to make multi-layered crystals and a plurality of masking elements, top elements 16-19 and bottom elements 20-23. The holder 14 is made of graphite and includes (1) a forked section 24, including two arms 24a and 24b which are adapteed to be connected to the insertion equipment (not shown) used to insert the holder into the liquid melt of the crystal material, and (2) a window section 26 in which the rectanglular crystalline substrate is inserted. The window section 26 includes a rectangular recessed portion 28 and a plate member 30 integral with the side walls of recess portion 28. Along the sides of window 26 is a ledge 38 on which the crystalline substrate 40 is placed. The plate member 30 includes a threaded hole 42 which receives a graphite screw 44 that successively holds the four top masking elements 16-19 in position through openings 42. There is a complementary hole on the underside of the plate member 30 which successively holds the four bottom masking elements 20-23 in position when a second graphite screw 46 is inserted through aligned openings 48 in the masking elements 20-23.
Referring to the top masking elements 16-19, there is shown four almost identical masking elements which are adapted to be aligned and placed in registration so that they fit within the window section 26 and may be detachably secured by means of the screw 44. Each of these masking elements includes a pair of outwardly extending legs 50; these legs provide support to the masking elements and can be eliminated if the masking element is sufficiently strong. These legs are connected by an integral connecting member 52 and the legs and member define an opening 53.
Referring to masking element 16 in FIG. 1, there is shown a triangular cover piece 54 situated in one corner of the rectangular opening. The second masking element 17, as shown in FIG. 1, is similar to the first element 16, except that it has two cover pieces 56 and 58 situated in opposite corners. The third masking element 18, as shown in FIG. 1, again is similar to the elements 16 and 17, except that it has three cover pieces 60, 61, 62 situated at three corners. The fourth masking element 19 is the same as the preceeding elements 16, 17 and 18 except that it has four cover pieces 63, 64, 65 and 66 situated in each of its corners. The thickness of the cover pieces will vary in order to fit snugly in the unplated portions of the prior layers. This is best illustrated in FIG. 1 by cover pieces 54', 56', 58', 60', 61', 62', 63', 64', 65', 66' which shows the progressive thickening of the cover pieces. In the case of masking element 16, the cover piece 54 will be flush with the bottom surface of element 16 because this element rests directly on substrate 40, whereas cover piece 54' on masking element 20 must be thick enough to compensate for lower recess in window 36.
The Method:
The multiple layers of crystal material are formed on the substrate 40 (FIG. 2) in accordance with conventional practice. The significant difference is that the holder and successive masking elements are employed to block off portions of the multi-layers so that electrical leads can be connected to these layers.
In accordance with one method of this invention, the rectangular substrate 40 is placed in window 36 in the holder 14, resting on the ledge 38, and then the masking elements 16 and 20 are secured so that they overlie both the top and bottom sides of the substrate. With these masking elements 16 and 20 in place, the holder 14 is then placed in the liquid melt of the crystalline material and allowed to cool so that there is formed on the upper and lower surface of the substrate two distinct crystal layers. Because of the use of the cover pieces 54 and 54', the corner edges of the substrate 40 are blocked off so that the newly formed crystal layers have a truncated corner. This is best illustrated in FIG. la which shows the upper and lower crystal layers 70 and 70', respectively, formed as a result of the first immersion step. Because of the cover pieces 54 and 54', as illustrated in FIG. 1, the layers 70 and 70' will grow over the substrate except in corners 54a and 54b, respectively. As best illustrated in FIG. 1 with respect to masking elements 20, 21, 22 and 23, the thickness of the corner pieces progressively increases to fit snugly over prior uncoated areas.
The next step of the method consists of replacing masking elements 16 and 20 with the masking elements 17 and 21 in the holder. This assembly is then placed into the liquid melt and again two layers 71 and 71' (FIG. 1a) are formed on the previously formed layers 70 and 70', respectively.
The process is again repeated using the masking elements 18 and 22. The layers 72 and 72' formed in this step, as shown in FIG. 1a, have three truncated corners. The fourth set of masking elements 19 and 23 are attached to the holder 14 and this assembly is again reinserted into the liquid melt to form the final top and bottom layers 73 and 73' of the multi-layered cyrstal 12. The assembly is then removed from the liquid melt, cleaned, and the masking elements are detached from the holder 14. The multi-layered crystal 12 thus formed is shown in FIG. 3. This crystal 12 will have a number of edge portions, e.g., 54a and 54b, so exposed so that each layer may be connected to an electrical lead.
The above description presents the best mode contemplated of carrying out the present invention as depicted by the embodiment disclosed. The features illustrated by this embodiment provides the advantages of this invention. This invention is, however, susceptible to modifications and alternate constructions from the embodiment shown in the drawings and described above. Consequently, it is not the intention to limit it to the particular embodiment disclosed. On the contrary, the intention is to cover all modifications and alternates falling within the scope of the invention as generally expressed by the following claims. | Disclosed is a device for making multi-layer crystals. It includes a holder and a plurality of masking elements adapted to be secured successively to the holder. The masking elements have cover pieces that overlie the area protected by the preceding cover pieces and have an additional cover piece. This produces a device having progressively truncated corner sections. There is thus formed a multi-layered crystal having portions adapted to be connected to electrical leads. | Provide a concise summary of the essential information conveyed in the given context. | [
"This invention was developed under a contract with the United States Government and is subject to the rights of the Government.",
"This is a division of application Ser.",
"No. 846,411 filed Mar. 31, 1986, now abandoned.",
"BACKGROUND OF THE INVENTION 1.",
"Field of the Invention The invention relates to a method and device for growing multi-layer crystals and, in particular, to a device used to mask off portions of a substrate on which such a crystal is growing so that the various multi-layers have edge portions exposed that may be connected to electrical leads.",
"Description of Related Art Solid-state electronic devices employ crystalline materials.",
"These crystalline materials are very fragile and some devices require multi-layers of thin crystal material to be formed on a suitable crystalline substrate.",
"When such multi-layered crystals are made, it is important that the successive layers of crystals have portions exposed so that these portions can be connected to electrical leads.",
"The present techniques for accomplishing this are very cumbersome and frequently lead to the breakage of the crystalline material.",
"Some crystalline materials are particularly fragile, and there are suitable ways to accomplishy this task without breakage.",
"SUMMARY OF THE INVENTION The present invention provides both a simplified method and device for forming multi-layered crystals with edge portions exposed.",
"Typically, a rectangular multi-layered crystal is formed by growing successive layers of crystalline material on a rectangular, preferably square shaped, crystalline substrate.",
"It is not critical for the purposes of this invention what crystalline material is employed for the layers other than it is of the type that, upon melting and then cooling, will form the crystalline layer.",
"A suitable crystalline material substrate is, for example, silver gallium sulfide (AgGaS 2 ).",
"The same or different crystalline materials are then grown on this substrate.",
"For example, these successive multi-layers of crystal may be gallium arsenide, but the layers will alternate between low resistivity and high resistivity.",
"If the layers are essentially of the same material, the resistivity will be controlled by appropriate doping, as known in the art.",
"In accordance with this invention, the rectangular substrate is placed in a holder.",
"The holder is made from a material which can withstand the high temperatures of the liquid crystal melt, in which the substrate and holder will be dipped.",
"For example, the holder may be of graphite.",
"The holder has a window or opening in it, in which the substrate sits.",
"The masking element leaves most of the substrate exposed except that a cover piece, usually a corner, rests over a holder over the substrate.",
"A masking element is placed on the portion on the surface of the substrate.",
"The substrate and masking element are detachably secured together to the holder.",
"This assembly is dipped into a molten liquid crystal of low resistivity.",
"The molten material is allowed to cool slowly while a thin layer of crystalline material is formed on the substrate.",
"By proper control of residence time and temperature of the molten material, a thin, smooth layer can be produced;",
"this will also depend on the nature of the molten material.",
"This crystalline material, however, does not form on the surface of the substrate where the cover piece of the masking element rests on it.",
"When the thin layer of crystalline material is formed on the substrate, the assembly is removed from the bath, cleaned, the masking element is removed and a second masking element is placed in the holder over the substrate.",
"The main difference between the two masking elements is that the second masking element includes two cover pieces, one of which corresponds in size, shape and location as the cover piece on the first masking element.",
"The thickness of this cover piece is greater than the thickness of the second cover piece so that it sets in the recess or uncoated area created by the cover piece in the first masking element.",
"This assembly of holder, substrate, and the second masking element is then reinserted into a melt of high resistivity, which is again allowed to cool to form a second crystalline layer that overlies the first crystalline layer except where the cover pieces are located.",
"Upon removal of the holder from the liquid melt, the substrate has two layers on it.",
"The substrate has one uncoated corner;",
"the first layer has a void corresponding to that uncoated corner and a second corner that is uncoated.",
"By progressively using additional masking elements which have additional cover pieces, additional crystalline layers of alternating resistivity may be added to the substrate and each layer will have a uniquely positioned exposed portion for electrical contact.",
"If the holder is open on both sides of the substrate, masking elements on each side of the substrate can be used to form crystalline layers on each side.",
"For convenience, it is preferred that the successive pairs of masking elements have matching cover pieces.",
"BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the holder of this invention and a set of the masking elements shown in exploded positions.",
"FIG. 1a is an exploded perspective of the multi-layered crystal made using the device of this invention, with the multi-layers being in the same relative positions as masking elements of FIG. 1 used to form them.",
"FIG. 2 is a perspective view of the holder, with the substrate and one masking element in place.",
"FIG. 3 is an exaggerated perspective view of an eight-layered crystal formed using the device of this invention.",
"DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 1 and 2, there is shown the holder 14 of this invention used to make multi-layered crystals and a plurality of masking elements, top elements 16-19 and bottom elements 20-23.",
"The holder 14 is made of graphite and includes (1) a forked section 24, including two arms 24a and 24b which are adapteed to be connected to the insertion equipment (not shown) used to insert the holder into the liquid melt of the crystal material, and (2) a window section 26 in which the rectanglular crystalline substrate is inserted.",
"The window section 26 includes a rectangular recessed portion 28 and a plate member 30 integral with the side walls of recess portion 28.",
"Along the sides of window 26 is a ledge 38 on which the crystalline substrate 40 is placed.",
"The plate member 30 includes a threaded hole 42 which receives a graphite screw 44 that successively holds the four top masking elements 16-19 in position through openings 42.",
"There is a complementary hole on the underside of the plate member 30 which successively holds the four bottom masking elements 20-23 in position when a second graphite screw 46 is inserted through aligned openings 48 in the masking elements 20-23.",
"Referring to the top masking elements 16-19, there is shown four almost identical masking elements which are adapted to be aligned and placed in registration so that they fit within the window section 26 and may be detachably secured by means of the screw 44.",
"Each of these masking elements includes a pair of outwardly extending legs 50;",
"these legs provide support to the masking elements and can be eliminated if the masking element is sufficiently strong.",
"These legs are connected by an integral connecting member 52 and the legs and member define an opening 53.",
"Referring to masking element 16 in FIG. 1, there is shown a triangular cover piece 54 situated in one corner of the rectangular opening.",
"The second masking element 17, as shown in FIG. 1, is similar to the first element 16, except that it has two cover pieces 56 and 58 situated in opposite corners.",
"The third masking element 18, as shown in FIG. 1, again is similar to the elements 16 and 17, except that it has three cover pieces 60, 61, 62 situated at three corners.",
"The fourth masking element 19 is the same as the preceeding elements 16, 17 and 18 except that it has four cover pieces 63, 64, 65 and 66 situated in each of its corners.",
"The thickness of the cover pieces will vary in order to fit snugly in the unplated portions of the prior layers.",
"This is best illustrated in FIG. 1 by cover pieces 54', 56', 58', 60', 61', 62', 63', 64', 65', 66'",
"which shows the progressive thickening of the cover pieces.",
"In the case of masking element 16, the cover piece 54 will be flush with the bottom surface of element 16 because this element rests directly on substrate 40, whereas cover piece 54'",
"on masking element 20 must be thick enough to compensate for lower recess in window 36.",
"The Method: The multiple layers of crystal material are formed on the substrate 40 (FIG.",
"2) in accordance with conventional practice.",
"The significant difference is that the holder and successive masking elements are employed to block off portions of the multi-layers so that electrical leads can be connected to these layers.",
"In accordance with one method of this invention, the rectangular substrate 40 is placed in window 36 in the holder 14, resting on the ledge 38, and then the masking elements 16 and 20 are secured so that they overlie both the top and bottom sides of the substrate.",
"With these masking elements 16 and 20 in place, the holder 14 is then placed in the liquid melt of the crystalline material and allowed to cool so that there is formed on the upper and lower surface of the substrate two distinct crystal layers.",
"Because of the use of the cover pieces 54 and 54', the corner edges of the substrate 40 are blocked off so that the newly formed crystal layers have a truncated corner.",
"This is best illustrated in FIG. la which shows the upper and lower crystal layers 70 and 70', respectively, formed as a result of the first immersion step.",
"Because of the cover pieces 54 and 54', as illustrated in FIG. 1, the layers 70 and 70'",
"will grow over the substrate except in corners 54a and 54b, respectively.",
"As best illustrated in FIG. 1 with respect to masking elements 20, 21, 22 and 23, the thickness of the corner pieces progressively increases to fit snugly over prior uncoated areas.",
"The next step of the method consists of replacing masking elements 16 and 20 with the masking elements 17 and 21 in the holder.",
"This assembly is then placed into the liquid melt and again two layers 71 and 71'",
"(FIG.",
"1a) are formed on the previously formed layers 70 and 70', respectively.",
"The process is again repeated using the masking elements 18 and 22.",
"The layers 72 and 72'",
"formed in this step, as shown in FIG. 1a, have three truncated corners.",
"The fourth set of masking elements 19 and 23 are attached to the holder 14 and this assembly is again reinserted into the liquid melt to form the final top and bottom layers 73 and 73'",
"of the multi-layered cyrstal 12.",
"The assembly is then removed from the liquid melt, cleaned, and the masking elements are detached from the holder 14.",
"The multi-layered crystal 12 thus formed is shown in FIG. 3. This crystal 12 will have a number of edge portions, e.g., 54a and 54b, so exposed so that each layer may be connected to an electrical lead.",
"The above description presents the best mode contemplated of carrying out the present invention as depicted by the embodiment disclosed.",
"The features illustrated by this embodiment provides the advantages of this invention.",
"This invention is, however, susceptible to modifications and alternate constructions from the embodiment shown in the drawings and described above.",
"Consequently, it is not the intention to limit it to the particular embodiment disclosed.",
"On the contrary, the intention is to cover all modifications and alternates falling within the scope of the invention as generally expressed by the following claims."
] |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates to a method for producing a basic amino acid such as L-lysine known as an important additive for livestock feed or L-arginine or L-histidine useful as a drug such as an infusion solution (i.e., parenteral fluid) or the like.
[0003] 2. Related Art
[0004] In a conventionally known method for producing a basic amino acid by means of fermentation, sulfate ions or chloride ions (chlorine ions) have heretofore been generally used as counter anions so as to maintain electrical neutrality of a culture medium. These are supplied mostly in the form of ammonium sulfate as described in, for example, Japanese Patent Application Laid-Open Nos. 30985/'93, 244969/'93, and the like.
[0005] Meanwhile, a basic amino acid such as lysine or the like is often sold in the form of the chloride salt (hydrochloride) since it is difficult to crystallize a basic amino acid such lysine or the like in the free state. However, in the production method of a basic amino acid by means of fermentation, since a hydrochloride causes corrosion of a fermentation tank, or the like, a sulfate is often used for fermentation for the purpose of avoiding the corrosion of the tank.
[0006] In this case, however, since a basic amino acid product as such resulting from such fermentation is different in counter anion from a basic amino acid product (to be) placed in distribution, the counter anions (such as sulfate ions) are once removed from the basic amino acid salt produced by means of such fermentation, with the use of, e.g., an anion exchange resin and desired counter anions (such as chloride ions) are then added in the form of a free acid, whereby the target basic amino acid salt is produced. Such use of a resin, however, increases loads on environmental protection such as drainage resulting from use of the resin, and the like.
[0007] Further, since such use of a resin requires excess acid and alkali, a variety of by-products are also discharged in addition to the target amino acid salt.
[0008] In addition, when a basic amino acid such as lysine or the like is to be placed in distribution in the form of a solution-type amino acid feed additive, the solubility of the amino acid in the feed additive solution decreases due to the presence of counter anions, if present therein, so that the counter anions must be removed with the use of a resin in order to obtain an amino acid solution with a high concentration.
[0009] In the case of lysine as an example, lysine hydrochloride can be dissolved in water at 10° C. in an amount of at most 43 g in terms of lysine per 100 g of water, and lysine ½ sulfate can be dissolved in an amount of at most 68 g per 100 g of water. On the other hand, in the case of a solution having only lysine dissolved therein (a free lysine solution), the solution is alkaline in nature, and lysine can be dissolved therein in an amount of as much as 120 g per 100 g of water. In this connection, refer to Japanese Patent Application Laid-Open No. 256290/2000.
[0010] As could be understood from the above, removal of the counter anions from a basic amino acid solution is essential or indispensable to prepare a basic amino acid solution having a high concentration.
[0011] There has been known as a conventional method for purifying an amino acid fermentation broth with the use of an ion exchange membrane, a method (as disclosed in Japanese Patent Publication No. 7666/1960) in which the amino acid moiety in an aqueous solution of an amino acid salt is caused to pass through the ion exchange membranes with the use of an electrodialyser equipped with a plurality of cation exchange membranes and anion exchange membranes, the two kinds of ion exchange membranes being disposed alternately, whereby the amino acid is produced. The performance of the method, however, is not necessarily high in terms of electrical efficiency due to low mobility of organic molecules such amino acid or the like.
[0012] Further, in the case of a solution which contains a large amount of various organic metabolites and the like resulting from microbial fermentation, which, in turn, cannot pass through a cation exchange membrane and an anion exchange membrane, their concentrations become so significantly high at the surfaces of the ion exchange membranes that these organic metabolites are deposited or agglomerated and eventually accumulated on the surfaces of the ion exchange membranes to clog the membranes, which ends in making a continuous operation impossible disadvantageously.
SUMMARY OF THE INVENTION
[0013] [Problems to be Solved by the Invention]
[0014] It is an object of the present invention to provide a method for obtaining a basic amino acid solution having a high concentration within the concentration range in which crystals of a basic amino acid salt are not deposited, by removing the counter anions from a solution of the basic amino acid salt efficiently by use of electrodialysis.
[0015] [Means for Solving the Problems]
[0016] The present inventors have made extensive and intensive studies to achieve the above object and found that, in removing the counter anions of a basic amino acid by means of electrodialysis, when an alkali aqueous solution is added to a solution of the basic amino acid salt (solution to be subjected to electrodialysis) during the electrodialysis, the counter anions of the basic amino acid such as sulfate ions or the like can be efficiently removed to such degree that they remain in an amount of 40 mol % or smaller based on the amino acid. The present invention has been completed on the basis of these findings.
[0017] Accordingly, the present invention relates to a method for producing a basic amino acid solution which comprises subjecting a solution of a basic amino acid salt to electrodialysis with the use of an electrodialyser equipped with cation exchange membranes and anion exchange membranes in combination, wherein an alkali aqueous solution is added to the solution of a basic amino acid salt during the electrodialysis, whereby not only desalting is caused but also the counter anions of the basic amino acid are removed to such degree that the said counter anions remain in an amount of 40 mol % or smaller based on the basic amino acid, and also to a method for producing a basic amino acid solution which comprises subjecting a solution of a basic amino acid salt to electrodialysis with the use of an electrodialyser equipped with anion exchange membrane alone, wherein an alkali aqueous solution is added to the solution of a basic amino acid salt to adjust the pH of the solution to 7 to 10 during the electrodialysis, whereby the counter anions are removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 shows a schematic diagram for illustrating an example of an electrodialyser to be used in the practice of the method of the present invention.
DESCRIPTION OF SYMBOLS
[0019] [0019] 1 : ELECTRODIALYSER.
[0020] A 1 to A 10 ANION EXCHANGE MEMBRANES.
[0021] K 1 to K 12 : CATION EXCHANGE MEMBRANES.
[0022] [0022] 3 : ANODE
[0023] [0023] 4 : CATHODE
[0024] [0024] 5 to 15 : CONDUITS FOR SUPPLYING A SOLUTION TO BE DIALYZED.
[0025] [0025] 5 ′ to 15 ′: CONDUITS FOR DISCHARGING THE SOLUTION DIALYZED.
[0026] [0026] 16 to 27 : CONDUITS FOR SUPPLYING A DIALYSIS SOLVENT FOR COLLECTING THE COUNTER ANIONS DIALYZED.
[0027] [0027] 16 ′ to 27 ′: CONDUITS FOR DISCHARGING THE DIALYSIS SOLVENT WHICH HAS COLLECTED THE DIALYZED COUNTER ANIONS.
[0028] [0028] 28 to 30 : CONDUITS FOR SUPPLYING AN ELECTRODE SOLUTION.
[0029] [0029] 28 ′ to 30 ′: CONDUITS FOR DISCHARGING THE ELECTRODE SOLUTION.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Hereinbelow, the present invention will be described in great detail.
[0031] The method of the present invention is carried out by using an electrodialyser equipped with sulfonic acid type or carboxylic acid type cation exchange membrane(s) and quaternary ammonium base type or tertiary amine type anion exchange membrane(s) in combination or an electrodialyser equipped with quaternary ammonium base type or tertiary amine type anion exchange membrane(s). The number of ion exchange membranes disposed in the electrodialyser, the capacity of the electrodialyser, the number of the isolated chambers for a solution to be dialyzed and for a dialysis solvent in the electrodialyser and the size of the isolated chambers can be selected by those skilled in the art in a given case so appropriately as to achieve the object of the present invention.
[0032] There may be mentioned as a specific example of an electrodialyser to be used according to the present invention an electrodialyser in which an anode chamber, a raw material solution chamber (a chamber for a solution to be dialyzed), a salt recovering solvent chamber (dialysis solvent chamber) and a cathode chamber are separated with anion exchange membrane(s) and a cation exchange membrane(s). In the electrodialyser, a 5% sodium sulfate solution or the like is circulated in the cathode and anode chambers. In the raw material solution chamber, a basic amino acid salt solution such as a lysine fermentation broth or the like is made to pass, and in the adjacent salt recovering solvent chamber, pure water or the like is made to pass initially.
[0033] A plurality of raw material solution chambers and salt recovering solvent chambers can be of course used. To be more specific, electrodialysis can be carried out with the use of an appratus shown in FIG. 1, for example. In FIG. 1, in an electrodialyser 1 , cation exchange membranes K 1 K 2 , K 3 , . . . , K 10 and anion exchange membranes A 1 , A 2 , A 3 , . . . , A 10 are disposed alternately, one cation exchange membrane after another anion exchange membrane and cation exchange membranes K 11 and K 12 are in turn disposed after the anion exchange membrane A 10 so as to constitute a plurality of isolated chambers 2 , 2 , . . . , 2 . In the electrodialyser, an anode 3 (anode chamber) and a cathode 4 (cathode chamber) are provided at the ends so as to oppose each other.
[0034] A sample solution (raw material solution, solution to be dialyzed) is supplied into the electrodialyser via a conduit 5 and branch pipes 6 , 7 , 8 , . . . , 15 , flows through raw material solution chambers between the anion exchange membranes and the cation exchange membranes, and is discharged from the electrodialyser via branch pipes 6 ′, 7 ′, 8 ′, . . . , 15 ′ and a conduit 5 ′. Further, a dialysis solvent such as pure water or the like for collecting the dialyzed counter anions is supplied into the electrodialyser via a conduit 16 and branch pipes 17 , 18 , 19 , . . . , 27 and discharged from the electrodialyser via branch pipes 17 ′, 18 ′, 19 ′, . . . , 27 ′ and a conduit 16 ′. Meanwhile, a solution of a salt such as sodium sulfate which is appropriate as an electrode is introduced into the electrodialyser via a conduit 28 and branch pipes 29 and 30 and discharged from the electrodialyser via branch pipes 29 ′ and 30 ′ and a conduit 28 ′. During this operation, a direct current is made to pass between the electrodes.
[0035] According to the above-described electrodialysis using cation exchange membranes and anion exchange membranes in combination, desalting is carried out in addition to removal of counter anions. The removal of counter anions can still be achieved with the sole use of anion exchange membranes, in addition to the above concurrent use of cation exchange membranes and anion exchange membranes.
[0036] When only anion exchange membranes are used, an electrodialyser obtained by replacing all the cation exchange membranes K 1 , K 2 , K 3 , . . . , K 10 of the electrodialyser shown in FIG. 1 with anion exchange membranes can be used, for example. As a dialysis solvent to be supplied into the electrodialyser via the conduit 16 and the branch pipes 17 , 18 , 19 , . . . , 27 and discharged from the electrodialyser via the branch pipes 17 ′, 18 ′, 19 ′, . . . , 27 ′ and the conduit 16 ′, an alkal aqueous solution can be used. A solution to be dialyzed is subjected to electrodialysis after an alkali aqueous solution is added to the solution to adjust the pH of the solution to 7 to 10 so as to remove counter anions.
[0037] As an inflow velocity of the sample solution, a membrane surface linear velocity of not lower than 1 cm/sec, preferably 4 to 6 cm/sec, can be used. Conditions for electrodialysis such as a current density, a voltage, a duration of electrodialysis, and the like can be selected appropriately, depending upon characteristics of a basic amino acid salt solution which is a solution to be dialyzed, coexisting salts, the types and numbers of cation exchange membranes and anion exchange membranes to be used, the size of an electrodialyser, and the like. In general, good results can be obtained at a current density of about 1 to 5 A/dm 2 . The temperature can be room temperature to 70° C.
[0038] When electrodialysis is carried out by concurrent use of cation exchange membranes and anion exchange membranes, counter anions are dialyzed via the anion exchange membranes and removed from the raw material solution chambers, while foreign cations are dialyzed via the cation exchange membranes and removed into the salt recovering chambers. In this case, in order to remove the counter anions of a basic amino acid with the basic amino acid being left in the raw material solution, the amount of cations to be removed into the salt recovering chambers gets relatively insufficient. Therefore, an alkali aqueous solution such as ammonia water or the like which contains cations which pass through the cation exchange membranes easily, is added to the raw material solution, whereby the counter anions of the basic amino acid can be removed into the salt recovering solvent without the target amino acid being lost into the salt recovering solvent.
[0039] Illustrative examples of anion exchange membranes and cation exchange membranes to be used according to the production method of the present invention include “CEMILEON AMV” and “CELEMION CMV” (products of Asahi Glass Company), and “ACIPLEX A-211” and “ACIPLEX A-201”, and “ACIPLEX K-101” (products of Asahi Kasei Corporation).
[0040] As ion exchange membranes to be used for electrodialysis according to present invention, ordinary ion exchange membranes as described above may be used. However, the fractional molecular weight of a cation exchange membrane is preferably smaller than the molecular weight of the basic amino acid from the viewpoint of prevention of outflow of the basic amino acid and, for example, a cation exchange membrane having a fractional molecular weight of about 100 is preferably used. On the other hand, when the fractional molecular weight of an anion exchange membrane is too small, efficiency of removal of counter anions is reduced. Therefore, a membrane having a fractional molecular weight slightly larger than the molecular weight of the main anions to be removed, is preferably used. E.g., when sulfate ions are to be removed, they can be removed efficiently with the use of a membrane having a fractional molecular weight of at least 300, for example.
[0041] An alkali aqueous solution to be added and used according the production method of the present invention is not particularly limited, and may be ammonia water or an aqueous solution of a hydroxide of an alkali metal such as sodium, potassium or the like, for example. However, when a desalted solution resulting from electrodialysis is to be concentrated, use of ammonia water makes it possible to remove ammonia into the drain. Therefore, in this case, use of ammonia is preferred. However, it is not limited thereto when the concentration is carried out by loose RO or the like.
[0042] The concentration of the alkali aqueous solution is not particularly limited, either. However, when the solution gets diluted, loads on concentration or the like in the subsequent step increase. To avoid this, the concentration of ammonia water should be 25 to 29%, and the concentration of an alkali aqueous solution containing cations of an alkali metal such as sodium or the like should be around 25 to 48%.
[0043] The amount of an alkali to be added and used is such an amount that is an equimolar amount of the anions to be removed or an amount corresponding to electric charges of the basic amino acid as required, in addition thereto. An excess amount of an alkali exceeding the amount is not necessary.
[0044] As an amino acid solution to be subjected to electrodialysis according to the present invention, a basic amino acid solution having a basic amino acid salt such as commercially available lysine hydrochloride or the like dissolved therein, can be used. In addition, an amino acid solution obtained by a synthesis method, a fermentation method, a proteolysis method or the like, as well as a crystallization mother liquor resulting from crystallization of crystals of lysine hydrochloride or the like, can also be used.
[0045] Further, in the basic amino acid salt solution to be subjected to electrodialysis, cations, proteins, organic acids or the like derived from a fermentation broth or a synthesis solution may be contained in such amounts that do not inhibit the efficiency of the electrodialysis.
[0046] Regarding addition of an alkali aqueous solution at the time of electrodialysis, it may be added to a basic amino acid salt solution to be subjected to electrodialysis in advance or may be added gradually during the electrodialysis process.
[0047] A basic amino acid solution produced by the production method of the present invention and having a reduced amount of counter ions can be concentrated to a high concentration because an amino acid is not easily deposited therefrom when concentrated. Although such a high-concentration amino acid solution can be used as it is as an amino acid solution, it can be highly purified by adding desired counter anions such as chloride ions or the like in the form of an free acid, whereby crystals of a basic amino acid salt are formed.
[0048] Further, utiligation of the present invention makes it possible to convert a basic amino acid solution having a variety of counter anions into an amino acid salt having a desired kind of counter anions.
[0049] A salt waste solvent (salt-recovered solvent) obtained by use of the present invention contains salts derived mainly from the counter anions. Therefore, the salts can be recovered from the salt waste solvent and recycled as raw materials for fermentation or the like.
EXAMPLES
[0050] The present invention will be described in detail with reference to examples hereinafter.
Example 1
Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Fermentation Broth)
[0051] Electrodialysis was carried out by use of 1.040 g of a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in the solution to be subjected to electrodialysis was 9.7%, and the concentration of sulfate ions as the counter anions was 4.0%. In addition to these, 0.3% of organic acids and 0.25% of alkali metal ions such as potassium ions, sodium ions and the like were also contained therein. This solution was subjected to electrodialysis with the use of a “Micro Acilyzer G3” electrodialyser of Asahi Kasei corporation. The ion exchange membrane used in the electrodialysis was an “AC-120-400 type” membrane comprising cation exchange membranes and anion exchange membranes in combination. The fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .
[0052] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent. After 8 minutes from the initiation of the electrodialysis, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.8 g/min, and the electrodialysis was then continued until no reduction in conductivity was recognized. The average electric current and the average voltage during the electrodialysis were 1.4 A/dm 2 and 13.8 V, respectively. The time spent for the electrodialysis was 120 minutes, and the final pH of the solution dialyzed was 9.6.
[0053] When the amino acid solution after the electrodialysis was analyzed, 94% of the lysine had been recovered. At this point in time, 75% of the sulfate ions which were the counter anions had been removed, and the proportion thereof was reduced to 33 mol % based on the lysine. The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 90%, and the removal ratio of the ammonium ions including the added portion was 80%. The removal ratio of the organic acids was 45%, and the amount of the lysine in the solid content of the solution was increased to 85% from 65% as compared with that before the electrodialysis (increase in purity). This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 51% could be prepared at room temperature without observing deposition of lysine crystals.
Example 2
Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Fermentation Broth)
[0054] Electrodialysis was carried out by use of 998 g of a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in the solution to be subjected to electrodialysis was 12%, the concentration of sulfate ions as the counter anions was 1.3%, and the concentration of chloride ions (chlorine ions) was 2.4%. In addition to these, 0.3% of alkali metal ions such as potassium ions, sodium ions and the like was also contained therein. This solution was subjected to electrodialysis with the use of a “Micro Acilyzer G3” electrodialyser of Asahi Kasei Corporation. The ion exchange membrane used in the electrodialysis was an “AC-120-400 type” membrane comprising cation exchange membranes and anion exchange membranes in combination. The fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .
[0055] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent. After 5 minutes from the initiation of the electrodialysis, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.72 g/min, and the electrodialysis was then continued until no reduction in conductivity was recognized. The time spent for the electrodialysis was 100 minutes, and the final pH of the solution dialyzed was 9.3.
[0056] When the amino acid solution after the electrodialysis was analyzed, 94% of the lysine had been recovered. At this point in time, 97% of the chloride ions had been removed, 80% of the sulfate ions had been removed, and the remaining counter anions had been reduced to 29 mol % based on the lysine. The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 90%, and the amount of the lysine in the solid content of the solution was increased to 82% from 65% as compared with that before the electrodialysis (increase in purity). This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 49% could be prepared at room temperature without observing deposition of lysine crystals.
Example 3
Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Crystallization Mother Liquor)
[0057] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 470 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in the solution to be subjected to electrodialysis was 10.9%, the concentration of chloride ions was 4.25%, the concentration of sulfate ions was 5.7%, the concentration of sodium ions was 0.6%, the concentration of potassium ions was 0.55%, the concentration of ammonium ions was 1.9%, and the concentration of organic acids was 1.3%. The proportion of lysine in the solid content of this solution was 34%. This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3” electrodialyser of Asahi Kasei Corporation. The ion exchange membrane used in the electrodialysis was an “AC-120-400 type” membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .
[0058] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent. After 70 minutes from the initiation of the electrodialysis where the voltage which had been once decreased began to be increased again, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.64 g/min, and the electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased. The time spent for the electrodialysis was 150 minutes, and the final pH of the solution dialyzed was 9.4. The average electric current and the average voltage during the electrodialysis were 2 A/dm 2 and 12.2 V, respectively.
[0059] When the amino acid solution after the electrodialysis was analyzed, 94.5% of the lysine had been recovered. At this point in time, 96% of the chloride ions had been removed, 90% of the sulfate ions had been removed, and the proportion of the remaining counter anions was reduced to 21 mol % based on the lysine. The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 96%, and the removal ratio of the ammonium ions including the added portion was 85%. The removal ratio of the organic acids was 57% on the average, and the amount of the lysine in the solid content of the solution was increased to 53% from 34% as compared with that before the electrodialysis (increase in purity). This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 32% could be prepared without observing deposition of lysine crystals, though it was increased in viscosity to 2.4 Pa·s(10° C.), said concentration of 32% being about three times 10.9% which was, in turn, the lysine concentration of the crystallization mother liquor before the electrodialysis.
Example 4
Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Crystallization Mother Liquor)
[0060] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 467 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in the solution to be subjected to electrodialysis was 10.8%, the concentration of chloride ions was 4.05%, the concentration of sulfate ions was 5.3%, the concentration of sodium ions was 0.5%, the concentration of potassium ions was 0.5%, the concentration of ammonium ions was 1.8%, and the concentration of organic acids was 1.3%. The proportion of lysine in the solid content of this solution was 34%. This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3” electrodialyser of Asahi Kasei Corporation. The ion exchange membrane used in the electrodialysis was an “AC-130-400 type” membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .
[0061] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent. After 80 minutes from the initiation of the electrodialysis where the voltage which had been once decreased began to be increased again, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.61 g/min, and the electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased. The time spent for the electrodialysis was 180 minutes, and the final pH of the solution dialyzed was 9.6. The average electric current and the average voltage during the electrodialysis were 1.9 A/dm 2 and 11.2 V, respectively.
[0062] When the amino acid solution after the electrodialysis was analyzed, 90% of the lysine had been recovered. At this point in time, 95% of the chloride ions had been removed, 80% of the sulfate ions had been removed, and the proportion of the remaining counter anions was reduced to 39 mol % based on the lysine. The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 96%, and the removal ratio of the ammonium ions including the added portion was 85%. The removal ratio of the organic acids was 67% on the average, and the amount of the lysine in the solid content of the solution was increased to 50% from 34% as compared with that before the electrodialysis (increase in purity). This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 31% could be prepared without observing deposition of lysine crystals, said concentration of 31% being about three times 10.8% which was, in turn, the lysine concentration of the crystallization mother liquor before the electrodialysis.
Example 5
Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Crystallization Mother Liquor)
[0063] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 470 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in the solution to be subjected to electrodialysis was 9.9%, the concentration of chloride ions was 4.1%, the concentration of sulfate ions was 5.7%, the concentration of sodium ions was 0.6%, the concentration of potassium ions was 0.56%, the concentration of ammonium ions was 1.8%, and the concentration of organic acids was 1.3%. The proportion of lysine in the solid content of this solution was 34%. This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3” electrodialyser of Asahi Kasei Corporation. The ion exchange membrane used in the electrodialysis was an “AC-120-400 type” membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .
[0064] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent. After 84 minutes from the initiation of the electrodialysis where the voltage which had been once decreased began to be increased again, addition of 28% ammonia water was carried out in an amount of 99.6 g until the pH of the solution to be dialyzed got to the isoelectyric point of lysine, and the electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased. The time spent for the electrodialysis was 208 minutes.
[0065] When the amino acid solution after the electrodialysis was analyzed, 75% of the lysine had been recovered. At this point in time, 98% of the chloride ions had been removed, 94% of the sulfate ions had been removed, and the proportion of the remaining counter anions was reduced to 19 mol % based on the lysine. The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 95%, and the removal ratio of the ammonium ions including the added portion was 93%. The removal ratio of the organic acids was 67% on the average, and the amount of the lysine in the solid content of the solution was increased to 50% from 34% as compared with that before the electrodialysis (increase in purity). This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 30% could be prepared without observing deposition of lysine crystals, said concentration of 30% being about three times 9.9% which was, in turn, the lysine concentration of the crystallization mother liquor before the electrodialysis.
Example 6
Sole Use of Anion Exchange Membranes
[0066] Electrodialysis was carried out by use of 8,560 g of a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in a solution to be subjected to electrodialysis was 10.0%, the concentration of sulfate ions as the counter anions was 3.8%, the concentration of organic acids was 0.3%, and the concentration of alkali metal ions such as potassium ions, sodium ions and the like was 0.25%. As an electrodialyser, a commercially available experimental electrodialyser “CELEMION ELECTODIALYSER DU-06” of Asahi Kasei Corporation was used. Twenty sheets of commercially available anion exchange membrane “CELEMION AMV” of Asahi Glass Corporation were installed in the electrodialyser with an effective area of 209 cm 2 /sheet at an interval between the sheets of 2 mm. An alkali solution was passed through the anode chamber, a lysine solution which was a solution to be dialyzed was passed through a chamber adjacent to the anode chamber, and an alkali aqueous solution as the dialysis solvent was passed through a chamber adjacent to the chamber through which the lysine solution was passed, and so on, whereby the lysine solution to be dialyzed and the alkali aqueous solution as the dialysis solvent were passed alternately, through next chamber to each other, and concurrently. In the last cathode chamber, a sodium hydroxide aqueous solution was circulated in such a manner that it was isolated from other alkali aqueous solutions.
[0067] The electrodialysis was continued by passing a current of 1 A/dm 2 through the electrodialyser while a solution obtained by adjusting the pH of the lysine solution which was a solution to be dialyzed to a pH of 8.5 by use of ammonia solution was circulated at a rate of 35 L/hr on the average. As a result, it took 4 hours and 30 minutes to complete removal of the anions.
[0068] When the amino acid solution after the electrodialysis was analyzed, 96% of the lysine had been recovered. At this point in time, 72% of the sulfate ions which were the counter anions had been removed, and the proportion thereof was reduced to 33 mol % based on the lysine. The amount of the lysine in the solid content of the solution was increased to 83% from 65% as compared with that before the electrodialysis (increase in purity). This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 48% could be prepared at room temperature without observing deposition of lysine crystals.
Comparative Example 1
Non-Addition of Alkali Aqueous Solution
[0069] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 474 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability. The concentration of lysine in the solution to be subjected to electrodialysis was 10.8%, the concentration of chloride ions was 3.9%, the concentration of sulfate ions was 4.9%, the concentration of sodium ions was 0.41%, the concentration of potassium ions was 0.39%, the concentration of ammonium ions was 1.8%, and the concentration of organic acids was 1.0%. The proportion of lysine in the solid content of this solution was 34%. This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3” electrodialyser of Asahi Kasei Corporation. The ion exchange membrane used in the electrodialysis was an “AC-120-400 type” membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .
[0070] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent. After the initiation of the electrodialysis, the voltage was once decreased and increased again, and the electric current began to be decreased. The electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased enough. The time spent for the electrodialysis was 150 minutes, and the pH of the solution dialyzed was 5.9.
[0071] When the amino acid solution after the electrodialysis was analyzed, 92% of the lysine had been recovered, and 92% of the chloride ions had been removed. Hoever, only 50% of the sulfate ions had been removed, and the proportion of the remaining counter anions was 130 mol % based on the lysine.
[0072] It can be understood from the above that although removal of excess salts might be achieved by mere electrodialysis, it fails to remove the counter anions of lysine. Further, the amount of lysine in the solid content of the solution was increased to at most 45% from 34%, and an increase in purity was small as compared with Example 3.
[0073] [Effect of the Invention]
[0074] As described above, according to the present invention, the counter anions as well as excess salts can be removed from a solution of the salt of a basic amino acid such as lysine or the like, by adding an alkali aqueous solution such as ammonia water or the like to the solution when subjected to electrodialysis. Thereby, a high-concentration amino acid solution can be produced, and costs in transportation and preservation of a basic amino acid can be reduced. Further, when a basic amino acid solution is subjected to spray granulation or the like, a solution having a high concentration can be subjected to spraying. In addition, since counter anions can be removed from a fermentation broth or the like of a basic amino acid salt or the like according to the present invention, crystals of an amino acid salt having the target counter anions can be produced by adding the desired anions to the solution again. | Herein are disclosed a method for producing a basic amino acid solution which comprises subjecting a solution of a basic amino acid salt to electrodialysis with the use of an electrodialyser equipped with cation exchange membranes and anion exchange membranes in combination, wherein an alkali aqueous solution is added to the solution of a basic amino acid salt during the electrodialysis, whereby not only desalting is caused but also the counter anions of the basic amino acid are removed to such degree that the said counter anions remain in an amount of 40 mol % or smaller based on the basic amino acid, as well as a method for producing a basic amino acid solution which comprises subjecting a solution of a basic amino acid salt to electrodialysis with the use of an electrodialyser equipped with anion exchange membrane alone, wherein an alkali aqueous solution is added to the solution of a basic amino acid salt to adjust the pH of the solution to 7 to 10 during the electrodialysis, whereby the counter anions are removed.
According to these methods, a basic amino acid solution having a high concentration within the concentration range in which crystals of a basic amino acid salt are not deposited, can be easily provided, by removing the counter anions from a solution of a basic amino acid salt efficiently by use of electrodialysis. | Summarize the information, clearly outlining the challenges and proposed solutions. | [
"BACKGROUND OF THE INVENTION [0001] 1.",
"Technical Field of the Invention [0002] The present invention relates to a method for producing a basic amino acid such as L-lysine known as an important additive for livestock feed or L-arginine or L-histidine useful as a drug such as an infusion solution (i.e., parenteral fluid) or the like.",
"[0003] 2.",
"Related Art [0004] In a conventionally known method for producing a basic amino acid by means of fermentation, sulfate ions or chloride ions (chlorine ions) have heretofore been generally used as counter anions so as to maintain electrical neutrality of a culture medium.",
"These are supplied mostly in the form of ammonium sulfate as described in, for example, Japanese Patent Application Laid-Open Nos. 30985/'93, 244969/'93, and the like.",
"[0005] Meanwhile, a basic amino acid such as lysine or the like is often sold in the form of the chloride salt (hydrochloride) since it is difficult to crystallize a basic amino acid such lysine or the like in the free state.",
"However, in the production method of a basic amino acid by means of fermentation, since a hydrochloride causes corrosion of a fermentation tank, or the like, a sulfate is often used for fermentation for the purpose of avoiding the corrosion of the tank.",
"[0006] In this case, however, since a basic amino acid product as such resulting from such fermentation is different in counter anion from a basic amino acid product (to be) placed in distribution, the counter anions (such as sulfate ions) are once removed from the basic amino acid salt produced by means of such fermentation, with the use of, e.g., an anion exchange resin and desired counter anions (such as chloride ions) are then added in the form of a free acid, whereby the target basic amino acid salt is produced.",
"Such use of a resin, however, increases loads on environmental protection such as drainage resulting from use of the resin, and the like.",
"[0007] Further, since such use of a resin requires excess acid and alkali, a variety of by-products are also discharged in addition to the target amino acid salt.",
"[0008] In addition, when a basic amino acid such as lysine or the like is to be placed in distribution in the form of a solution-type amino acid feed additive, the solubility of the amino acid in the feed additive solution decreases due to the presence of counter anions, if present therein, so that the counter anions must be removed with the use of a resin in order to obtain an amino acid solution with a high concentration.",
"[0009] In the case of lysine as an example, lysine hydrochloride can be dissolved in water at 10° C. in an amount of at most 43 g in terms of lysine per 100 g of water, and lysine ½ sulfate can be dissolved in an amount of at most 68 g per 100 g of water.",
"On the other hand, in the case of a solution having only lysine dissolved therein (a free lysine solution), the solution is alkaline in nature, and lysine can be dissolved therein in an amount of as much as 120 g per 100 g of water.",
"In this connection, refer to Japanese Patent Application Laid-Open No. 256290/2000.",
"[0010] As could be understood from the above, removal of the counter anions from a basic amino acid solution is essential or indispensable to prepare a basic amino acid solution having a high concentration.",
"[0011] There has been known as a conventional method for purifying an amino acid fermentation broth with the use of an ion exchange membrane, a method (as disclosed in Japanese Patent Publication No. 7666/1960) in which the amino acid moiety in an aqueous solution of an amino acid salt is caused to pass through the ion exchange membranes with the use of an electrodialyser equipped with a plurality of cation exchange membranes and anion exchange membranes, the two kinds of ion exchange membranes being disposed alternately, whereby the amino acid is produced.",
"The performance of the method, however, is not necessarily high in terms of electrical efficiency due to low mobility of organic molecules such amino acid or the like.",
"[0012] Further, in the case of a solution which contains a large amount of various organic metabolites and the like resulting from microbial fermentation, which, in turn, cannot pass through a cation exchange membrane and an anion exchange membrane, their concentrations become so significantly high at the surfaces of the ion exchange membranes that these organic metabolites are deposited or agglomerated and eventually accumulated on the surfaces of the ion exchange membranes to clog the membranes, which ends in making a continuous operation impossible disadvantageously.",
"SUMMARY OF THE INVENTION [0013] [Problems to be Solved by the Invention] [0014] It is an object of the present invention to provide a method for obtaining a basic amino acid solution having a high concentration within the concentration range in which crystals of a basic amino acid salt are not deposited, by removing the counter anions from a solution of the basic amino acid salt efficiently by use of electrodialysis.",
"[0015] [Means for Solving the Problems] [0016] The present inventors have made extensive and intensive studies to achieve the above object and found that, in removing the counter anions of a basic amino acid by means of electrodialysis, when an alkali aqueous solution is added to a solution of the basic amino acid salt (solution to be subjected to electrodialysis) during the electrodialysis, the counter anions of the basic amino acid such as sulfate ions or the like can be efficiently removed to such degree that they remain in an amount of 40 mol % or smaller based on the amino acid.",
"The present invention has been completed on the basis of these findings.",
"[0017] Accordingly, the present invention relates to a method for producing a basic amino acid solution which comprises subjecting a solution of a basic amino acid salt to electrodialysis with the use of an electrodialyser equipped with cation exchange membranes and anion exchange membranes in combination, wherein an alkali aqueous solution is added to the solution of a basic amino acid salt during the electrodialysis, whereby not only desalting is caused but also the counter anions of the basic amino acid are removed to such degree that the said counter anions remain in an amount of 40 mol % or smaller based on the basic amino acid, and also to a method for producing a basic amino acid solution which comprises subjecting a solution of a basic amino acid salt to electrodialysis with the use of an electrodialyser equipped with anion exchange membrane alone, wherein an alkali aqueous solution is added to the solution of a basic amino acid salt to adjust the pH of the solution to 7 to 10 during the electrodialysis, whereby the counter anions are removed.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0018] [0018 ]FIG. 1 shows a schematic diagram for illustrating an example of an electrodialyser to be used in the practice of the method of the present invention.",
"DESCRIPTION OF SYMBOLS [0019] [0019] 1 : ELECTRODIALYSER.",
"[0020] A 1 to A 10 ANION EXCHANGE MEMBRANES.",
"[0021] K 1 to K 12 : CATION EXCHANGE MEMBRANES.",
"[0022] [0022] 3 : ANODE [0023] [0023] 4 : CATHODE [0024] [0024] 5 to 15 : CONDUITS FOR SUPPLYING A SOLUTION TO BE DIALYZED.",
"[0025] [0025] 5 ′ to 15 ′: CONDUITS FOR DISCHARGING THE SOLUTION DIALYZED.",
"[0026] [0026] 16 to 27 : CONDUITS FOR SUPPLYING A DIALYSIS SOLVENT FOR COLLECTING THE COUNTER ANIONS DIALYZED.",
"[0027] [0027] 16 ′ to 27 ′: CONDUITS FOR DISCHARGING THE DIALYSIS SOLVENT WHICH HAS COLLECTED THE DIALYZED COUNTER ANIONS.",
"[0028] [0028] 28 to 30 : CONDUITS FOR SUPPLYING AN ELECTRODE SOLUTION.",
"[0029] [0029] 28 ′ to 30 ′: CONDUITS FOR DISCHARGING THE ELECTRODE SOLUTION.",
"DETAILED DESCRIPTION OF THE INVENTION [0030] Hereinbelow, the present invention will be described in great detail.",
"[0031] The method of the present invention is carried out by using an electrodialyser equipped with sulfonic acid type or carboxylic acid type cation exchange membrane(s) and quaternary ammonium base type or tertiary amine type anion exchange membrane(s) in combination or an electrodialyser equipped with quaternary ammonium base type or tertiary amine type anion exchange membrane(s).",
"The number of ion exchange membranes disposed in the electrodialyser, the capacity of the electrodialyser, the number of the isolated chambers for a solution to be dialyzed and for a dialysis solvent in the electrodialyser and the size of the isolated chambers can be selected by those skilled in the art in a given case so appropriately as to achieve the object of the present invention.",
"[0032] There may be mentioned as a specific example of an electrodialyser to be used according to the present invention an electrodialyser in which an anode chamber, a raw material solution chamber (a chamber for a solution to be dialyzed), a salt recovering solvent chamber (dialysis solvent chamber) and a cathode chamber are separated with anion exchange membrane(s) and a cation exchange membrane(s).",
"In the electrodialyser, a 5% sodium sulfate solution or the like is circulated in the cathode and anode chambers.",
"In the raw material solution chamber, a basic amino acid salt solution such as a lysine fermentation broth or the like is made to pass, and in the adjacent salt recovering solvent chamber, pure water or the like is made to pass initially.",
"[0033] A plurality of raw material solution chambers and salt recovering solvent chambers can be of course used.",
"To be more specific, electrodialysis can be carried out with the use of an appratus shown in FIG. 1, for example.",
"In FIG. 1, in an electrodialyser 1 , cation exchange membranes K 1 K 2 , K 3 , .",
", K 10 and anion exchange membranes A 1 , A 2 , A 3 , .",
", A 10 are disposed alternately, one cation exchange membrane after another anion exchange membrane and cation exchange membranes K 11 and K 12 are in turn disposed after the anion exchange membrane A 10 so as to constitute a plurality of isolated chambers 2 , 2 , .",
", 2 .",
"In the electrodialyser, an anode 3 (anode chamber) and a cathode 4 (cathode chamber) are provided at the ends so as to oppose each other.",
"[0034] A sample solution (raw material solution, solution to be dialyzed) is supplied into the electrodialyser via a conduit 5 and branch pipes 6 , 7 , 8 , .",
", 15 , flows through raw material solution chambers between the anion exchange membranes and the cation exchange membranes, and is discharged from the electrodialyser via branch pipes 6 ′, 7 ′, 8 ′, .",
", 15 ′ and a conduit 5 ′.",
"Further, a dialysis solvent such as pure water or the like for collecting the dialyzed counter anions is supplied into the electrodialyser via a conduit 16 and branch pipes 17 , 18 , 19 , .",
", 27 and discharged from the electrodialyser via branch pipes 17 ′, 18 ′, 19 ′, .",
", 27 ′ and a conduit 16 ′.",
"Meanwhile, a solution of a salt such as sodium sulfate which is appropriate as an electrode is introduced into the electrodialyser via a conduit 28 and branch pipes 29 and 30 and discharged from the electrodialyser via branch pipes 29 ′ and 30 ′ and a conduit 28 ′.",
"During this operation, a direct current is made to pass between the electrodes.",
"[0035] According to the above-described electrodialysis using cation exchange membranes and anion exchange membranes in combination, desalting is carried out in addition to removal of counter anions.",
"The removal of counter anions can still be achieved with the sole use of anion exchange membranes, in addition to the above concurrent use of cation exchange membranes and anion exchange membranes.",
"[0036] When only anion exchange membranes are used, an electrodialyser obtained by replacing all the cation exchange membranes K 1 , K 2 , K 3 , .",
", K 10 of the electrodialyser shown in FIG. 1 with anion exchange membranes can be used, for example.",
"As a dialysis solvent to be supplied into the electrodialyser via the conduit 16 and the branch pipes 17 , 18 , 19 , .",
", 27 and discharged from the electrodialyser via the branch pipes 17 ′, 18 ′, 19 ′, .",
", 27 ′ and the conduit 16 ′, an alkal aqueous solution can be used.",
"A solution to be dialyzed is subjected to electrodialysis after an alkali aqueous solution is added to the solution to adjust the pH of the solution to 7 to 10 so as to remove counter anions.",
"[0037] As an inflow velocity of the sample solution, a membrane surface linear velocity of not lower than 1 cm/sec, preferably 4 to 6 cm/sec, can be used.",
"Conditions for electrodialysis such as a current density, a voltage, a duration of electrodialysis, and the like can be selected appropriately, depending upon characteristics of a basic amino acid salt solution which is a solution to be dialyzed, coexisting salts, the types and numbers of cation exchange membranes and anion exchange membranes to be used, the size of an electrodialyser, and the like.",
"In general, good results can be obtained at a current density of about 1 to 5 A/dm 2 .",
"The temperature can be room temperature to 70° C. [0038] When electrodialysis is carried out by concurrent use of cation exchange membranes and anion exchange membranes, counter anions are dialyzed via the anion exchange membranes and removed from the raw material solution chambers, while foreign cations are dialyzed via the cation exchange membranes and removed into the salt recovering chambers.",
"In this case, in order to remove the counter anions of a basic amino acid with the basic amino acid being left in the raw material solution, the amount of cations to be removed into the salt recovering chambers gets relatively insufficient.",
"Therefore, an alkali aqueous solution such as ammonia water or the like which contains cations which pass through the cation exchange membranes easily, is added to the raw material solution, whereby the counter anions of the basic amino acid can be removed into the salt recovering solvent without the target amino acid being lost into the salt recovering solvent.",
"[0039] Illustrative examples of anion exchange membranes and cation exchange membranes to be used according to the production method of the present invention include “CEMILEON AMV”",
"and “CELEMION CMV”",
"(products of Asahi Glass Company), and “ACIPLEX A-211”",
"and “ACIPLEX A-201”, and “ACIPLEX K-101”",
"(products of Asahi Kasei Corporation).",
"[0040] As ion exchange membranes to be used for electrodialysis according to present invention, ordinary ion exchange membranes as described above may be used.",
"However, the fractional molecular weight of a cation exchange membrane is preferably smaller than the molecular weight of the basic amino acid from the viewpoint of prevention of outflow of the basic amino acid and, for example, a cation exchange membrane having a fractional molecular weight of about 100 is preferably used.",
"On the other hand, when the fractional molecular weight of an anion exchange membrane is too small, efficiency of removal of counter anions is reduced.",
"Therefore, a membrane having a fractional molecular weight slightly larger than the molecular weight of the main anions to be removed, is preferably used.",
"E.g., when sulfate ions are to be removed, they can be removed efficiently with the use of a membrane having a fractional molecular weight of at least 300, for example.",
"[0041] An alkali aqueous solution to be added and used according the production method of the present invention is not particularly limited, and may be ammonia water or an aqueous solution of a hydroxide of an alkali metal such as sodium, potassium or the like, for example.",
"However, when a desalted solution resulting from electrodialysis is to be concentrated, use of ammonia water makes it possible to remove ammonia into the drain.",
"Therefore, in this case, use of ammonia is preferred.",
"However, it is not limited thereto when the concentration is carried out by loose RO or the like.",
"[0042] The concentration of the alkali aqueous solution is not particularly limited, either.",
"However, when the solution gets diluted, loads on concentration or the like in the subsequent step increase.",
"To avoid this, the concentration of ammonia water should be 25 to 29%, and the concentration of an alkali aqueous solution containing cations of an alkali metal such as sodium or the like should be around 25 to 48%.",
"[0043] The amount of an alkali to be added and used is such an amount that is an equimolar amount of the anions to be removed or an amount corresponding to electric charges of the basic amino acid as required, in addition thereto.",
"An excess amount of an alkali exceeding the amount is not necessary.",
"[0044] As an amino acid solution to be subjected to electrodialysis according to the present invention, a basic amino acid solution having a basic amino acid salt such as commercially available lysine hydrochloride or the like dissolved therein, can be used.",
"In addition, an amino acid solution obtained by a synthesis method, a fermentation method, a proteolysis method or the like, as well as a crystallization mother liquor resulting from crystallization of crystals of lysine hydrochloride or the like, can also be used.",
"[0045] Further, in the basic amino acid salt solution to be subjected to electrodialysis, cations, proteins, organic acids or the like derived from a fermentation broth or a synthesis solution may be contained in such amounts that do not inhibit the efficiency of the electrodialysis.",
"[0046] Regarding addition of an alkali aqueous solution at the time of electrodialysis, it may be added to a basic amino acid salt solution to be subjected to electrodialysis in advance or may be added gradually during the electrodialysis process.",
"[0047] A basic amino acid solution produced by the production method of the present invention and having a reduced amount of counter ions can be concentrated to a high concentration because an amino acid is not easily deposited therefrom when concentrated.",
"Although such a high-concentration amino acid solution can be used as it is as an amino acid solution, it can be highly purified by adding desired counter anions such as chloride ions or the like in the form of an free acid, whereby crystals of a basic amino acid salt are formed.",
"[0048] Further, utiligation of the present invention makes it possible to convert a basic amino acid solution having a variety of counter anions into an amino acid salt having a desired kind of counter anions.",
"[0049] A salt waste solvent (salt-recovered solvent) obtained by use of the present invention contains salts derived mainly from the counter anions.",
"Therefore, the salts can be recovered from the salt waste solvent and recycled as raw materials for fermentation or the like.",
"EXAMPLES [0050] The present invention will be described in detail with reference to examples hereinafter.",
"Example 1 Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Fermentation Broth) [0051] Electrodialysis was carried out by use of 1.040 g of a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in the solution to be subjected to electrodialysis was 9.7%, and the concentration of sulfate ions as the counter anions was 4.0%.",
"In addition to these, 0.3% of organic acids and 0.25% of alkali metal ions such as potassium ions, sodium ions and the like were also contained therein.",
"This solution was subjected to electrodialysis with the use of a “Micro Acilyzer G3”",
"electrodialyser of Asahi Kasei corporation.",
"The ion exchange membrane used in the electrodialysis was an “AC-120-400 type”",
"membrane comprising cation exchange membranes and anion exchange membranes in combination.",
"The fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .",
"[0052] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent.",
"After 8 minutes from the initiation of the electrodialysis, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.8 g/min, and the electrodialysis was then continued until no reduction in conductivity was recognized.",
"The average electric current and the average voltage during the electrodialysis were 1.4 A/dm 2 and 13.8 V, respectively.",
"The time spent for the electrodialysis was 120 minutes, and the final pH of the solution dialyzed was 9.6.",
"[0053] When the amino acid solution after the electrodialysis was analyzed, 94% of the lysine had been recovered.",
"At this point in time, 75% of the sulfate ions which were the counter anions had been removed, and the proportion thereof was reduced to 33 mol % based on the lysine.",
"The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 90%, and the removal ratio of the ammonium ions including the added portion was 80%.",
"The removal ratio of the organic acids was 45%, and the amount of the lysine in the solid content of the solution was increased to 85% from 65% as compared with that before the electrodialysis (increase in purity).",
"This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 51% could be prepared at room temperature without observing deposition of lysine crystals.",
"Example 2 Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Fermentation Broth) [0054] Electrodialysis was carried out by use of 998 g of a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in the solution to be subjected to electrodialysis was 12%, the concentration of sulfate ions as the counter anions was 1.3%, and the concentration of chloride ions (chlorine ions) was 2.4%.",
"In addition to these, 0.3% of alkali metal ions such as potassium ions, sodium ions and the like was also contained therein.",
"This solution was subjected to electrodialysis with the use of a “Micro Acilyzer G3”",
"electrodialyser of Asahi Kasei Corporation.",
"The ion exchange membrane used in the electrodialysis was an “AC-120-400 type”",
"membrane comprising cation exchange membranes and anion exchange membranes in combination.",
"The fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .",
"[0055] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent.",
"After 5 minutes from the initiation of the electrodialysis, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.72 g/min, and the electrodialysis was then continued until no reduction in conductivity was recognized.",
"The time spent for the electrodialysis was 100 minutes, and the final pH of the solution dialyzed was 9.3.",
"[0056] When the amino acid solution after the electrodialysis was analyzed, 94% of the lysine had been recovered.",
"At this point in time, 97% of the chloride ions had been removed, 80% of the sulfate ions had been removed, and the remaining counter anions had been reduced to 29 mol % based on the lysine.",
"The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 90%, and the amount of the lysine in the solid content of the solution was increased to 82% from 65% as compared with that before the electrodialysis (increase in purity).",
"This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 49% could be prepared at room temperature without observing deposition of lysine crystals.",
"Example 3 Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Crystallization Mother Liquor) [0057] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 470 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in the solution to be subjected to electrodialysis was 10.9%, the concentration of chloride ions was 4.25%, the concentration of sulfate ions was 5.7%, the concentration of sodium ions was 0.6%, the concentration of potassium ions was 0.55%, the concentration of ammonium ions was 1.9%, and the concentration of organic acids was 1.3%.",
"The proportion of lysine in the solid content of this solution was 34%.",
"This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3”",
"electrodialyser of Asahi Kasei Corporation.",
"The ion exchange membrane used in the electrodialysis was an “AC-120-400 type”",
"membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .",
"[0058] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent.",
"After 70 minutes from the initiation of the electrodialysis where the voltage which had been once decreased began to be increased again, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.64 g/min, and the electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased.",
"The time spent for the electrodialysis was 150 minutes, and the final pH of the solution dialyzed was 9.4.",
"The average electric current and the average voltage during the electrodialysis were 2 A/dm 2 and 12.2 V, respectively.",
"[0059] When the amino acid solution after the electrodialysis was analyzed, 94.5% of the lysine had been recovered.",
"At this point in time, 96% of the chloride ions had been removed, 90% of the sulfate ions had been removed, and the proportion of the remaining counter anions was reduced to 21 mol % based on the lysine.",
"The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 96%, and the removal ratio of the ammonium ions including the added portion was 85%.",
"The removal ratio of the organic acids was 57% on the average, and the amount of the lysine in the solid content of the solution was increased to 53% from 34% as compared with that before the electrodialysis (increase in purity).",
"This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 32% could be prepared without observing deposition of lysine crystals, though it was increased in viscosity to 2.4 Pa·s(10° C.), said concentration of 32% being about three times 10.9% which was, in turn, the lysine concentration of the crystallization mother liquor before the electrodialysis.",
"Example 4 Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Crystallization Mother Liquor) [0060] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 467 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in the solution to be subjected to electrodialysis was 10.8%, the concentration of chloride ions was 4.05%, the concentration of sulfate ions was 5.3%, the concentration of sodium ions was 0.5%, the concentration of potassium ions was 0.5%, the concentration of ammonium ions was 1.8%, and the concentration of organic acids was 1.3%.",
"The proportion of lysine in the solid content of this solution was 34%.",
"This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3”",
"electrodialyser of Asahi Kasei Corporation.",
"The ion exchange membrane used in the electrodialysis was an “AC-130-400 type”",
"membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .",
"[0061] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent.",
"After 80 minutes from the initiation of the electrodialysis where the voltage which had been once decreased began to be increased again, addition of 28% ammonia water was started to the solution to be dialyzed at a rate of 0.61 g/min, and the electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased.",
"The time spent for the electrodialysis was 180 minutes, and the final pH of the solution dialyzed was 9.6.",
"The average electric current and the average voltage during the electrodialysis were 1.9 A/dm 2 and 11.2 V, respectively.",
"[0062] When the amino acid solution after the electrodialysis was analyzed, 90% of the lysine had been recovered.",
"At this point in time, 95% of the chloride ions had been removed, 80% of the sulfate ions had been removed, and the proportion of the remaining counter anions was reduced to 39 mol % based on the lysine.",
"The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 96%, and the removal ratio of the ammonium ions including the added portion was 85%.",
"The removal ratio of the organic acids was 67% on the average, and the amount of the lysine in the solid content of the solution was increased to 50% from 34% as compared with that before the electrodialysis (increase in purity).",
"This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 31% could be prepared without observing deposition of lysine crystals, said concentration of 31% being about three times 10.8% which was, in turn, the lysine concentration of the crystallization mother liquor before the electrodialysis.",
"Example 5 Concurrent Use of Cation Exchange Membranes and Anion Exchange Membranes (Crystallization Mother Liquor) [0063] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 470 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in the solution to be subjected to electrodialysis was 9.9%, the concentration of chloride ions was 4.1%, the concentration of sulfate ions was 5.7%, the concentration of sodium ions was 0.6%, the concentration of potassium ions was 0.56%, the concentration of ammonium ions was 1.8%, and the concentration of organic acids was 1.3%.",
"The proportion of lysine in the solid content of this solution was 34%.",
"This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3”",
"electrodialyser of Asahi Kasei Corporation.",
"The ion exchange membrane used in the electrodialysis was an “AC-120-400 type”",
"membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .",
"[0064] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent.",
"After 84 minutes from the initiation of the electrodialysis where the voltage which had been once decreased began to be increased again, addition of 28% ammonia water was carried out in an amount of 99.6 g until the pH of the solution to be dialyzed got to the isoelectyric point of lysine, and the electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased.",
"The time spent for the electrodialysis was 208 minutes.",
"[0065] When the amino acid solution after the electrodialysis was analyzed, 75% of the lysine had been recovered.",
"At this point in time, 98% of the chloride ions had been removed, 94% of the sulfate ions had been removed, and the proportion of the remaining counter anions was reduced to 19 mol % based on the lysine.",
"The removal ratio of the alkali metal ions such as potassium ions, sodium ions and the like was 95%, and the removal ratio of the ammonium ions including the added portion was 93%.",
"The removal ratio of the organic acids was 67% on the average, and the amount of the lysine in the solid content of the solution was increased to 50% from 34% as compared with that before the electrodialysis (increase in purity).",
"This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 30% could be prepared without observing deposition of lysine crystals, said concentration of 30% being about three times 9.9% which was, in turn, the lysine concentration of the crystallization mother liquor before the electrodialysis.",
"Example 6 Sole Use of Anion Exchange Membranes [0066] Electrodialysis was carried out by use of 8,560 g of a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in a solution to be subjected to electrodialysis was 10.0%, the concentration of sulfate ions as the counter anions was 3.8%, the concentration of organic acids was 0.3%, and the concentration of alkali metal ions such as potassium ions, sodium ions and the like was 0.25%.",
"As an electrodialyser, a commercially available experimental electrodialyser “CELEMION ELECTODIALYSER DU-06”",
"of Asahi Kasei Corporation was used.",
"Twenty sheets of commercially available anion exchange membrane “CELEMION AMV”",
"of Asahi Glass Corporation were installed in the electrodialyser with an effective area of 209 cm 2 /sheet at an interval between the sheets of 2 mm.",
"An alkali solution was passed through the anode chamber, a lysine solution which was a solution to be dialyzed was passed through a chamber adjacent to the anode chamber, and an alkali aqueous solution as the dialysis solvent was passed through a chamber adjacent to the chamber through which the lysine solution was passed, and so on, whereby the lysine solution to be dialyzed and the alkali aqueous solution as the dialysis solvent were passed alternately, through next chamber to each other, and concurrently.",
"In the last cathode chamber, a sodium hydroxide aqueous solution was circulated in such a manner that it was isolated from other alkali aqueous solutions.",
"[0067] The electrodialysis was continued by passing a current of 1 A/dm 2 through the electrodialyser while a solution obtained by adjusting the pH of the lysine solution which was a solution to be dialyzed to a pH of 8.5 by use of ammonia solution was circulated at a rate of 35 L/hr on the average.",
"As a result, it took 4 hours and 30 minutes to complete removal of the anions.",
"[0068] When the amino acid solution after the electrodialysis was analyzed, 96% of the lysine had been recovered.",
"At this point in time, 72% of the sulfate ions which were the counter anions had been removed, and the proportion thereof was reduced to 33 mol % based on the lysine.",
"The amount of the lysine in the solid content of the solution was increased to 83% from 65% as compared with that before the electrodialysis (increase in purity).",
"This solution was concentrated by removing the ammonia therefrom, whereby a high-concentration lysine solution having a concentration of 48% could be prepared at room temperature without observing deposition of lysine crystals.",
"Comparative Example 1 Non-Addition of Alkali Aqueous Solution [0069] Electrodialysis was carried out by use of a solution obtained by adding 300 g of pure water to 474 g of a crystallization mother liquor resulting from removal of the lysine hydrochloride crystals from a lysine solution obtained by removing the microbial cells by means of an ultrafiltration membrane from a lysine fermentation broth obtained by culturing a microorganism having a lysine producing capability.",
"The concentration of lysine in the solution to be subjected to electrodialysis was 10.8%, the concentration of chloride ions was 3.9%, the concentration of sulfate ions was 4.9%, the concentration of sodium ions was 0.41%, the concentration of potassium ions was 0.39%, the concentration of ammonium ions was 1.8%, and the concentration of organic acids was 1.0%.",
"The proportion of lysine in the solid content of this solution was 34%.",
"This solution was subjected to electrodialysis by use of a “Micro Acilyzer G3”",
"electrodialyser of Asahi Kasei Corporation.",
"The ion exchange membrane used in the electrodialysis was an “AC-120-400 type”",
"membrane, the fractional molecular weight of the cation exchange membranes was 100, and the fractional molecular weight of the anion exchange membranes was 300, the membrane areas of the cation and anion exchange membranes being both 400 cm 2 .",
"[0070] The electrodialysis was initiated by use of 300 g of pure water as the dialysis solvent as a salt recovering solvent.",
"After the initiation of the electrodialysis, the voltage was once decreased and increased again, and the electric current began to be decreased.",
"The electrodialysis was continued until no reduction in conductivity was recognized after the electric current was decreased enough.",
"The time spent for the electrodialysis was 150 minutes, and the pH of the solution dialyzed was 5.9.",
"[0071] When the amino acid solution after the electrodialysis was analyzed, 92% of the lysine had been recovered, and 92% of the chloride ions had been removed.",
"Hoever, only 50% of the sulfate ions had been removed, and the proportion of the remaining counter anions was 130 mol % based on the lysine.",
"[0072] It can be understood from the above that although removal of excess salts might be achieved by mere electrodialysis, it fails to remove the counter anions of lysine.",
"Further, the amount of lysine in the solid content of the solution was increased to at most 45% from 34%, and an increase in purity was small as compared with Example 3.",
"[0073] [Effect of the Invention] [0074] As described above, according to the present invention, the counter anions as well as excess salts can be removed from a solution of the salt of a basic amino acid such as lysine or the like, by adding an alkali aqueous solution such as ammonia water or the like to the solution when subjected to electrodialysis.",
"Thereby, a high-concentration amino acid solution can be produced, and costs in transportation and preservation of a basic amino acid can be reduced.",
"Further, when a basic amino acid solution is subjected to spray granulation or the like, a solution having a high concentration can be subjected to spraying.",
"In addition, since counter anions can be removed from a fermentation broth or the like of a basic amino acid salt or the like according to the present invention, crystals of an amino acid salt having the target counter anions can be produced by adding the desired anions to the solution again."
] |
BACKGROUND OF INVENTION
[0001] Work machines such as tractors are often used to pull implements such as box blades, compactors, rollers, scrapers, etc. These implements may be supported by wheels or may drag along the ground. Implements are typically not dedicated to a particular work machine and therefore are in the need of a fast, efficient and effective means to couple the implement to the work machine (hereinafter tractor). Tractors typically have a three point hitch arrangement and many implements only use two points of the three point hitch arrangement particularly those implements utilizing one or more wheels for support. Two point hitch arrangements utilize the two draft arms which are selectively moveable between elevated and lowered positions and retainable at one of various positions between a lowered position and an elevated position. A cross bar may be secured to the draft arms to extend therebetween and is typically pivoted to the draft arms for rotation about a generally horizontal axis or an axis generally parallel to the axis of the rear wheel axles of the tractor.
[0002] Numerous types of couplers have been devised for connecting an implement to a tractor. The couplers may be divided into three categories. The first category is the coupler that attaches to a draw bar with multiple pivots trailing behind the draw bar a substantial distance. Examples of these can be found in U.S. Pat. Nos. 5,706,901, 5,531,283 and 4,838,015. This style of coupler, unless the implement is supported by front and rear wheels can apply a significant amount of downward force to the tractor hitch and can result, in some cases, in lifting the front wheels of the tractor from the ground. To avoid this, implements have been provided with front and rear wheels when such implements or their loads are heavy.
[0003] A second type of coupler releasably attaches the tongue of the implement to the draw bar as for example with a ball or pin or the like. The tongue rests on the draw bar and pivotal movement is accomplished by rotation about the ball in multi-axes or about a hitch pin through holes within the coupler arrangement. While effective, the freedom of movement about a ball or hitch pin is limited. A pintle hook is another such type of hitch.
[0004] A third form of coupler arrangement is shown in U.S. Pat. No. 2,091,009. As shown, and described, the coupler is required to be forward of the rear wheels in order to prevent lifting of the front wheels when heavy loads are encountered. To accomplish that goal, a large U-shaped yoke bridges the drive train in front of the rear wheel differential allowing pivoting in a forward and rearward direction by being hinged at pins connected to the drive train. Second and third pivots are provided to provide both steering pivoting and irregular terrain pivoting. However such an arrangement is cumbersome and eliminates, at least for modern tractors, the ability to use the seat on the tractor. Also, because of the large height of the coupler, large moments (torque) will result. Such an arrangement would also be difficult to attach an implement to the tractor and the ability to raise and lower the implement is precluded.
[0005] One common element to many of these hitches, particularly of the first and third categories just described, is the ability to provide pivoting about three distinct axes using three separate pivot arrangements. Further, the first and third categories tend to be complex mechanisms that do not accommodate the applied forces necessarily very well. Thus, there is a need for an improved coupler and tractor/implement/coupler arrangement.
SUMMARY OF INVENTION
[0006] The present invention involves the provision of a tractor, implement and coupler arrangement that includes a coupler attachable to the draft arms of a tractor and having three pivot devices for allowing the tractor and implement to pivot relative to one another about three axes. The axes of the pivots are such as to substantially intersect with one another to provide a low profile coupler arrangement. The coupler interconnects the tractor hitch arrangement and hence the tractor to an implement having a draw tongue. The tongue is preferably, at least for certain types of implements, a goose neck type tongue to help provide clearance for tight turns without interfering with the rear wheels or other portions of the tractor. The implement may use support wheels or may have support wheels that are selectively engageable with the ground or in certain cases the implements may not utilize wheels for support. The coupler permits the use of a link from the third point of a three point hitch, in a selective manner, to elevate certain implements for transport by using the three point hitch arrangement on the tractor.
BRIEF DESCRIPTION OF DRAWINGS
[0007] [0007]FIG. 1 is a side elevation view of a tractor, implement and coupler connecting the implement to the tractor.
[0008] [0008]FIG. 2 is a plan view of the tractor implement and coupler as shown in FIG. 1 with various pivoted positions of the implement relative to the tractor shown in phantom.
[0009] [0009]FIG. 3 is an enlarged perspective view of one form of coupler device.
[0010] [0010]FIG. 4 is an exploded view of the coupler as seen in FIG. 3.
[0011] [0011]FIG. 5 is an enlarged perspective view of a second form of coupler device.
[0012] [0012]FIG. 6 is an exploded view of the coupler of FIG. 5.
[0013] Like numbers utilized throughout the various Figures designate like or similar parts.
DETAILED DESCRIPTION
[0014] A work machine (herein “tractor), designated generally 1 , includes a hitch mechanism designated generally 2 that is semi-permanently attached to the tractor. A coupler device designated generally 4 is attached to the hitch 2 and a tongue 6 of an implement 7 , releasably coupling the implement to the tractor 1 .
[0015] The tractor 1 includes a frame 11 on which are mounted motive members 13 such as tires or tracks. A power plant 15 such as an internal combustion engine is provided and through a drive train 17 selectively drives a tractor 1 forward and/or rearward. The tractor is also steerable for left and right turns as is well known in the art. An operator station 19 is provided as well as a steering device 20 for steering the tractor during movement.
[0016] The tractor 1 includes the hitch mechanism 2 . Typical hitch mechanisms for wheeled tractors includes a three point hitch arrangement that can be used as a three point or two point hitch. The hitch 2 includes a pair of draft arms 22 pivotally mounted at their forward ends to the tractor and also to a hydraulic drive arrangement 24 via links 25 which will selectively move the draft arms 22 between a lowered position and an elevated position and is operable to selectively fix the draft arms at any position between the low and high positions. Such hitch arrangements are well know in the art. Connectors 26 are secured to the distal ends of the draft arms and preferably are balls 27 in sockets with through bores for the receipt of hitch pins 28 (FIGS. 2, 4, 6 ) therethrough. The draft arms 22 are mounted in a manner to permit their side to side pivoting at their mounting to the tractor whereby the distal ends can be varied in the degree of separation to accommodate different type and sizes of couplers and hitch arrangements. A three point hitch arrangement on a tractor includes an upper pivot 30 to which a link (not shown) may be connected, which link would have a free end connectable to an implement. Such three point hitch arrangements are well known in the art and need not be further described herein.
[0017] The implement 7 can be any suitable implement for example an earth scraper, box blade, compactor, roller, chisel, mower, rototiller or the like. In a preferred embodiment the implement 7 includes one or more support wheels 33 usable for supporting the implement body 34 . The wheel(s) 33 may be selectively adjustable relative to the body 34 for positioning of portions of the implement relative to the ground. Mechanism may be provided to allow the wheel(s) 33 to be in a down position for transport of the implement and in an up position when the implement is to be used, for example, in a grading project. Devices for positioning the wheel(s) 33 are well known in the art. The implement 7 includes the tongue 6 which in the illustrated structure is a goose neck type tongue having an elevated bight portion 36 and a distal connector portion 38 connected to the bight portion 36 and depending downwardly therefrom forming a clearance gap 39 . The tongue 6 may be raised and lowered by raising or lowering the draft arms 22 . Goose neck tongues are well known in the industry. Examples of the foregoing implements include RB Scrapers, DB Scrapers and TL Rollers available from Hoelscher, Inc. of Bushton, Kans.
[0018] The two forms of coupler 4 are best seen in FIGS. 3 - 6 . The coupler 4 includes three pivot arrangements designated generally 41 , 42 and 43 . The coupler 4 includes a trunnion 45 which is in the form of a flat cross bar having opposite ends 46 , 47 . The pivot arrangement 41 includes a pair of pivot pins 49 each extending outwardly from its respective end 46 , 47 and adapted for pivoting receipt within the pivot balls 27 of the draft arms 22 . A hitch pin 28 or other suitable keeper 28 is utilized to retain the pins 49 within the balls 27 and connected to the draft arms 22 . The trunnion 45 and pins 49 can pivot about a generally horizontal axis through the pins 49 and the balls 27 . As used herein the terms vertical and horizontal are used in the reference frame of the tractor and implement being on a horizontal surface. However, it is to be understood that in the use of the tractor and implement that many times the tractor and implement will not be on a horizontal plane or a common plane. The pivot axis X of the pins 49 and trunnion 45 is also generally parallel to the axis of the rear axles of the tractor. It is to be understood however that the draft arms may be adjustable relative to one another to induce a side to side (of the tractor) cant in the trunnion 45 changing the plane of the X pivot axis from horizontal to non-horizontal but it is still considered generally horizontal as used herein. The X pivot axis extends through the trunnion 45 and is preferably generally centrally located therein.
[0019] Two forms of pivots 42 are illustrated in FIGS. 3 - 6 . The first form of pivot 42 is shown in FIGS. 3 and 4 and the second form is shown in FIGS. 5 and 6. In the first form of the invention (FIGS. 3 and 4), the pivot 42 includes a pair of pivot pins 52 removably mounted in a through bore 53 through the trunnion 45 . An opening 55 extends between opposite faces of the trunnion 45 with the bore 53 opening into the opening 55 on opposite sides thereof. A coupler 57 such as a bearing block or other suitable pivot member is pivotally mounted on the pins 52 for rotation or pivoting movement about the Y axis within the opening 55 . Mounting the coupler 57 within the opening 55 provides a low profile for the coupler 4 . The opening 55 is sized such that the coupler 57 when in cooperative interengagement with the pivot device 43 can move, as shown by the arrows A, in a plane generally normal to the Y axis plus or minus about 45°. This plane of movement extends generally transverse to the longitudinal axis of the tractor. The plane of movement may be changed relative to the ground by pivoting the trunnion 45 about the X axis.
[0020] The pivot 43 , in the illustrated embodiment of FIGS. 3, 4 is shown as a pintle type pivot and includes a pin 61 cooperatively interengageable with a sleeve or socket 62 such that the trunnion 45 and tongue 6 can pivot relative to one another to provide pivoting about a Z axis. As shown, the pin 61 is mounted to the coupler 57 and is generally upstanding therefrom and the trunnion 45 . In the illustrated embodiment, the pin 61 extends through a through bore 63 of the coupler 57 and be rotatable relative thereto. The Z axis can be and is shown as generally vertical including its movement about the X and Y axes. In the illustrated structure, the socket 62 is secured to the tongue 7 preferably at the distal end of the tongue portion 38 . The socket 62 is preferably secured to the tongue 7 in a removable manner as by a plate 64 bolted to a corresponding plate 65 permanently secured to the tongue portion 38 . A keeper 67 allows the pin 61 to be removed from the socket 62 for separation of the coupler 4 from the implement 7 . A cylindrical bushing 68 is sleeved onto the lower portion of the pin 61 with the coupler 57 positioned between the bottom of the socket 62 and the top of the bushing 68 . A second keeper 67 also releasably secures the pin 61 to the coupler 57 and socket 62 . The bushing 68 acts as a spacer and a thrust washer. In normal use, the pin 61 may be left attached to the tongue 7 if desired. Suitable lubricating devices such as zerk grease fittings 69 may be provided for the pivots 41 , 42 , 43 .
[0021] In the illustrated embodiments of the coupler 4 , the X and Y axes lie generally in the same plane which is shown as a generally horizontal plane while the Z axis lies in a plane generally normal to the plane of the X and Y axes and is shown as a generally vertical plane when the pivots 41 , 42 , 43 and are each in a neutral or normal position, as shown in the Figures. The X, Y and Z axes are generally normal to one another. The X, Y and Z axes substantially intersect with one another and particularly the X and Y axes substantially intersect providing the low profile arrangement. It is preferred that the X, Y and Z axes substantially intersect with one another by passing within approximately 3 inches of each other more preferably within about 2 inches of each other and most preferably within about 1 inch of each other. Preferably the pivot pins 49 , 52 and 61 are removable for maintenance purposes. The pins 49 may be threaded into the trunnion 45 while the pins 52 may be held within the bore 53 by a screw or bolt 67 or frictional engagement. The pin 61 may, in addition to the mounting described above, be threaded into the coupler 57 and rotatable in the socket 62 or may be permanently attached thereto and replaceable either on its own or in combination with the coupler 57 . A spacer 70 can be used to space the bottom of the socket 62 from the coupling 57 to permit the pivotal movement of the pin 61 about the pivot pins 52 . Such a spacer may be, for example, a thrust washer or bushing sleeved over the pin 61 or could be part of the socket 62 . The Y pivot axis is generally parallel to the longitudinal axis of the tractor 1 while the pivot axis X is generally transverse to the longitudinal axis of the tractor. The Y pivot axis moves in a plane that is generally transverse to the longitudinal axis of the tractor when the pin 61 is in a generally vertical plane.
[0022] [0022]FIGS. 5, 6 illustrate an alternate embodiment of the coupler. It includes a trunnion in the form of a cross bar or tow bar 71 similar to the trunnion 45 but without the need for through opening 55 . The bar 71 has pins 49 secured to and extending from opposite ends thereof. One or two pivot pins 73 can be used to connect a clevis 75 to the bar. The clevis 75 has arms 76 , 77 forming a gap 79 therebetween which receives the bar 71 therein. As shown, the pin 73 extends through each of the arms 76 , 77 and pivotally mounts the clevis 75 to the bar 71 and can be removably secured to the clevis 75 and bar 71 with hitch pins 28 . The clevis can pivot about the Y axis as does the coupler 57 . A cross member 81 joins the arms 76 , 77 together and provides a mounting member for the pin 61 . The pin 61 is secured to the clevis 75 as by threaded engagement or welding or may be integral therewith. The pin 61 rotates relative to the socket 62 . A bearing bushing 85 may be sleeved over the pin 61 to be positioned between the clevis 75 and socket 62 . In function and arrangement of the X, Y and Z axes, the coupler 4 shown in FIGS. 5, 6 is the same as that of the coupler 4 shown in FIGS. 3, 4.
[0023] In operation, the implement 7 is towed behind the tractor 1 with the implement being pivotable relative to the tractor about three axes to accommodate for changes and differences in terrain supporting the tractor and implement. The tractor 1 may turn left and right allowing the implement to pivot on the pivot arrangement 43 . The goose neck tongue 6 may be high enough to accommodate sharp turns by providing clearance over the top of the tires and fenders on the rear of the tractor. The implement and tractor may pivot relative to one another about the axis X to accommodate ditches, hills, etc. A left-right slope change between the implement and tractor, as viewed from the operators position can be accommodated by rotation about the Y axis. Because of the low profile, the moment applied to the hitch arrangement from the force needed to pull or resist forward movement of the implement relative to the tractor is reduced. Also, by having the X, Y and Z axes substantially intersect, the magnitude of other moments may be reduced. Also, by having the Z axis over the draft arms and close to the end of the tractor, the downward force on the tractor hitch can be reduced (relative to trailing hitches) thereby reducing the tendency of the front wheels to pick up from the ground.
[0024] The use of the inventive coupler 4 facilitates attachment of the tractor 1 to the implement 7 and alignment of the draft arms 23 with the pins 49 to effect the attachment. The operator backs the tractor 1 into approximate position relative to the implement, may then exit the tractor 1 to place one pin 49 in a respective ball 23 and attach the pin to the draft arm with a suitable keeper. Because of the pivoting nature of the pivots 41 , 42 , 43 , the free or unattached end of the pivot 41 may be simply and without the application of force to lift the implement align the other pin 49 with its ball by up and down or forward and back movement of the pin 23 and insert the pin into the ball 23 . A suitable keeper would then be placed on that pin 49 to releasably attach the coupler to the tractor hitch.
[0025] Thus, there has been shown and described several embodiments of an implement coupler. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. Many changes, modifications, variations and other uses and applications of the present constructions will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | A coupler for attaching an implement to a tractor is provided. The coupler has three pivot arrangements allowing pivoting about three axes that are generally normal to one another with two axes of pivoting lying in substantially in a first plane and the third axis of pivoting intersecting that plane at a variable angle in a second plane generally perpendicular to the first plane. The three axes of pivoting substantially intersect and the implement may be attached wherein the load from the implement is directed downwardly and over the draft arms of the tractor. | Briefly summarize the invention's components and working principles as described in the document. | [
"BACKGROUND OF INVENTION [0001] Work machines such as tractors are often used to pull implements such as box blades, compactors, rollers, scrapers, etc.",
"These implements may be supported by wheels or may drag along the ground.",
"Implements are typically not dedicated to a particular work machine and therefore are in the need of a fast, efficient and effective means to couple the implement to the work machine (hereinafter tractor).",
"Tractors typically have a three point hitch arrangement and many implements only use two points of the three point hitch arrangement particularly those implements utilizing one or more wheels for support.",
"Two point hitch arrangements utilize the two draft arms which are selectively moveable between elevated and lowered positions and retainable at one of various positions between a lowered position and an elevated position.",
"A cross bar may be secured to the draft arms to extend therebetween and is typically pivoted to the draft arms for rotation about a generally horizontal axis or an axis generally parallel to the axis of the rear wheel axles of the tractor.",
"[0002] Numerous types of couplers have been devised for connecting an implement to a tractor.",
"The couplers may be divided into three categories.",
"The first category is the coupler that attaches to a draw bar with multiple pivots trailing behind the draw bar a substantial distance.",
"Examples of these can be found in U.S. Pat. Nos. 5,706,901, 5,531,283 and 4,838,015.",
"This style of coupler, unless the implement is supported by front and rear wheels can apply a significant amount of downward force to the tractor hitch and can result, in some cases, in lifting the front wheels of the tractor from the ground.",
"To avoid this, implements have been provided with front and rear wheels when such implements or their loads are heavy.",
"[0003] A second type of coupler releasably attaches the tongue of the implement to the draw bar as for example with a ball or pin or the like.",
"The tongue rests on the draw bar and pivotal movement is accomplished by rotation about the ball in multi-axes or about a hitch pin through holes within the coupler arrangement.",
"While effective, the freedom of movement about a ball or hitch pin is limited.",
"A pintle hook is another such type of hitch.",
"[0004] A third form of coupler arrangement is shown in U.S. Pat. No. 2,091,009.",
"As shown, and described, the coupler is required to be forward of the rear wheels in order to prevent lifting of the front wheels when heavy loads are encountered.",
"To accomplish that goal, a large U-shaped yoke bridges the drive train in front of the rear wheel differential allowing pivoting in a forward and rearward direction by being hinged at pins connected to the drive train.",
"Second and third pivots are provided to provide both steering pivoting and irregular terrain pivoting.",
"However such an arrangement is cumbersome and eliminates, at least for modern tractors, the ability to use the seat on the tractor.",
"Also, because of the large height of the coupler, large moments (torque) will result.",
"Such an arrangement would also be difficult to attach an implement to the tractor and the ability to raise and lower the implement is precluded.",
"[0005] One common element to many of these hitches, particularly of the first and third categories just described, is the ability to provide pivoting about three distinct axes using three separate pivot arrangements.",
"Further, the first and third categories tend to be complex mechanisms that do not accommodate the applied forces necessarily very well.",
"Thus, there is a need for an improved coupler and tractor/implement/coupler arrangement.",
"SUMMARY OF INVENTION [0006] The present invention involves the provision of a tractor, implement and coupler arrangement that includes a coupler attachable to the draft arms of a tractor and having three pivot devices for allowing the tractor and implement to pivot relative to one another about three axes.",
"The axes of the pivots are such as to substantially intersect with one another to provide a low profile coupler arrangement.",
"The coupler interconnects the tractor hitch arrangement and hence the tractor to an implement having a draw tongue.",
"The tongue is preferably, at least for certain types of implements, a goose neck type tongue to help provide clearance for tight turns without interfering with the rear wheels or other portions of the tractor.",
"The implement may use support wheels or may have support wheels that are selectively engageable with the ground or in certain cases the implements may not utilize wheels for support.",
"The coupler permits the use of a link from the third point of a three point hitch, in a selective manner, to elevate certain implements for transport by using the three point hitch arrangement on the tractor.",
"BRIEF DESCRIPTION OF DRAWINGS [0007] [0007 ]FIG. 1 is a side elevation view of a tractor, implement and coupler connecting the implement to the tractor.",
"[0008] [0008 ]FIG. 2 is a plan view of the tractor implement and coupler as shown in FIG. 1 with various pivoted positions of the implement relative to the tractor shown in phantom.",
"[0009] [0009 ]FIG. 3 is an enlarged perspective view of one form of coupler device.",
"[0010] [0010 ]FIG. 4 is an exploded view of the coupler as seen in FIG. 3. [0011] [0011 ]FIG. 5 is an enlarged perspective view of a second form of coupler device.",
"[0012] [0012 ]FIG. 6 is an exploded view of the coupler of FIG. 5. [0013] Like numbers utilized throughout the various Figures designate like or similar parts.",
"DETAILED DESCRIPTION [0014] A work machine (herein “tractor), designated generally 1 , includes a hitch mechanism designated generally 2 that is semi-permanently attached to the tractor.",
"A coupler device designated generally 4 is attached to the hitch 2 and a tongue 6 of an implement 7 , releasably coupling the implement to the tractor 1 .",
"[0015] The tractor 1 includes a frame 11 on which are mounted motive members 13 such as tires or tracks.",
"A power plant 15 such as an internal combustion engine is provided and through a drive train 17 selectively drives a tractor 1 forward and/or rearward.",
"The tractor is also steerable for left and right turns as is well known in the art.",
"An operator station 19 is provided as well as a steering device 20 for steering the tractor during movement.",
"[0016] The tractor 1 includes the hitch mechanism 2 .",
"Typical hitch mechanisms for wheeled tractors includes a three point hitch arrangement that can be used as a three point or two point hitch.",
"The hitch 2 includes a pair of draft arms 22 pivotally mounted at their forward ends to the tractor and also to a hydraulic drive arrangement 24 via links 25 which will selectively move the draft arms 22 between a lowered position and an elevated position and is operable to selectively fix the draft arms at any position between the low and high positions.",
"Such hitch arrangements are well know in the art.",
"Connectors 26 are secured to the distal ends of the draft arms and preferably are balls 27 in sockets with through bores for the receipt of hitch pins 28 (FIGS.",
"2, 4, 6 ) therethrough.",
"The draft arms 22 are mounted in a manner to permit their side to side pivoting at their mounting to the tractor whereby the distal ends can be varied in the degree of separation to accommodate different type and sizes of couplers and hitch arrangements.",
"A three point hitch arrangement on a tractor includes an upper pivot 30 to which a link (not shown) may be connected, which link would have a free end connectable to an implement.",
"Such three point hitch arrangements are well known in the art and need not be further described herein.",
"[0017] The implement 7 can be any suitable implement for example an earth scraper, box blade, compactor, roller, chisel, mower, rototiller or the like.",
"In a preferred embodiment the implement 7 includes one or more support wheels 33 usable for supporting the implement body 34 .",
"The wheel(s) 33 may be selectively adjustable relative to the body 34 for positioning of portions of the implement relative to the ground.",
"Mechanism may be provided to allow the wheel(s) 33 to be in a down position for transport of the implement and in an up position when the implement is to be used, for example, in a grading project.",
"Devices for positioning the wheel(s) 33 are well known in the art.",
"The implement 7 includes the tongue 6 which in the illustrated structure is a goose neck type tongue having an elevated bight portion 36 and a distal connector portion 38 connected to the bight portion 36 and depending downwardly therefrom forming a clearance gap 39 .",
"The tongue 6 may be raised and lowered by raising or lowering the draft arms 22 .",
"Goose neck tongues are well known in the industry.",
"Examples of the foregoing implements include RB Scrapers, DB Scrapers and TL Rollers available from Hoelscher, Inc. of Bushton, Kans.",
"[0018] The two forms of coupler 4 are best seen in FIGS. 3 - 6 .",
"The coupler 4 includes three pivot arrangements designated generally 41 , 42 and 43 .",
"The coupler 4 includes a trunnion 45 which is in the form of a flat cross bar having opposite ends 46 , 47 .",
"The pivot arrangement 41 includes a pair of pivot pins 49 each extending outwardly from its respective end 46 , 47 and adapted for pivoting receipt within the pivot balls 27 of the draft arms 22 .",
"A hitch pin 28 or other suitable keeper 28 is utilized to retain the pins 49 within the balls 27 and connected to the draft arms 22 .",
"The trunnion 45 and pins 49 can pivot about a generally horizontal axis through the pins 49 and the balls 27 .",
"As used herein the terms vertical and horizontal are used in the reference frame of the tractor and implement being on a horizontal surface.",
"However, it is to be understood that in the use of the tractor and implement that many times the tractor and implement will not be on a horizontal plane or a common plane.",
"The pivot axis X of the pins 49 and trunnion 45 is also generally parallel to the axis of the rear axles of the tractor.",
"It is to be understood however that the draft arms may be adjustable relative to one another to induce a side to side (of the tractor) cant in the trunnion 45 changing the plane of the X pivot axis from horizontal to non-horizontal but it is still considered generally horizontal as used herein.",
"The X pivot axis extends through the trunnion 45 and is preferably generally centrally located therein.",
"[0019] Two forms of pivots 42 are illustrated in FIGS. 3 - 6 .",
"The first form of pivot 42 is shown in FIGS. 3 and 4 and the second form is shown in FIGS. 5 and 6.",
"In the first form of the invention (FIGS.",
"3 and 4), the pivot 42 includes a pair of pivot pins 52 removably mounted in a through bore 53 through the trunnion 45 .",
"An opening 55 extends between opposite faces of the trunnion 45 with the bore 53 opening into the opening 55 on opposite sides thereof.",
"A coupler 57 such as a bearing block or other suitable pivot member is pivotally mounted on the pins 52 for rotation or pivoting movement about the Y axis within the opening 55 .",
"Mounting the coupler 57 within the opening 55 provides a low profile for the coupler 4 .",
"The opening 55 is sized such that the coupler 57 when in cooperative interengagement with the pivot device 43 can move, as shown by the arrows A, in a plane generally normal to the Y axis plus or minus about 45°.",
"This plane of movement extends generally transverse to the longitudinal axis of the tractor.",
"The plane of movement may be changed relative to the ground by pivoting the trunnion 45 about the X axis.",
"[0020] The pivot 43 , in the illustrated embodiment of FIGS. 3, 4 is shown as a pintle type pivot and includes a pin 61 cooperatively interengageable with a sleeve or socket 62 such that the trunnion 45 and tongue 6 can pivot relative to one another to provide pivoting about a Z axis.",
"As shown, the pin 61 is mounted to the coupler 57 and is generally upstanding therefrom and the trunnion 45 .",
"In the illustrated embodiment, the pin 61 extends through a through bore 63 of the coupler 57 and be rotatable relative thereto.",
"The Z axis can be and is shown as generally vertical including its movement about the X and Y axes.",
"In the illustrated structure, the socket 62 is secured to the tongue 7 preferably at the distal end of the tongue portion 38 .",
"The socket 62 is preferably secured to the tongue 7 in a removable manner as by a plate 64 bolted to a corresponding plate 65 permanently secured to the tongue portion 38 .",
"A keeper 67 allows the pin 61 to be removed from the socket 62 for separation of the coupler 4 from the implement 7 .",
"A cylindrical bushing 68 is sleeved onto the lower portion of the pin 61 with the coupler 57 positioned between the bottom of the socket 62 and the top of the bushing 68 .",
"A second keeper 67 also releasably secures the pin 61 to the coupler 57 and socket 62 .",
"The bushing 68 acts as a spacer and a thrust washer.",
"In normal use, the pin 61 may be left attached to the tongue 7 if desired.",
"Suitable lubricating devices such as zerk grease fittings 69 may be provided for the pivots 41 , 42 , 43 .",
"[0021] In the illustrated embodiments of the coupler 4 , the X and Y axes lie generally in the same plane which is shown as a generally horizontal plane while the Z axis lies in a plane generally normal to the plane of the X and Y axes and is shown as a generally vertical plane when the pivots 41 , 42 , 43 and are each in a neutral or normal position, as shown in the Figures.",
"The X, Y and Z axes are generally normal to one another.",
"The X, Y and Z axes substantially intersect with one another and particularly the X and Y axes substantially intersect providing the low profile arrangement.",
"It is preferred that the X, Y and Z axes substantially intersect with one another by passing within approximately 3 inches of each other more preferably within about 2 inches of each other and most preferably within about 1 inch of each other.",
"Preferably the pivot pins 49 , 52 and 61 are removable for maintenance purposes.",
"The pins 49 may be threaded into the trunnion 45 while the pins 52 may be held within the bore 53 by a screw or bolt 67 or frictional engagement.",
"The pin 61 may, in addition to the mounting described above, be threaded into the coupler 57 and rotatable in the socket 62 or may be permanently attached thereto and replaceable either on its own or in combination with the coupler 57 .",
"A spacer 70 can be used to space the bottom of the socket 62 from the coupling 57 to permit the pivotal movement of the pin 61 about the pivot pins 52 .",
"Such a spacer may be, for example, a thrust washer or bushing sleeved over the pin 61 or could be part of the socket 62 .",
"The Y pivot axis is generally parallel to the longitudinal axis of the tractor 1 while the pivot axis X is generally transverse to the longitudinal axis of the tractor.",
"The Y pivot axis moves in a plane that is generally transverse to the longitudinal axis of the tractor when the pin 61 is in a generally vertical plane.",
"[0022] [0022 ]FIGS. 5, 6 illustrate an alternate embodiment of the coupler.",
"It includes a trunnion in the form of a cross bar or tow bar 71 similar to the trunnion 45 but without the need for through opening 55 .",
"The bar 71 has pins 49 secured to and extending from opposite ends thereof.",
"One or two pivot pins 73 can be used to connect a clevis 75 to the bar.",
"The clevis 75 has arms 76 , 77 forming a gap 79 therebetween which receives the bar 71 therein.",
"As shown, the pin 73 extends through each of the arms 76 , 77 and pivotally mounts the clevis 75 to the bar 71 and can be removably secured to the clevis 75 and bar 71 with hitch pins 28 .",
"The clevis can pivot about the Y axis as does the coupler 57 .",
"A cross member 81 joins the arms 76 , 77 together and provides a mounting member for the pin 61 .",
"The pin 61 is secured to the clevis 75 as by threaded engagement or welding or may be integral therewith.",
"The pin 61 rotates relative to the socket 62 .",
"A bearing bushing 85 may be sleeved over the pin 61 to be positioned between the clevis 75 and socket 62 .",
"In function and arrangement of the X, Y and Z axes, the coupler 4 shown in FIGS. 5, 6 is the same as that of the coupler 4 shown in FIGS. 3, 4.",
"[0023] In operation, the implement 7 is towed behind the tractor 1 with the implement being pivotable relative to the tractor about three axes to accommodate for changes and differences in terrain supporting the tractor and implement.",
"The tractor 1 may turn left and right allowing the implement to pivot on the pivot arrangement 43 .",
"The goose neck tongue 6 may be high enough to accommodate sharp turns by providing clearance over the top of the tires and fenders on the rear of the tractor.",
"The implement and tractor may pivot relative to one another about the axis X to accommodate ditches, hills, etc.",
"A left-right slope change between the implement and tractor, as viewed from the operators position can be accommodated by rotation about the Y axis.",
"Because of the low profile, the moment applied to the hitch arrangement from the force needed to pull or resist forward movement of the implement relative to the tractor is reduced.",
"Also, by having the X, Y and Z axes substantially intersect, the magnitude of other moments may be reduced.",
"Also, by having the Z axis over the draft arms and close to the end of the tractor, the downward force on the tractor hitch can be reduced (relative to trailing hitches) thereby reducing the tendency of the front wheels to pick up from the ground.",
"[0024] The use of the inventive coupler 4 facilitates attachment of the tractor 1 to the implement 7 and alignment of the draft arms 23 with the pins 49 to effect the attachment.",
"The operator backs the tractor 1 into approximate position relative to the implement, may then exit the tractor 1 to place one pin 49 in a respective ball 23 and attach the pin to the draft arm with a suitable keeper.",
"Because of the pivoting nature of the pivots 41 , 42 , 43 , the free or unattached end of the pivot 41 may be simply and without the application of force to lift the implement align the other pin 49 with its ball by up and down or forward and back movement of the pin 23 and insert the pin into the ball 23 .",
"A suitable keeper would then be placed on that pin 49 to releasably attach the coupler to the tractor hitch.",
"[0025] Thus, there has been shown and described several embodiments of an implement coupler.",
"As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art.",
"Many changes, modifications, variations and other uses and applications of the present constructions will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings.",
"All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow."
] |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application no. 61/212,816 filed on Apr. 16, 2009.
REFERENCE TO A COMPUTER PROGRAM LISTING APPENDIX
[0002] Incorporated by reference are program listings contained on an accompanying CD-ROM (with copy filed herewith), containing two files, LLC-HMI and LLC-PLC created on Mar. 29, 2010.
BACKGROUND OF THE INVENTION
[0003] This invention concerns twin sheet thermoforming machines and more particularly platen drives for platens included in a forming station. In the forming station, upper and lower molds are carried by upper and lower platens respectively for forming separate part halves in a well known manner. After the part halves are formed, the upper and lower platens are moved together to fuse the two part halves together. This process and such thermoforming machines are described in U.S. Pat. Nos. 5,814,185 and 6,969,246 assigned to the same assignee as the present application, and are incorporated herein by reference.
[0004] It is critical that the molds mate perfectly in order to produce a uniform seam thickness for such a twin sheet molding process when the platens are advanced together, and this requirement in turn requires both platens to be perfectly level to be parallel when fully advanced, partially with large platens.
[0005] However, it is difficult to achieve level platens with large area platens and requires extremely time consuming manual adjustments requiring disassembling of gearing. The meshing of drive gearing with fixed gear rack guide posts typically used to guide the platen motion makes this very slow, difficult and time tedious since variations of the degree of engagement of the drive unit gearing engagement with the four gear racks affects the level condition of such a platen, i.e. a greater degree of engagement slightly elevates the associated platen and a lesser degree of engagement slightly lowers the platen changing the degree of gear engagement with one post may affect another gear-post engagement.
[0006] In addition, the perfectly plumbed guide gear rack posts engage guide bushings on the platens during travel of the platens, and even a slight out of level condition would create significant binding in the post/sleeve engagement surfaces, particularly in large area platens and result in rapid wear of the guide bushings to significantly increase maintenance costs.
[0007] Conventional platen drives involve one or two motors driving respective sets of gearing which engage associated fixed gear posts to drive the platens.
[0008] Machining a large platen is costly as very large machining centers are required to accommodate such platens and align bores at either end of the platen for the respective gearing.
[0009] Accordingly, it is an object of the present invention to provide a method for the leveling platens in a thermoforming machine station which reduces the time and difficulty of setting the platens level.
[0010] It is a further object to provide a platen drive for thermoforming machine forming station platen which allows simplified leveling of the platens and also lower a cost manufacture of the platens.
SUMMARY OF THE INVENTION
[0011] The above recited objects and other objects which will become apparent by those skilled in the art upon a reading of the following specification and claims are achieved by providing thermoformer platen drive comprised of four independently operated platen drive units arranged in two unit sub sets on opposite sides of an associated platen which each drive units include an electric servo motor with encoder and gearing which are normally simultaneously operated to vertically drive each leveled platen up or down. The drive unit controls allow the practice of a method of platen leveling in which each of servo motor may be operated individually in a leveling mode to enable bringing the platen into a level condition quickly and easily by operating each servo motor as needed to level the platen. Differences in the degree of meshing engagement of the various drive pinions with respect to a respective gear rack in this arrangement can be accommodated by the individual servo motor operation and thus does not affect the ability to level the platens.
[0012] Thereafter, the individual drive units are operated simultaneously to vertically move each engaged part of the platen precisely equally to maintain a level condition of the platen.
[0013] The independent operation of each drive unit allows each gear box/motor drive unit mount to be individually machined and assembled to locating surfaces on the platen machined level in machining centers. Since bore alignment between the mounts are not necessary because of the independently operated drive units, lower cost machining of the platens and drive unit mounts is made possible.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a front elevational view of a lower platen and support structure incorporating a platen drive system according to the present invention.
[0015] FIG. 1A is an end view of one of the drive units shown in FIG. 1 .
[0016] FIG. 2 is a plan view of the lower platen structure shown in FIG. 1 with a diagrammatic depiction of the servo motor control operating the four electric servo motors.
[0017] FIG. 2A is a top view of one of the drive units shown in FIG. 2 .
[0018] FIG. 3 is a side elevational view of the lower platen structure shown in FIGS. 1 and 2 .
[0019] FIG. 4 is an enlarged view of the section 4 - 4 taken in FIG. 2 .
[0020] FIG. 4A is an enlarged fragmentary sectional view of a portion of the gear post and guide box shown in FIG. 4 .
[0021] FIG. 4B is an enlarged fragmentary sectional view of a one end of the gear post attachment shown in FIG. 4 .
[0022] FIG. 5 is an enlarged view of the section 5 - 5 in FIG. 2 .
[0023] FIG. 6 is a pictorial view of the lower platen structure shown in FIGS. 1-3
[0024] FIG. 7 is an inverted pictorial view of a lower platens shown in FIGS. 1-3 .
[0025] FIG. 8 is a pictorial view from one side of a drive unit mount.
[0026] FIG. 9 is a pictorial view of the drive mount shown in FIG. 8 from the reverse side.
[0027] FIG. 10 is a plan view of the upper platen structure with a diagrammatic representation of the servo motor control operating the four electric servo motors.
[0028] FIG. 11 is a front elevational view of the upper platen structure shown in FIG. 10 .
[0029] FIG. 12 is an enlarged view of the section 12 - 12 taken in FIG. 10 .
[0030] FIG. 13 is an enlarged view of the section 13 - 13 taken in FIG. 10 .
[0031] FIG. 14 as a pictorial view from the bottom of the upper platen structure shown in FIGS. 10 and 11 .
[0032] FIG. 15 is a view of a screen shot of one made of the servo motor controller seen in a platen leveling set up mode of the controller.
DETAILED DESCRIPTION
[0033] In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.
[0034] Referring to the drawings, FIGS. 1-9 show a lower platen structure 10 and details thereof, which include a lower platen assembly 12 movably mounted vertically on a support framework 14 .
[0035] Such platen assemblies are used in the forming station of twin sheet thermoforming machines as mentioned above and described in the molds (not shown) are normally mounted on the platens above referenced patents, incorporated herein by reference.
[0036] There are a set of four electric servo motor/gear box drive units provided, in subsets of two drive units 16 A, 16 B mount on opposite sides of the platen 12 , here the front and rear side of the lower platen 12 assembly movable mounted on the lower platen support framework 14 .
[0037] The drive units 16 A are more closely spaced to allow clearance for feeding sheets between the upper and lower platens on a rotary transfer machine in the well known manner. The sides of the platens are normally left clear of support posts in order to allow sheet material to be loaded onto the molds in the well known manner.
[0038] The drive units 16 A, 16 B include an electric servo motor and a right angle gear box 22 having a hollow shaft output 24 . Suitable drive units are of a type commercially available under the trade name SEW EURO DRIVE. These motors include a built in encoder which allow precise control over the extent of rotation of the tubular output shaft 24 in the manner well known in the art.
[0039] A respective pinion shaft 26 (FIGS. 4 , 5 ) is received in each of the hollow gear box output shaft 24 and clamped thereto with a clamping collar 25 to be rotatably connected thereto.
[0040] A pinion gear 28 is keyed to the pinion shaft 26 , which has its outer end passed through a bore 42 in plate 33 of a drive unit mount 30 , and supported in a bearing 40 .
[0041] A gear rack 50 machined into a support-guide post 44 adjacent each drive unit 16 A, 16 B is engaged by the associated pinion gear 28 as seen in FIG. 4 . Each guide post 44 is fixedly mounted to the lower platen structure frame 14 at the top and bottom ends, the ends adjusted at assembly to plumb the posts 44 . When the drive units 16 A, 16 B are operated, the lower platen 12 is moved up or down on the lower platen support frame 14 .
[0042] Each support guide post 44 is received in a guide sleeve 46 and is slidable in guide bushings 48 at the top and bottom of the sleeve 46 ( FIG. 4A ) included in each of the mounts 30 . Each sleeve 46 has a cut out to allow the pinion gear 28 to be positioned to engage a gear rack 50 machined into one side of the guide post 44 .
[0043] The guide post 44 is slidable within the bushings 48 . In practice, one of the posts 44 is initially plumbed with respect to the frame structure 14 by end plates 52 fastened to slotted blocks 54 fixed to frame 14 by screws passing through slots 56 allowing adjustment in one direction. A shimming space 58 allows adjustment in the other direction. Once plumbing of one of the posts 44 is achieved, the plates 54 , 52 are welded together.
[0044] The other three posts 44 are then plumbed by making any adjustments necessary to release any binding that occurs when the platen 12 is elevated up and down on the posts 44 .
[0045] The independent operation of the platen drive units 16 A, 16 B eliminates the need to accurately align bores in the mounts 30 with each other on the platen, greatly easing the difficulty of the machining requirements.
[0046] A series of hydraulic bayonet couplings 58 are provided for enabling twin sheet thermoforming operations where two part halves are fused together as described in U.S. Pat. Nos. 5,814,185 and 6,969,246 thermoforming machines assigned to the same assignee as the present application. The other features and details of such twin sheet thermoforming machines are not set forth herein, not forming a part of the present invention.
[0047] Initially, the platen 12 is leveled using a machinists' level. In this mode, the drive units 16 A, 16 B are set for independent operation in a set up mode to carry the platen out leveling process.
[0048] FIG. 15 shows the operator's control screen in that mode.
[0049] In this mode, each servo motor 17 is briefly operated (or “bumped”) individually as necessary until the platen 12 is brought to a level. The encoder condition for each motors 17 included in the drive units is then zeroed.
[0050] During normal operation, the motors 17 are all operated simultaneously to move exactly the same distance using the encoder outputs to achieve such operation moving the platen 12 vertically while maintaining a level condition, in the well known manner. A suitable software program for carrying out the leveling control is contained in the accompanying Appendix CD's.
[0051] FIGS. 10-14 show an upper platen structure 60 also included in a twin sheet thermoformer forming station which is similar to the lower platen structure 10 , also including two sets of independent electric servo motors/gear box drive units 62 A, 62 B mounted to an upper platen 64 . These units power vertical movement of the upper platen 64 on an upper platen support frame 66 .
[0052] Each drive unit has an output hollow tube 68 receiving a pinion shaft 70 clamped thereto at one end with a clamp 71 ( FIG. 13 ). A pinion gear 74 is keyed to the shaft 70 which is supported in a mount 72 located on horizontal machined surfaces 75 on the upper platen 64 . Each pinion gear 74 engages teeth on a gear rack/support guide post 76 received in a guide sleeve 78 included in the mount 72 . The gear rack/support guide post 76 is adjusted to be plumb by caps 80 and slotted blocks 82 so that the upper platen 64 can move freely without binding, as described above in connection with the lower platen 12 .
[0053] Rods 84 have ends 88 adapted to be locked to the hydraulic bayonet couplings 58 on the lower platen 12 to carry out squeeze fusing of twin parts in the manner described in the U.S. patents referenced above.
[0054] Thus, a much simplified platen leveling process is enabled as well as reduced machining costs for large platen forming presses by the independent four motor drive arrangement shown. | A platen drive system and method of leveling platens in a forming station of a twin sheet thermoforming machine in which each platen is driven vertically by four independently operated drive units, each having an electric servo motor, the drive units arranged in two sub sets disposed on opposite sides of an associated platen. The platen is leveled during set up by individual operation of the servo motors. | Condense the core contents of the given document. | [
"CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. provisional application no. 61/212,816 filed on Apr. 16, 2009.",
"REFERENCE TO A COMPUTER PROGRAM LISTING APPENDIX [0002] Incorporated by reference are program listings contained on an accompanying CD-ROM (with copy filed herewith), containing two files, LLC-HMI and LLC-PLC created on Mar. 29, 2010.",
"BACKGROUND OF THE INVENTION [0003] This invention concerns twin sheet thermoforming machines and more particularly platen drives for platens included in a forming station.",
"In the forming station, upper and lower molds are carried by upper and lower platens respectively for forming separate part halves in a well known manner.",
"After the part halves are formed, the upper and lower platens are moved together to fuse the two part halves together.",
"This process and such thermoforming machines are described in U.S. Pat. Nos. 5,814,185 and 6,969,246 assigned to the same assignee as the present application, and are incorporated herein by reference.",
"[0004] It is critical that the molds mate perfectly in order to produce a uniform seam thickness for such a twin sheet molding process when the platens are advanced together, and this requirement in turn requires both platens to be perfectly level to be parallel when fully advanced, partially with large platens.",
"[0005] However, it is difficult to achieve level platens with large area platens and requires extremely time consuming manual adjustments requiring disassembling of gearing.",
"The meshing of drive gearing with fixed gear rack guide posts typically used to guide the platen motion makes this very slow, difficult and time tedious since variations of the degree of engagement of the drive unit gearing engagement with the four gear racks affects the level condition of such a platen, i.e. a greater degree of engagement slightly elevates the associated platen and a lesser degree of engagement slightly lowers the platen changing the degree of gear engagement with one post may affect another gear-post engagement.",
"[0006] In addition, the perfectly plumbed guide gear rack posts engage guide bushings on the platens during travel of the platens, and even a slight out of level condition would create significant binding in the post/sleeve engagement surfaces, particularly in large area platens and result in rapid wear of the guide bushings to significantly increase maintenance costs.",
"[0007] Conventional platen drives involve one or two motors driving respective sets of gearing which engage associated fixed gear posts to drive the platens.",
"[0008] Machining a large platen is costly as very large machining centers are required to accommodate such platens and align bores at either end of the platen for the respective gearing.",
"[0009] Accordingly, it is an object of the present invention to provide a method for the leveling platens in a thermoforming machine station which reduces the time and difficulty of setting the platens level.",
"[0010] It is a further object to provide a platen drive for thermoforming machine forming station platen which allows simplified leveling of the platens and also lower a cost manufacture of the platens.",
"SUMMARY OF THE INVENTION [0011] The above recited objects and other objects which will become apparent by those skilled in the art upon a reading of the following specification and claims are achieved by providing thermoformer platen drive comprised of four independently operated platen drive units arranged in two unit sub sets on opposite sides of an associated platen which each drive units include an electric servo motor with encoder and gearing which are normally simultaneously operated to vertically drive each leveled platen up or down.",
"The drive unit controls allow the practice of a method of platen leveling in which each of servo motor may be operated individually in a leveling mode to enable bringing the platen into a level condition quickly and easily by operating each servo motor as needed to level the platen.",
"Differences in the degree of meshing engagement of the various drive pinions with respect to a respective gear rack in this arrangement can be accommodated by the individual servo motor operation and thus does not affect the ability to level the platens.",
"[0012] Thereafter, the individual drive units are operated simultaneously to vertically move each engaged part of the platen precisely equally to maintain a level condition of the platen.",
"[0013] The independent operation of each drive unit allows each gear box/motor drive unit mount to be individually machined and assembled to locating surfaces on the platen machined level in machining centers.",
"Since bore alignment between the mounts are not necessary because of the independently operated drive units, lower cost machining of the platens and drive unit mounts is made possible.",
"DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 is a front elevational view of a lower platen and support structure incorporating a platen drive system according to the present invention.",
"[0015] FIG. 1A is an end view of one of the drive units shown in FIG. 1 .",
"[0016] FIG. 2 is a plan view of the lower platen structure shown in FIG. 1 with a diagrammatic depiction of the servo motor control operating the four electric servo motors.",
"[0017] FIG. 2A is a top view of one of the drive units shown in FIG. 2 .",
"[0018] FIG. 3 is a side elevational view of the lower platen structure shown in FIGS. 1 and 2 .",
"[0019] FIG. 4 is an enlarged view of the section 4 - 4 taken in FIG. 2 .",
"[0020] FIG. 4A is an enlarged fragmentary sectional view of a portion of the gear post and guide box shown in FIG. 4 .",
"[0021] FIG. 4B is an enlarged fragmentary sectional view of a one end of the gear post attachment shown in FIG. 4 .",
"[0022] FIG. 5 is an enlarged view of the section 5 - 5 in FIG. 2 .",
"[0023] FIG. 6 is a pictorial view of the lower platen structure shown in FIGS. 1-3 [0024] FIG. 7 is an inverted pictorial view of a lower platens shown in FIGS. 1-3 .",
"[0025] FIG. 8 is a pictorial view from one side of a drive unit mount.",
"[0026] FIG. 9 is a pictorial view of the drive mount shown in FIG. 8 from the reverse side.",
"[0027] FIG. 10 is a plan view of the upper platen structure with a diagrammatic representation of the servo motor control operating the four electric servo motors.",
"[0028] FIG. 11 is a front elevational view of the upper platen structure shown in FIG. 10 .",
"[0029] FIG. 12 is an enlarged view of the section 12 - 12 taken in FIG. 10 .",
"[0030] FIG. 13 is an enlarged view of the section 13 - 13 taken in FIG. 10 .",
"[0031] FIG. 14 as a pictorial view from the bottom of the upper platen structure shown in FIGS. 10 and 11 .",
"[0032] FIG. 15 is a view of a screen shot of one made of the servo motor controller seen in a platen leveling set up mode of the controller.",
"DETAILED DESCRIPTION [0033] In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.",
"[0034] Referring to the drawings, FIGS. 1-9 show a lower platen structure 10 and details thereof, which include a lower platen assembly 12 movably mounted vertically on a support framework 14 .",
"[0035] Such platen assemblies are used in the forming station of twin sheet thermoforming machines as mentioned above and described in the molds (not shown) are normally mounted on the platens above referenced patents, incorporated herein by reference.",
"[0036] There are a set of four electric servo motor/gear box drive units provided, in subsets of two drive units 16 A, 16 B mount on opposite sides of the platen 12 , here the front and rear side of the lower platen 12 assembly movable mounted on the lower platen support framework 14 .",
"[0037] The drive units 16 A are more closely spaced to allow clearance for feeding sheets between the upper and lower platens on a rotary transfer machine in the well known manner.",
"The sides of the platens are normally left clear of support posts in order to allow sheet material to be loaded onto the molds in the well known manner.",
"[0038] The drive units 16 A, 16 B include an electric servo motor and a right angle gear box 22 having a hollow shaft output 24 .",
"Suitable drive units are of a type commercially available under the trade name SEW EURO DRIVE.",
"These motors include a built in encoder which allow precise control over the extent of rotation of the tubular output shaft 24 in the manner well known in the art.",
"[0039] A respective pinion shaft 26 (FIGS.",
"4 , 5 ) is received in each of the hollow gear box output shaft 24 and clamped thereto with a clamping collar 25 to be rotatably connected thereto.",
"[0040] A pinion gear 28 is keyed to the pinion shaft 26 , which has its outer end passed through a bore 42 in plate 33 of a drive unit mount 30 , and supported in a bearing 40 .",
"[0041] A gear rack 50 machined into a support-guide post 44 adjacent each drive unit 16 A, 16 B is engaged by the associated pinion gear 28 as seen in FIG. 4 .",
"Each guide post 44 is fixedly mounted to the lower platen structure frame 14 at the top and bottom ends, the ends adjusted at assembly to plumb the posts 44 .",
"When the drive units 16 A, 16 B are operated, the lower platen 12 is moved up or down on the lower platen support frame 14 .",
"[0042] Each support guide post 44 is received in a guide sleeve 46 and is slidable in guide bushings 48 at the top and bottom of the sleeve 46 ( FIG. 4A ) included in each of the mounts 30 .",
"Each sleeve 46 has a cut out to allow the pinion gear 28 to be positioned to engage a gear rack 50 machined into one side of the guide post 44 .",
"[0043] The guide post 44 is slidable within the bushings 48 .",
"In practice, one of the posts 44 is initially plumbed with respect to the frame structure 14 by end plates 52 fastened to slotted blocks 54 fixed to frame 14 by screws passing through slots 56 allowing adjustment in one direction.",
"A shimming space 58 allows adjustment in the other direction.",
"Once plumbing of one of the posts 44 is achieved, the plates 54 , 52 are welded together.",
"[0044] The other three posts 44 are then plumbed by making any adjustments necessary to release any binding that occurs when the platen 12 is elevated up and down on the posts 44 .",
"[0045] The independent operation of the platen drive units 16 A, 16 B eliminates the need to accurately align bores in the mounts 30 with each other on the platen, greatly easing the difficulty of the machining requirements.",
"[0046] A series of hydraulic bayonet couplings 58 are provided for enabling twin sheet thermoforming operations where two part halves are fused together as described in U.S. Pat. Nos. 5,814,185 and 6,969,246 thermoforming machines assigned to the same assignee as the present application.",
"The other features and details of such twin sheet thermoforming machines are not set forth herein, not forming a part of the present invention.",
"[0047] Initially, the platen 12 is leveled using a machinists'",
"level.",
"In this mode, the drive units 16 A, 16 B are set for independent operation in a set up mode to carry the platen out leveling process.",
"[0048] FIG. 15 shows the operator's control screen in that mode.",
"[0049] In this mode, each servo motor 17 is briefly operated (or “bumped”) individually as necessary until the platen 12 is brought to a level.",
"The encoder condition for each motors 17 included in the drive units is then zeroed.",
"[0050] During normal operation, the motors 17 are all operated simultaneously to move exactly the same distance using the encoder outputs to achieve such operation moving the platen 12 vertically while maintaining a level condition, in the well known manner.",
"A suitable software program for carrying out the leveling control is contained in the accompanying Appendix CD's.",
"[0051] FIGS. 10-14 show an upper platen structure 60 also included in a twin sheet thermoformer forming station which is similar to the lower platen structure 10 , also including two sets of independent electric servo motors/gear box drive units 62 A, 62 B mounted to an upper platen 64 .",
"These units power vertical movement of the upper platen 64 on an upper platen support frame 66 .",
"[0052] Each drive unit has an output hollow tube 68 receiving a pinion shaft 70 clamped thereto at one end with a clamp 71 ( FIG. 13 ).",
"A pinion gear 74 is keyed to the shaft 70 which is supported in a mount 72 located on horizontal machined surfaces 75 on the upper platen 64 .",
"Each pinion gear 74 engages teeth on a gear rack/support guide post 76 received in a guide sleeve 78 included in the mount 72 .",
"The gear rack/support guide post 76 is adjusted to be plumb by caps 80 and slotted blocks 82 so that the upper platen 64 can move freely without binding, as described above in connection with the lower platen 12 .",
"[0053] Rods 84 have ends 88 adapted to be locked to the hydraulic bayonet couplings 58 on the lower platen 12 to carry out squeeze fusing of twin parts in the manner described in the U.S. patents referenced above.",
"[0054] Thus, a much simplified platen leveling process is enabled as well as reduced machining costs for large platen forming presses by the independent four motor drive arrangement shown."
] |
FIELD OF THE INVENTION
[0001] The present invention relates to light emitting color display devices and more particularly to color display having fiber optic faceplates.
BACKGROUND OF THE INVENTION
[0002] Digital imaging displays use individual addressable picture subpixels or pixels to display imagery and data on the displays. These pixels are designed to meet a variety of objectives for a product and for manufacturing processes. For example, pixel layout density, process design rules, interconnect cross-talk, and power distribution are all concerns for imaging displays. The displays are also designed to match the needs of the human visual system.
[0003] Typical pixel layouts used in digital imaging displays are shown in FIGS. 2 and 3. Referring to FIG. 2, a prior art stripe pattern of alternating red 10 , green 12 , and blue 14 light emitting pixel columns are interspersed with non-light emitting areas. A typical design attempts to reduce the amount of non-light emitting area to increase the amount of light that can be emitted from the device. The ratio between the light emitting area and the non-light emitting area is called the fill factor. Referring to FIG. 3, a prior art delta pattern is illustrated in which alternate rows 22 and 24 of the stripes of FIG. 2 are placed out of phase.
[0004] Digital imaging displays using the pixel layouts illustrated in FIGS. 2 and 3 can be found in various display technologies. In particular, they may be applied in organic light emitting diode (OLED) displays. OLED displays have many advantages as a flat-panel display device and are useful in optical systems.
[0005] It is well known in the art to use fiber-optic subpixels in conjunction with display devices to transport the light from a display to a different location. Conventionally, fiber subpixels or faceplates are placed above the cover of a display, for example an LCD or OLED device. Sakai et al. describe a tiled display application in U.S. Pat. No. 5,465,315, issued Nov. 7, 1995, using fiber arrays in conjunction with LCD displays. However, most fiber subpixels or light pipes have a circular cross-section. This circular cross-section does not match the typical, rectangular shape of pixels causing light loss in coupling from a display to a fiber for applications in which a single fiber or light pipe is associated with pixels or subpixels. In the best case, only 78% of the light from a square pixel enters a circular light fiber centered on, and touching, a square pixel, as shown in FIG. 4. Referring to FIG. 4, a circle 30 is shown superimposed above a square 32 circumscribing it. If the fibers are made larger, so as to cover a greater portion of the area of the pixel (as shown in FIG. 5, which illustrates a square 32 circumscribed by a circle 40 ), the density of pixels is reduced. Rectangular pixels with larger aspect ratios become progressively worse. The situation is exacerbated when the fill factor of the display is taken into account. Any non-light emitting area located within the fiber area is effectively wasted and increases the cost of the fiber. If the fibers are made very small so that many fibers are associated with every pixel, costs also increase and the fill factor of the device is replicated on the viewing surface. Moreover, fiber plates with many small subpixels are more expensive than arrays of larger plastic light pipes. If single, larger fibers are associated with an entire conventional three-color pixel, the fill factor and light coupling are even more problematic.
[0006] JP07028050 entitled “Image Display Device” describes an image displaying device where many dot-shaped pixels are arranged two-dimensionally and a filter consisting of optical fibers is arranged on the display optical path of the image displaying device. It is also known to create hexagonal pixel shapes as described in, for example, JP 7261166 A.
[0007] In all of these designs, one or more fibers or light pipes are associated with a single pixel subpixel of one color. Hence, the fiber subpixels associated with each color component of a pixel must be small relative to the pixel size.
[0008] There is a need therefore for an improved color display design with improved coupling to an optical fiber faceplate.
SUMMARY OF THE INVENTION
[0009] The need is met according to the present invention by providing a display device that includes: an array of color pixels each color pixel including a plurality of individually addressable subpixels for emitting different colored light; and a fiber optic faceplate arranged adjacent the array of color pixels, with one fiber for each color pixel.
ADVANTAGES
[0010] The present invention has the advantage that it increases the efficiency of display devices having optical fiber faceplates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a diagram illustrating a circular three-color pixel having pie-shaped subpixels according to one embodiment of the present invention;
[0012] [0012]FIG. 2 illustrates a prior art striped pattern for flat-panel displays;
[0013] [0013]FIG. 3 illustrates a prior art delta pattern for flat-panel displays;
[0014] [0014]FIG. 4 is a diagram showing a circular light pipe having a diameter equal to the side of a square pixel;
[0015] [0015]FIG. 5 is a diagram showing a circular light pipe having a diameter equal to the diagonal of a square pixel;
[0016] [0016]FIG. 6 is a side view of a display device having a fiber optic faceplate;
[0017] [0017]FIG. 7 illustrates a hexagonal pixel according to one embodiment of the present invention;
[0018] [0018]FIG. 8 illustrates an octagonal pixel according to one embodiment of the present invention;
[0019] [0019]FIG. 9 illustrates a cruciform pixel according to one embodiment of the present invention; and
[0020] [0020]FIG. 10 illustrates a rectilinear pixel with smaller features according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIG. 1, one embodiment of the present invention is shown. In FIG. 1, the pixel geometry consists of a circular light-emitting, three-color pixel 50 with three subpixels 51 R, G, and B within a square pixel area 52 wherein each subpixel is a different color. Although the subpixels are shown having equal sizes, they may be of different sizes. Any necessary circuitry, for example power and control connections and transistors are located around the pixel 50 , for example in the corners of the square area 52 . Referring to FIG. 6, a display device 57 includes an array 55 of pixels 50 , configured according to the present invention, located in close alignment with light pipes or optical fibers 58 in a fiber optic faceplate 59 located over the array of pixels 50 to convey the light to a preferred location. The array of pixels 50 may form a two-dimensional regular array as is well known for traditional displays.
[0022] In practice, tolerance limitations of manufacturing processes require that the active area of subpixels have a gap 53 between them as illustrated in FIG. 1. The degree of separation is specified by the tolerances of the manufacturing process.
[0023] Some manufacturing processes or display layout geometries can be further constrained in the shapes and orientation of features that are supported. In an alternative embodiment of the present invention, subpixels can be limited to shapes having straight edges. For example, a hexagonal shaped pixel can be utilized as shown in FIG. 7. Each of the three colored subpixels 51 R, G, B is a rhombus that together, forms a hexagonal pixel 50 within a square pixel area 52 . The pixel 50 is shown with gaps between the subpixels 51 . In this example, it is straightforward to make the three subpixels 51 the same size, since the hexagonal shape of pixel 51 is readily divided into three identical portions.
[0024] In an alternative embodiment, an octagonal shape can be utilized as shown in FIG. 8. Octagonal pixel shapes may be preferred since they have edges at 45 degrees to the vertical and horizontal, thus improving the display quality for diagonal lines. The pixel 50 comprises the three color subpixels 51 R, G, B as shown within a square pixel area 52 . In an octagon, the central rectangle includes one half of the area while the two side subpixels include the other half of the area. Hence, in order to make the three subpixels the same size, the central rectangle has an edge smaller than the edge of the octagon and the side subpixels include some of the central area.
[0025] In a further alternative embodiment, the features of the pixel are rectilinear. Rectilinear shapes are easier to lay out and are more compatible with conventional interconnect and electronic component structures, such as those found in an active matrix display. Referring to FIG. 9, a pixel 50 has three components 51 , a central rectangle and two side subpixels whose aspect ratio is approximately the inverse of the central rectangle. The pixel 50 represents the active, light-emitting area of the pixel, the square 52 represents the entire pixel area, including any non-light emitting elements such as wiring, transistors and capacitors (not shown) within the square 52 . As shown in FIG. 9, the light emitting area is largely included within a circle 56 circumscribed by the square 52 so that a light fiber with a circular cross-section placed in close proximity to the pixel 50 will transmit nearly all of the light emitted by the pixel 50 . At the same time, the pixel area 52 and light emitting subpixels 51 have rectilinear boundaries, thereby enhancing the manufacturability of the display. The relative widths and heights of the subpixels 51 R, G, B may be altered to suit differing fill factors, color intensities or lifetimes of the color components or materials.
[0026] Given, as an example, a 50% fill factor in a square layout, one half of the overall pixel area 52 is filled with equal sized light emitting subpixels 51 . In this case, if the pixel edge is designated h and the width of the vertical component is x, then the area of subpixel 51 G is hx. The area of subpixels 51 R and B are the same and equal to the area of 51 G. For convenience in design, we can arbitrarily set the height of subpixels 51 R and B to one half that of subpixel 51 G and the width of the square area 52 equal to the height. Therefore, hx=(h/2)((h/2)−x). Solving for x yields x=h/6. Therefore, for a configuration in which the fill factor is 50%, the three color subpixels are of equal size and half the height of the central subpixel, the central subpixel is h by h/6 and the two side subpixels are h/2 by h/3. All have the same area: h 2 /6. In this configuration, the present invention improves the light coupling area from 39% to nearly 100%. Moreover, the fill factor of the viewed side of the array of light pipes can be, for example, 78% if the circular pipes are touching, while the fill factor of the display device itself is only 39%. This improvement is not possible if many small fibers are used in a traditional face-plate.
[0027] The configuration of FIG. 9 provides large rectilinear feature sizes. If smaller feature sizes and tolerances can be achieved in a manufacturing process, the shape of the light emitting pixel 50 can become more circular, thus enhancing the coupling of light from the light emitting pixel to the fiber. For example, FIG. 10 illustrates a rectilinear layout that is more nearly circular but has smaller rectilinear features. In FIG. 10, the subpixels have stepped edges 70 . The exact configuration of the edges will depend on the various factors cited above.
[0028] It is also known to provide fiber optic faceplates with light pipes having rectangular cross sections. In such a case, the pixel and subpixels can be rectangularly shaped.
[0029] A wide variety of configurations using the present invention are possible. Different fill factors may be used, the colors may change position or relative size, the horizontal and vertical components can be exchanged, the ratio of height of the horizontal components to the vertical may be changed. In particular, the subpixels may be of different sizes to accommodate differences in efficiency or lifetimes of the materials comprising the different colored subpixels.
[0030] The present invention can applied to emissive displays made of OLED materials, either top- or bottom-emitting (emitting light from the cover or the substrate). The fiber optic faceplate can comprise the cover or substrate of the OLED display device.
[0031] The invention may be employed in a device that includes Organic Light Emitting Diodes (OLEDs) which are composed of small molecule or polymeric OLEDs as disclosed in but not limited to U.S. Pat. No. 4,769,292, issued Sep. 6, 1988 to Tang et al., and U.S. Pat. No. 5,061,569, issued Oct. 29, 1991 to VanSlyke et al. Many combinations and variations of organic light emitting displays can be used to fabricate such a device.
[0032] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
[0033] Parts List
10 red pixel 12 green pixel 14 blue pixel 22 row of stripes 24 row of stripes 30 circle 32 square 40 circle 50 color pixel 51R red subpixel 51G green subpixel 51B blue subpixel 52 square pixel area 53 gap 55 pixel array 56 circle 57 display device 58 light pipe or optical fiber 59 fiber optic faceplate 70 stepped edges | A display device includes: an array of color pixels each color pixel including a plurality of individually addressable subpixels for emitting different colored light; and a fiber optic faceplate arranged adjacent the array of color pixels, with one fiber for each color pixel. | Briefly summarize the invention's components and working principles as described in the document. | [
"FIELD OF THE INVENTION [0001] The present invention relates to light emitting color display devices and more particularly to color display having fiber optic faceplates.",
"BACKGROUND OF THE INVENTION [0002] Digital imaging displays use individual addressable picture subpixels or pixels to display imagery and data on the displays.",
"These pixels are designed to meet a variety of objectives for a product and for manufacturing processes.",
"For example, pixel layout density, process design rules, interconnect cross-talk, and power distribution are all concerns for imaging displays.",
"The displays are also designed to match the needs of the human visual system.",
"[0003] Typical pixel layouts used in digital imaging displays are shown in FIGS. 2 and 3.",
"Referring to FIG. 2, a prior art stripe pattern of alternating red 10 , green 12 , and blue 14 light emitting pixel columns are interspersed with non-light emitting areas.",
"A typical design attempts to reduce the amount of non-light emitting area to increase the amount of light that can be emitted from the device.",
"The ratio between the light emitting area and the non-light emitting area is called the fill factor.",
"Referring to FIG. 3, a prior art delta pattern is illustrated in which alternate rows 22 and 24 of the stripes of FIG. 2 are placed out of phase.",
"[0004] Digital imaging displays using the pixel layouts illustrated in FIGS. 2 and 3 can be found in various display technologies.",
"In particular, they may be applied in organic light emitting diode (OLED) displays.",
"OLED displays have many advantages as a flat-panel display device and are useful in optical systems.",
"[0005] It is well known in the art to use fiber-optic subpixels in conjunction with display devices to transport the light from a display to a different location.",
"Conventionally, fiber subpixels or faceplates are placed above the cover of a display, for example an LCD or OLED device.",
"Sakai et al.",
"describe a tiled display application in U.S. Pat. No. 5,465,315, issued Nov. 7, 1995, using fiber arrays in conjunction with LCD displays.",
"However, most fiber subpixels or light pipes have a circular cross-section.",
"This circular cross-section does not match the typical, rectangular shape of pixels causing light loss in coupling from a display to a fiber for applications in which a single fiber or light pipe is associated with pixels or subpixels.",
"In the best case, only 78% of the light from a square pixel enters a circular light fiber centered on, and touching, a square pixel, as shown in FIG. 4. Referring to FIG. 4, a circle 30 is shown superimposed above a square 32 circumscribing it.",
"If the fibers are made larger, so as to cover a greater portion of the area of the pixel (as shown in FIG. 5, which illustrates a square 32 circumscribed by a circle 40 ), the density of pixels is reduced.",
"Rectangular pixels with larger aspect ratios become progressively worse.",
"The situation is exacerbated when the fill factor of the display is taken into account.",
"Any non-light emitting area located within the fiber area is effectively wasted and increases the cost of the fiber.",
"If the fibers are made very small so that many fibers are associated with every pixel, costs also increase and the fill factor of the device is replicated on the viewing surface.",
"Moreover, fiber plates with many small subpixels are more expensive than arrays of larger plastic light pipes.",
"If single, larger fibers are associated with an entire conventional three-color pixel, the fill factor and light coupling are even more problematic.",
"[0006] JP07028050 entitled “Image Display Device”",
"describes an image displaying device where many dot-shaped pixels are arranged two-dimensionally and a filter consisting of optical fibers is arranged on the display optical path of the image displaying device.",
"It is also known to create hexagonal pixel shapes as described in, for example, JP 7261166 A. [0007] In all of these designs, one or more fibers or light pipes are associated with a single pixel subpixel of one color.",
"Hence, the fiber subpixels associated with each color component of a pixel must be small relative to the pixel size.",
"[0008] There is a need therefore for an improved color display design with improved coupling to an optical fiber faceplate.",
"SUMMARY OF THE INVENTION [0009] The need is met according to the present invention by providing a display device that includes: an array of color pixels each color pixel including a plurality of individually addressable subpixels for emitting different colored light;",
"and a fiber optic faceplate arranged adjacent the array of color pixels, with one fiber for each color pixel.",
"ADVANTAGES [0010] The present invention has the advantage that it increases the efficiency of display devices having optical fiber faceplates.",
"BRIEF DESCRIPTION OF THE DRAWINGS [0011] [0011 ]FIG. 1 is a diagram illustrating a circular three-color pixel having pie-shaped subpixels according to one embodiment of the present invention;",
"[0012] [0012 ]FIG. 2 illustrates a prior art striped pattern for flat-panel displays;",
"[0013] [0013 ]FIG. 3 illustrates a prior art delta pattern for flat-panel displays;",
"[0014] [0014 ]FIG. 4 is a diagram showing a circular light pipe having a diameter equal to the side of a square pixel;",
"[0015] [0015 ]FIG. 5 is a diagram showing a circular light pipe having a diameter equal to the diagonal of a square pixel;",
"[0016] [0016 ]FIG. 6 is a side view of a display device having a fiber optic faceplate;",
"[0017] [0017 ]FIG. 7 illustrates a hexagonal pixel according to one embodiment of the present invention;",
"[0018] [0018 ]FIG. 8 illustrates an octagonal pixel according to one embodiment of the present invention;",
"[0019] [0019 ]FIG. 9 illustrates a cruciform pixel according to one embodiment of the present invention;",
"and [0020] [0020 ]FIG. 10 illustrates a rectilinear pixel with smaller features according to one embodiment of the present invention.",
"DETAILED DESCRIPTION OF THE INVENTION [0021] Referring to FIG. 1, one embodiment of the present invention is shown.",
"In FIG. 1, the pixel geometry consists of a circular light-emitting, three-color pixel 50 with three subpixels 51 R, G, and B within a square pixel area 52 wherein each subpixel is a different color.",
"Although the subpixels are shown having equal sizes, they may be of different sizes.",
"Any necessary circuitry, for example power and control connections and transistors are located around the pixel 50 , for example in the corners of the square area 52 .",
"Referring to FIG. 6, a display device 57 includes an array 55 of pixels 50 , configured according to the present invention, located in close alignment with light pipes or optical fibers 58 in a fiber optic faceplate 59 located over the array of pixels 50 to convey the light to a preferred location.",
"The array of pixels 50 may form a two-dimensional regular array as is well known for traditional displays.",
"[0022] In practice, tolerance limitations of manufacturing processes require that the active area of subpixels have a gap 53 between them as illustrated in FIG. 1. The degree of separation is specified by the tolerances of the manufacturing process.",
"[0023] Some manufacturing processes or display layout geometries can be further constrained in the shapes and orientation of features that are supported.",
"In an alternative embodiment of the present invention, subpixels can be limited to shapes having straight edges.",
"For example, a hexagonal shaped pixel can be utilized as shown in FIG. 7. Each of the three colored subpixels 51 R, G, B is a rhombus that together, forms a hexagonal pixel 50 within a square pixel area 52 .",
"The pixel 50 is shown with gaps between the subpixels 51 .",
"In this example, it is straightforward to make the three subpixels 51 the same size, since the hexagonal shape of pixel 51 is readily divided into three identical portions.",
"[0024] In an alternative embodiment, an octagonal shape can be utilized as shown in FIG. 8. Octagonal pixel shapes may be preferred since they have edges at 45 degrees to the vertical and horizontal, thus improving the display quality for diagonal lines.",
"The pixel 50 comprises the three color subpixels 51 R, G, B as shown within a square pixel area 52 .",
"In an octagon, the central rectangle includes one half of the area while the two side subpixels include the other half of the area.",
"Hence, in order to make the three subpixels the same size, the central rectangle has an edge smaller than the edge of the octagon and the side subpixels include some of the central area.",
"[0025] In a further alternative embodiment, the features of the pixel are rectilinear.",
"Rectilinear shapes are easier to lay out and are more compatible with conventional interconnect and electronic component structures, such as those found in an active matrix display.",
"Referring to FIG. 9, a pixel 50 has three components 51 , a central rectangle and two side subpixels whose aspect ratio is approximately the inverse of the central rectangle.",
"The pixel 50 represents the active, light-emitting area of the pixel, the square 52 represents the entire pixel area, including any non-light emitting elements such as wiring, transistors and capacitors (not shown) within the square 52 .",
"As shown in FIG. 9, the light emitting area is largely included within a circle 56 circumscribed by the square 52 so that a light fiber with a circular cross-section placed in close proximity to the pixel 50 will transmit nearly all of the light emitted by the pixel 50 .",
"At the same time, the pixel area 52 and light emitting subpixels 51 have rectilinear boundaries, thereby enhancing the manufacturability of the display.",
"The relative widths and heights of the subpixels 51 R, G, B may be altered to suit differing fill factors, color intensities or lifetimes of the color components or materials.",
"[0026] Given, as an example, a 50% fill factor in a square layout, one half of the overall pixel area 52 is filled with equal sized light emitting subpixels 51 .",
"In this case, if the pixel edge is designated h and the width of the vertical component is x, then the area of subpixel 51 G is hx.",
"The area of subpixels 51 R and B are the same and equal to the area of 51 G. For convenience in design, we can arbitrarily set the height of subpixels 51 R and B to one half that of subpixel 51 G and the width of the square area 52 equal to the height.",
"Therefore, hx=(h/2)((h/2)−x).",
"Solving for x yields x=h/6.",
"Therefore, for a configuration in which the fill factor is 50%, the three color subpixels are of equal size and half the height of the central subpixel, the central subpixel is h by h/6 and the two side subpixels are h/2 by h/3.",
"All have the same area: h 2 /6.",
"In this configuration, the present invention improves the light coupling area from 39% to nearly 100%.",
"Moreover, the fill factor of the viewed side of the array of light pipes can be, for example, 78% if the circular pipes are touching, while the fill factor of the display device itself is only 39%.",
"This improvement is not possible if many small fibers are used in a traditional face-plate.",
"[0027] The configuration of FIG. 9 provides large rectilinear feature sizes.",
"If smaller feature sizes and tolerances can be achieved in a manufacturing process, the shape of the light emitting pixel 50 can become more circular, thus enhancing the coupling of light from the light emitting pixel to the fiber.",
"For example, FIG. 10 illustrates a rectilinear layout that is more nearly circular but has smaller rectilinear features.",
"In FIG. 10, the subpixels have stepped edges 70 .",
"The exact configuration of the edges will depend on the various factors cited above.",
"[0028] It is also known to provide fiber optic faceplates with light pipes having rectangular cross sections.",
"In such a case, the pixel and subpixels can be rectangularly shaped.",
"[0029] A wide variety of configurations using the present invention are possible.",
"Different fill factors may be used, the colors may change position or relative size, the horizontal and vertical components can be exchanged, the ratio of height of the horizontal components to the vertical may be changed.",
"In particular, the subpixels may be of different sizes to accommodate differences in efficiency or lifetimes of the materials comprising the different colored subpixels.",
"[0030] The present invention can applied to emissive displays made of OLED materials, either top- or bottom-emitting (emitting light from the cover or the substrate).",
"The fiber optic faceplate can comprise the cover or substrate of the OLED display device.",
"[0031] The invention may be employed in a device that includes Organic Light Emitting Diodes (OLEDs) which are composed of small molecule or polymeric OLEDs as disclosed in but not limited to U.S. Pat. No. 4,769,292, issued Sep. 6, 1988 to Tang et al.",
", and U.S. Pat. No. 5,061,569, issued Oct. 29, 1991 to VanSlyke et al.",
"Many combinations and variations of organic light emitting displays can be used to fabricate such a device.",
"[0032] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.",
"[0033] Parts List 10 red pixel 12 green pixel 14 blue pixel 22 row of stripes 24 row of stripes 30 circle 32 square 40 circle 50 color pixel 51R red subpixel 51G green subpixel 51B blue subpixel 52 square pixel area 53 gap 55 pixel array 56 circle 57 display device 58 light pipe or optical fiber 59 fiber optic faceplate 70 stepped edges"
] |
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